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Table of Contents
Timing Component Kits . . . . . . . . . . . . . . . I-IV WARNING
Be safe! Do not use Gates
Alphabetical/Application Listings belts, pulleys or sprockets on
with recommended replacement any aircraft propeller or rotor
drive systems or in-flight acces-
intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 sory drives. Those Gates prod-
ucts are not designed or
Changeover Listing . . . . . . . . . . . . . . . . . . .A-43 intended for aircraft use.
Manufacturers Part Numbers . . . . . . . . . .A-54 CAUTION
Use Gates products only on
Troubleshooting Guide . . . . . . . . . . . . . . . .A-56 applications specified in Gates
literature. Install and maintain
Overhead Valve Engine Identification . . .A-58 products according to the vehi-
cle manufacturer's recom-
Interference Engine Information . . . . . . . .A-59 mended procedures and with
recommended tools. Failure to
Belt Tensioning . . . . . . . . . . . . . . . . . . . . . . .A-60 follow these instructions could
Replacement Instructions . . . . . . . . . . . . . . . . .1 result in injury or property
damage. Gates disclaims all
liability due to failure to follow
these instructions.
Limited Warranty for the Life of the Merchandise

Merchandise is warranted to be free from defects in materials or workmanship for the life of the merchandise. Damages from misuse, abuse or gradual wear
from normal use are excluded from this warranty. The Gates Rubber Company will, at its option, replace or repair any merchandise proved defective in mate-
rial or workmanship,or both, during the warranty period. This is the exclusive remedy. For warranty service, please contact the Service Department, The
Gates Rubber Company, 990 South Broadway, Denver, Colorado 80209. THERE IS NO OTHER EXPRESSED WARRANTY. IMPLIED WARRANTIES, INCLUDING
THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE EXPRESSED WARRANTY PERIOD. LIABILITY FOR CONSE-
QUENTIAL OR INCIDENTAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW.
Some states do not allow the exclusion of limitation or incidental or consequential damages, and some states do not allow limitations on how long an
implied warranty lasts, so the above limitation and exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other
rights which vary from state to state.
DISCLAIMER OF WARRANTIES
Although the information contained within this volume has been obtained from sources generally believed to be reliable, no warranty (expressed or
implied) can be made as to its accuracy or completeness, nor is any responsibility assumed by Mitchell Repair Information Company or anyone con-
nected with it, for loss or damages suffered through reliance on any information contained in this volume.
SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE
IMPLIED WITH RESPECT TO THIS VOLUME AND ITS CONTENTS.
In no event will Mitchell Repair Information Company be liable for any damages, direct or indirect, consequential or compensatory, including, with-
out limitation, lost profits, for any representations, breaches or defaults arising out of the use of this volume. Customer agrees to indemnify
Mitchell Repair Information Company and hold it harmless against all claims and damages, including without limitation, reasonable attorneys fees
arising out of the use of this volume, unless such claims or damages result from the infringement of any copyright or other proprietary right of any
third party.
Questions regarding installation instructions or interference engine applications should be addressed to Mitchell
Repair Information Companys Tech Line at 888-724-6742 extension 6112. For questions regarding timing belt
part numbers, contact The Gates Rubber Companys Tech Line at (303) 744-5651.
Prepared Expressly for The Gates Rubber Company by Mitchell Repair Information Company
Copyright 2002 MITCHELL REPAIR INFORMATION COMPANY, LLC
All Right Reserved
Printed in the U.S. of America
Timing Component Kits
Why buy individual parts,
when you can have one
complete kit?
A broken timing belt can cause
severe engine damage. Belt failure
is often caused when the timing
belt tensioner or idler bearing fails.
Avoid the warranties and comebacks
by replacing all system components.
With Gates new Timing
Component Kits, you dont
have to shop for more
components, buy from
multiple sources or hassle
with returning compo-
nents that dont fit.
Gates timing component
kits provide a complete
system replacement solu-
tion, not just a part. Each kit
comes with all the right com-
ponents, plus detailed installa-
tion instructions specific to each
application, so theres no guesswork
required to get the proper fit.
To help your customer avoid costly

Each kit includes: engine damage, be sure to recommend
the Timing Belt Promotional Kit
Belt*
Tensioner* Order Form # 428-1459.
Idler*
Comes complete with:
Detailed installation
Timing Belt Replacement Chart
instructions Replace Timing Belt every 60,000
(sample illustrations on miles Poster
next page) Timing Belt Warning Stickers
*Certain kits contain multiple belts,
Timing Belt Replacement counter card
idlers and tensioners, depending on with pamphlets
the application.
I
Do the Job Right the First Time...Every Time
Warranties are one of the biggest concerns for 2. Timing Component Kits provide value-
installers, parts manufacturers and everyone in added features such as detailed installation
between. The best way for installers to reduce instruction sheets and tamper resistant
comebacks is to do the job right the first time packaging to assure that all needed parts
and always use the highest quality parts. are in the package.
Wear, misalignment and loss of lubricant limit 3. Ease of parts sourcing. Most counter people
timing belt tensioner and idler life. Most of and installers like engine kits because kits
these problems cannot be readily identified save time. They eliminate the need to look
by inspection. up each part number.
Many advantages exist to buy- 4. By replacing all of the timing belt system
ing Timing Component Kits over components, installers will reduce labor
individual components. claims and comebacks.
1. Provides the convenience and ease of buying 5. Since the belt is being replaced, there is
through the installers preferred aftermarket limited extra labor for replacing the idler
channel. 67% of installers surveyed bought and tensioner.
timing belt tensioners/idlers from automo-
tive dealerships due to limited aftermarket
availability.
Timing System
The crankshaft drives the
camshaft(s) and actuates the
valves via a belt or a chain.
Because of the advantages over
chain (lighter, quieter, uses less
space) the timing belt is widely
used by car manufacturers.
Important:
To achieve safe and thorough servic-
ing of the engine, we recommend
the belt, belt tensioner units 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 the belt tensioner unit and idler pulley. If they are
too little tension, vibration, high temperature, belt not changed together with the belt, early break-
misalignment, etc.) will also have affected the down may be encountered, resulting in serious
other rotating components of the system including damage to the engine.
II
Technical Support
Several factors can cause timing belt tension- Top Reasons to: Replace Belt
er or idler failure. Tensioner and Idler When
Bearing life is limited by wear, temperature, Replacing Timing Belt
misalignment, and loss of lubricant. Most of OEs recommend as part of normal preven-
these problems cannot be readily identified tative maintenance
by an inspection, so it is always best to Preventative maintenance should address
replace the tensioner and/or idlers as part of all forms of failure
the timing belt replacement 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 Gates leads the world in timing belt technol-
materials and tooth profiles are gone. ogy, assuring customers a replacement belt to
Improved new generation belts are providing match the capabilities of the original belts.
the extended durability and smoother per-
formance characteristics required by todays
High Strength Tensile Cord
engines. Designed for High Tension Applications
Improved Jacket
For Increased Wear Resistance
Highly Saturated Nitrile Compound
Formulated to Improve Heat Resistance and Durability
III
Tooth profiles arent
interchangeable
The earliest timing belts had a trapezoidal pro-
file. Competition and more demanding applica-
tions led to the development of a curvilinear
Trapezoidal
profile. This, in turn, evolved to a modified
curvilinear profile. Belts with different tooth pro-
files are not interchangeable.
Curvilinear
Gates complete line of more than 250 timing
belt numbers continues to grow and set the
industry standard. Our timing belts include the Modified Curvilinear
popular tooth profiles pictured at right.
NOTE: Trapezoidal, curvilinear and modified
Dont be misled by curvilinear tooth profiles will not interchange,
initial cost and a neoprene belt will not replace HSN (Highly
Saturated Nitrile). Replacing a high performance
The cost of the belt is only 5 10 percent of timing belt with a non-OE equivalent belt may
the cost of replacement. Changing any timing severely shorten the belt life. Gates offers OE
belt can be labor intensive and costly. In the equivalency in timing belt replacements.
case of interference engines*, the repair bill Many engines from other countries use different
for a failed timing belt can be up to 10 times timing belts and sprockets than like engines
the cost of replacing the belt. designed for the North American market. While
these engines may look identical and fit exactly
the same in similar vehicles, the belts may be
Gates first to use HSN vastly different. Please take special care to look
Neoprene, an excellent material in its own for these differences if you suspect your engine
right, was standard until 1985, when Gates may have been replaced with an imported
engine.
introduced the first belts made of highly-satu-
rated nitrile (HSN). In short supply, and diffi-
cult to engineer, HSN is the material of choice
for most new engine timing belts. An Easy installation
HSN-constructed belt appears no different
than a neoprene belt, but significantly outper-
every time
forms in the high-temperature engine com- Gates timing belts
partments of modern vehicles. have positioning
marks to make
installation fast
HSN belts are worth and easy. You
the price wont find that
with many com-
They cost more than neoprene belts, but theyre petitive belts,
a small percentage of the total cost of replacing which require you
a belt and theyre absolutely necessary for to count individual
acceptable service life. The fact is, theyre teeth to correctly
worth every penny. Todays engines require position the belt.
high-performance belts. Thats why car manu-
facturers use HSN in so many new engines.
*An interference engine is an engine in which the valves and the

piston may contact each other if the timing is not set correctly.
IV
ALPHABETICAL MODEL LISTING A-1
Make Timing Belt Recommended

Model/ Belt Component Interference Driven Water Replacement
Year Engine Part No. Kit Part No. Engine* Pump Interval (Miles) Page
ACURA
Passenger Cars
EL (Canadian)
1997-00 1.6L 4-Cyl. T224 Yes Yes 105,000 3 1
Integra
1986-89 1.6L 4-Cyl. T130 Yes Yes 60,000 1 4
1992-93 1.7L 4-Cyl. T227 Yes Yes 90,000 5
1990-94 1.8L 4-Cyl. (Exc. VTEC) T184 Yes Yes 90,000 7
1995-96 1.8L 4-Cyl. (Exc. VTEC) T184 Yes Yes 90,000 Normal
60,000 Severe 7
1997-01 1.8L 4-Cyl. (Exc. VTEC) T184 Yes Yes 105,000 3 7
1991-94 1.8L 4-Cyl. (VTEC) T247 Yes Yes 90,000 7
1995-96 1.8L 4-Cyl. (VTEC) T247 Yes Yes 90,000 Normal
60,000 Severe 7
1997-01 1.8L 4-Cyl. (VTEC) T247 Yes Yes 105,000 3 7
Legend
1986-87 2.5L V6 T129 Yes Yes 60,000 1 13
1988-89 2.7L V6 T129 Yes Yes 60,000 1 13
1990 2.7L V6 T129 Yes Yes 90,000 13
1991-94 3.2L V6 (C32A1) T193 Yes Yes 90,000 19
1995 3.2L V6 (C32A1) T193 Yes Yes 90,000 Normal 19
60,000 Severe 19
MDX
2001 3.5L V6 (J35A3) T286 Yes Yes 105,000 3 15
Vigor
1992-94 2.5L 5-Cyl. T211 Yes Yes 90,000 11
2.2CL
1997 2.2L 4-Cyl.
Balance Shaft T186 Yes Yes 90,000 Normal 2 9
60,000 Severe 9
Camshaft T244 Yes Yes 90,000 Normal 2
60,000 Severe 9
2.3CL
1999-98 2.3L 4-Cyl.
Balance Shaft T186 Yes Yes 105,000 3 9
Camshaft T244 Yes Yes 105,000 3 9
2.5TL
1995-96 2.5L 5-Cyl. T211 Yes Yes 90,000 Normal 11
60,000 Severe 11
1997-98 2.5L 5-Cyl. T211 Yes Yes 105,000 3 11
3.0CL
1997-99 3.0L V6 (J30A1) T286 Yes Yes 105,000 3 15
3.2CL
2001 3.2L V6 (J32A1/A2) T286 Yes Yes 105,000 3 15
3.2TL
1996 3.2L V6 (C32A6) T193 Yes Yes 90,000 Normal 19
60,000 Severe 19
1997-98 3.2L V6 (C32A6) T193 Yes Yes 105,000 3 19
1999-01 3.2L V6 (J32A1) T286 Yes Yes 105,000 3 15
3.5RL
1996 3.5L V6 (C35A1)
Balance Shaft T280 Yes Yes 90,000 Normal 2 22
60,000 Severe 22
Camshaft T279 Yes Yes 90,000 Normal 2 22
60,000 Severe 22
* - Interference engine. Other interference engine applications may exist which are not indicated here. See page A-59 for
interference engine cautions.
1
- Although the vehicle manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals.
2
- The vehicle manufacturer recommends replacing all belts at the same time.
3
- See timing belt repair procedure for more information on belt replacement interval.
A-2 ALPHABETICAL MODEL LISTING (Cont.)
ACURA (Cont.)
3.5RL (Cont.)
1997-01 3.5L V6
Light Trucks
SLX
1996-97 3.2L V6 (SOHC) T221 Yes 60,000 28
1999-98 3.5L V6 (DOHC) T303 Yes 75,000 26
ALFA ROMEO
164L, LS & S
1991-93 3.0L V6 T120 50,000 30
AMERICAN MOTORS
Concord
1978-79 2.0L 4-Cyl. T017 TCK017 60,000 1 32
Gremlin
1977-78 2.0L 4-Cyl. T017 TCK017 60,000 1 32
Spirit
1979 2.0L 4-Cyl. T017 TCK017 60,000 1 32
ASUNA
Passenger Cars
Sunfire (Canadian)
1993 1.8L 4-Cyl. T205 Yes 60,000 209
Light Trucks
Sunrunner (Canadian)
1989-95 1.6L 4-Cyl. (8-Valve)
California T212 60,000 215
Except California T164 60,000 215
1994-98 1.6L 4-Cyl. (16-Valve)
1999-01 1.6L 4-Cyl. (16-Valve) T212 60,000 217
AUDI
Allroad
2000 2.7L V6 DOHC T297 Yes Yes 105,000 57
A4
1997-99 1.8L 4-Cyl. Turbo T291 Yes 90,000 38
1996 2.8L V6, 12-Valve T218 Yes Yes 60,000 1 62
1997 2.8L V6, 12-Valve T218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve T297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve T297 Yes Yes 75,000 64
A4 Quattro
1997-99 1.8L 4-Cyl. Turbo T291 Yes 90,000 38
1996 2.8L V6, 12-Valve T218 Yes Yes 60,000 1 62
1997 2.8L V6, 12-Valve T218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve T297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve T297 Yes Yes 75,000 64
2000 2.7L V6 DOHC T297 Yes Yes 105,000 57
A6
1995-96 2.8L V6, 12-Valve T218 Yes Yes 60,000 1 62
1997 2.8L V6, 12-Valve T218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve T297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve T297 Yes Yes 75,000 64
2000 2.8L V6, 30-Valve T297 Yes Yes 105,000 64
* - Other interference engine applications may exist which are not indicated here. See page A-59 for
1
2
3
ALPHABETICAL MODEL LISTING (Cont.) A-3

AUDI (Cont.)
A6 Quattro & Quattro Turbo
1995-96 2.8L V6, 12-Valve T218 Yes Yes 60,000 1 62
1997 2.8L V6, 12-Valve T218 Yes Yes 90,000 62
1998 2.8L V6, 30-Valve T297 Yes Yes 90,000 64
1999 2.8L V6, 30-Valve T297 Yes Yes 75,000 64
2000 2.8L V6, 30-Valve T297 Yes Yes 105,000 64
A8
1997-98 3.7L V8 (AEW) T207 Yes Yes 90,000 72
1999 3.7L V8 (AEW) T207 Yes Yes 75,000 72
A8 Quattro
1997-98 3.7L V8 (AEW) T207 Yes Yes 90,000 72
1999 3.7L V8 (AEW) T207 Yes Yes 75,000 72
2000 4.2L V8 (AKB, AUX & AYS) T297 Yes Yes 105,000 76
Cabriolet
1994-96 2.8L V6, 12-Valve T218 Yes Yes 60,000 1 62
1997-98 2.8L V6, 12-Valve T218 Yes Yes 90,000 62
Coupe
1981-83 2.2L 5-Cyl. T065 Yes 60,000 1 79
1984-85 2.2L 5-Cyl.
113 Tooth Belt T065 Yes 60,000 1 79
120 Tooth Belt T127 Yes 60,000 1 79
Coupe GT
1986-87 2.2L 5-Cyl. T127 Yes 60,000 1 79
Coupe Quattro
1990-91 2.3L 5-Cyl. T197 Yes 60,000 1 47
Fox
1973-79 1.6L 4-Cyl T017 TCK017 4 Yes 60,000 1 34
Quattro
1983 2.2L 5-Cyl. T065 Yes 60,000 1 79
1984-85 2.2L 5-Cyl.
113 Tooth Belt T065 Yes 60,000 1 79
120 Tooth Belt T127 Yes 60,000 1 79
S4 Quattro
2001 2.7L V6 DOHC T297 Yes Yes 105,000 53
S4 Sedan
1992-94 2.2L 5-Cyl. Turbo T225 Yes 60,000 1 49
S6
1995 2.2L 5-Cyl. Turbo T225 Yes 60,000 1 49
S6 Quattro
1995 2.2L 5-Cyl. Turbo T225 Yes 60,000 1 49
TT Coupe
& Roadster 1.8L 4-Cyl. Turbo T306 Yes Yes 120,000 40
V8 Quattro
1990-91 3.6L V8 (PT Engine) T207 Yes 60,000 67
1992-94 4.2L V8 (ABH Engine) T207 Yes 90,000 67
80
1988-90 2.0L 4-Cyl. T017 TCK017 4 60,000 1 43
1991-92 2.3L 5-Cyl. T170 Yes 60,000 1 51
80 Quattro
1988 2.3L 5-Cyl. T127 Yes 60,000 1 51
90
1988-90 2.0L 4-Cyl. T017 TCK017 4 60,000 1 43
1988 2.3L 5-Cyl. T127 Yes 60,000 1 51
1
2
3
AUDI (Cont.)
90 (Cont.)
1989 2.3L 5-Cyl.
Up To Chas. 89J396702 T127 Yes 60,000 1 51
From Chas. 89J396703 T170 Yes 60,000 1 51
1990-91 2.3L 5-Cyl. T170 Yes 60,000 1 51
1993-95 2.8L V6, 12-Valve T218 Yes Yes 60,000 1 62
90 Quattro
1988 2.3L 5-Cyl. T127 Yes 60,000 1 51
1989 2.3L 5-Cyl.
Up To Chas. 89J394742 T127 Yes 60,000 1 51
From Chas. 89J394743 T170 Yes 60,000 1 51
1990-92 2.3L 5-Cyl. T170 Yes 60,000 1 51
1993-95 2.8L V6 (12-Valve) T218 Yes Yes 60,000 1 62
100
1988-91 2.3L 5-Cyl.
Thru Chas. 063969 T127 Yes 60,000 1 51
From Chas. 063970 T170 Yes 60,000 1 51
1990-91 2.3L 5-Cyl. T170 Yes 60,000 1 51
1992-94 2.8L V6 (12-Valve) T218 Yes Yes 60,000 1 62
100 Quattro
1988-91 2.3L 5-Cyl.
Thru Chas. 063969 T127 Yes 60,000 1 51
From Chas. 063970 T170 Yes 60,000 1 51
1990-91 2.3L 5-Cyl. T170 Yes 60,000 1 51
1992-94 2.8L V6 (12-Valve) T218 Yes Yes 60,000 1 62
200
1989 2.2L 5-Cyl.
Up To Chas. 44K400000 T127 Yes 60,000 1 79
1989 2.2L 5-Cyl.
From Chas. 44K400001 T170 Yes 60,000 1 79
1990-91 2.2L 5-Cyl. T170 Yes 60,000 1 79
200 Quattro
1989 2.2L 5-Cyl.
Thru Chas. 44K004457 T127 Yes 60,000 1 79
From Chas. 44K004458 T170 Yes 60,000 1 79
1990-91 2.2L 5-Cyl. T170 Yes 60,000 1 79
4000
1980-83 1.7L 4-Cyl. T017 TCK017 4 Yes 60,000 1 34
1982-83 1.6L 4-Cyl. Diesel T043 60,000 1 33
1980-81 2.2L 5-Cyl. T065 Yes 60,000 1 79
4000CS
1986-87 2.2L 5-Cyl. T127 Yes 60,000 1 79
4000CS Quattro
1987 2.2L 5-Cyl. T127 Yes 60,000 1 79
4000S
1984-87 1.8L 4-Cyl. T017 TCK017 4 Yes 60,000 1 36
4000S Quattro
1984-85 2.2L 5-Cyl.
113 Tooth Belt T065 Yes 60,000 1 79
120 Tooth Belt T127 Yes 60,000 1 79
1986 2.2L 5-Cyl. T127 Yes 60,000 1 79
1
2
3

AUDI (Cont.)
5000
1979-83 2.0L 5-Cyl. Diesel
Camshaft T083 Yes Yes 60,000 1, 2
45
Injection Pump T082 Yes Yes 60,000 1, 2
45
1979-83 2.0L 5-Cyl.Turbo Diesel
Camshaft T083 Yes Yes 60,000 1, 2 45
Injection Pump T082 Yes Yes 60,000 1, 2 45
1978-83 2.2L 5-Cyl. Turbo T065 Yes 60,000 1 79
5000 Quattro
1988 2.3L 5-Cyl. T127 Yes 60,000 1 51
5000CS Quattro
1987-88 2.2L 5-Cyl. T127 Yes 60,000 1 79
5000S
1987-88 2.3L 5-Cyl. T127 Yes 60,000 1 51
1984-85 2.2L 5-Cyl.
113 Tooth Belt T065 Yes 60,000 1 79
120 Tooth Belt T127 Yes 60,000 1 79
1986-87 2.2L 5-Cyl. T127 Yes 60,000 1 79
BMW
325 Series
1987-88 2.5L 6-Cyl.
127 Tooth Belt T131 Yes 60,000 81
128 Tooth Belt T106 Yes 60,000 81
1989-91 2.5L 6-Cyl. T131 Yes 60,000 81
1984-88 2.7L 6-Cyl.
127 Tooth Belt T131 Yes 60,000 81
128 Tooth Belt T106 Yes 60,000 81
525i
1989-95 2.5L 6-Cyl. T131 Yes 60,000 81
528e
1982-88 2.7L 6-Cyl.
127 Tooth Belt T131 Yes 60,000 81
128 Tooth Belt T106 Yes 60,000 81
BUICK
Skyhawk
1982-86 1.8L 4-Cyl. T081 Yes 60,000 1 228
1987-88 2.0L 4-Cyl. T081 Yes 60,000 1 229
CADILLAC
Catera
1997-01 3.0L V6 (DOHC) T285 Yes Yes 100,000 231
CHEVROLET
Passenger Cars
Chevette
1976 1.4L 4-Cyl. T037 60,000 1 221
1977 1.4L 4-Cyl. T039 60,000 1 221
1976 1.6L 4-Cyl. T037 60,000 1 221
1977-78 1.6L 4-Cyl. T039 60,000 1 221
1979-87 1.6L 4-Cyl. T061 60,000 1 221
1981-86 1.8L 4-Cyl. Diesel T076 Yes 60,000 1 226
Lumina (Exc. Van)
1991-95 3.4L V6 T192 Yes Yes 60,000 238
1996-97 3.4L V6 T273 Yes Yes 60,000 238
1
2
3
CHEVROLET (Cont.)
Metro
1989-00 1.0L 3-Cyl. T194 TCK194A 4 100,000 211
1998-01 1.3L 4-Cyl. T194 TCK194A 4 100,000 213
Monte Carlo
1995 3.4L V6 T192 Yes Yes 60,000 238
1996-97 3.4L V6 T273 Yes Yes 60,000 238
Nova
1988 1.6L 4-Cyl. (DOHC) T112 60,000 1 224
1985-88 1.6L 4-Cyl. (SOHC) T070 TCK070 4
60,000 1 224
Spectrum
1985-87 1.5L 4-Cyl
Up To 4/30/87 T118 Yes Yes 60,000 219
From 5/1/87 T162 Yes Yes 60,000 219
1988-89 1.5L 4-Cyl. T162 Yes Yes 60,000 219
Sprint
1985-88 1.0L 3-Cyl. T095 60,000 211
1989-91 1.0L 3-Cyl. T166 60,000 211
CHEVROLET/G.M.C.
Light Trucks
LUV
1981-82 2.2L 4-Cyl. Diesel T075 Yes 60,000 323
S10 & S15 Pickups
1983-85 2.2L 4-Cyl. Diesel T075 Yes 60,000 323
Tracker
1998 1.6L 4-Cyl. (16-Valve)
1999-01 1.6L 4-Cyl. (16-Valve) T212 60,000 217
CHRYSLER
Cirrus
2000 2.0L 4-Cyl. (SOHC, VIN C) T245 Yes Yes 100,000 Federal 93
105,000 Calif. 93
1995-99 2.4L 4-Cyl. (DOHC, VIN X) T265 Yes 105,000 106
2000 2.4L 4-Cyl. (DOHC, VIN X) T265 Yes 100,000 Federal 106
105,000 California 106
1995-00 2.5L V6 T259 Yes Yes 60,000 3 108
Concorde
1998-99 3.2L V6 T295 Yes Yes 105,000 123
2000 3.2L V6 T295 Yes Yes 100,000 Federal 123
1993-94 3.5L V6 T219 Yes 105,000 123
1995-97 3.5L V6 T255 Yes 105,000 123
2000 3.5LV6 T295 Yes 100,000 Federal 123
E Class
1983-84 2.2L 4-Cyl. T071 TCK0714 60,000 1 101
Executive Limo (Canadian)
1986 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
Intrepid (Canadian)
1998-99 3.2L V6 T295 Yes Yes 105,000 123
1993-94 3.5L V6 T219 Yes 105,000 123
1995-97 3.5L V6 T255 Yes 105,000 123
1
2
3

CHRYSLER (Cont.)
Laser
1984-86 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1986 2.5L 4-Cyl. T114 60,000 1 101
LeBaron & LeBaron GTS
1982-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989-90 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989-94 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1990-93 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
1994-95 3.0L V6 (SOHC) T139 TCK139 4 60,000 1 110
LHS
1994 3.5L V6 T219 Yes 105,000 123
1995-97 3.5L V6 T255 Yes 105,000 123
1998-99 3.5LV6 T295 Yes 105,000 123
2000 3.5LV6 T295 Yes 100,000 Federal 123
New Yorker
1983-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1988-89 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
1994 3.5L V6 T219 Yes 105,000 123
1995-96 3.5L V6 T255 Yes 105,000 123
Sebring Coupe
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) T246 Yes Yes 60,000 3 133
1995-00 2.5L V6 T259 Yes Yes 60,000 3 108
Sebring Convertible
1997-00 2.5L V6 T259 Yes Yes 60,000 3 108
TC
1990 2.2L 4-Cyl. (DOHC, VIN R) T153 TCK153 4 60,000 1 98
1990-91 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
Town & Country
1982-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
300M
1998-99 3.5LV6 T295 Yes 105,000 123
2000 3.5LV6 T295 Yes 100,000 Federal 123
DAEWOO
Laganza
1999-01 2.2L 4-Cyl. (DOHC) T305 Yes Yes 72,000 Federal 150
102,000 Federal 3 150
Lanos
102,000 Federal 3 145
Nubira
102,000 Federal 3 148
1
2
3
DAEWOO (Cont.)
Optima (Canadian)
1988-91 1.6L 4-Cyl. T081 Yes 60,000 1 147
1988-89 2.0L 4-Cyl. T081 Yes 60,000 1 147
1990-91 2.0L 4-Cyl. T163 TCK163 4 Yes 60,000 1 147
DAIHATSU
Passenger Cars
Charade
1988-92 1.0L 3-Cyl. T178 Yes 60,000 152
1988-92 1.3L 4-Cyl. T181 Yes 60,000 154
Light Trucks
Rocky
1990-92 1.6L 4-Cyl. T182 Yes 60,000 154
DATSUN (SEE NISSAN)
DODGE
Passenger Cars
Aries
1981-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
Avenger
1995-00 2.5L V6 T259 Yes Yes 60,000 3 108
Challenger
1978-79 (RWD) 1.6L 4-Cyl. w/o Bal. Shaft T064 60,000 87
1978-79 1.6L 4-Cyl.
Balance Shaft T062 60,000 2 85
Camshaft T013 60,000 2 85
Charger
1983 1.7L 4-Cyl T017 TCK017 4 60,000 1 89
1983-87 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
Colt
1979-84 1.4L 4-Cyl. T073 Yes 60,000 83
1985-86 1.5L 4-Cyl. T073 Yes 60,000 114
1987-90 1.5L 4-Cyl. T128 TCK128 4 Yes 60,000 114
1991-94 1.5L 4-Cyl. T191 TCK191 4 60,000 114
1979-82 (FWD)1.6L 4-Cyl. w/o Bal. Shaft T064 60,000 87
1983-89 1.6L 4-Cyl. w/o Bal. Shaft T093 60,000 87
1977-80 1.6L 4-Cyl.
Camshaft T013 60,000 2 85
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
1989-90 1.8L 4-Cyl. (VIN T) T093 60,000 91
1992-94 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
Colt (Canadian)
1985-86 1.5L 4-Cyl. T073 Yes 60,000 114
1989-91 1.5L 4-Cyl. T128 TCK128 4 Yes 60,000 114
1992 & 1995 1.5L 4-Cyl. T191 TCK191 4 60,000 114
1
2
3

DODGE (Cont.)
Colt Vista (Includes Canadian)
1992-94 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
1984-86 2.0L 4-Cyl. (SOHC)
Camshaft T089 60,000 2 121
1987-91 2.0L 4-Cyl. (SOHC)
Balance Shaft T159 TCK158A 4 60,000 2 121
Camshaft T158 TCK158A 4 60,000 2 121
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 136
1993 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
1994 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
Colt Wagon (Includes Canadian)
1989-90 1.8L 4-Cyl. (VIN T) T093 60,000 91
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 136
1993 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
1994 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
Colt 100 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
Colt 200 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
Daytona & Daytona Shelby
1984-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989-93 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
1992-93 2.2L 4-Cyl. (DOHC, VIN A) T206 60,000 1 96
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989-93 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1990-93 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
Dynasty
1989-93 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1988-93 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
Expo (Canadian)
1987-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
Intrepid
1998-99 3.2L V6 T295 Yes Yes 105,000 123
1993-94 3.5L V6 T219 105,000 123
1995-97 3.5L V6 T255 105,000 123
2000 3.5L V6 T295 100,000 Federal 123
1
2
3
DODGE (Cont.)
Lancer
1985-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
Neon
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) T246 Yes Yes 105,000 133
1995-00 2.0L 4-Cyl. (SOHC, VIN C) T245 Yes Yes 105,000 93
Omni
1978-83 1.7L 4-Cyl. T017 TCK017 4 60,000 1 89
1981-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989-90 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
Rampage
1982-84 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
Shadow
1987-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989-94 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989-94 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1992-93 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
1994 3.0L V6 (SOHC) T139 TCK139 4 60,000 3 110
Spirit
1991-92 2.2L 4-Cyl. (DOHC, VIN A) T206 60,000 1 96
1989-95 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1989-93 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 110
1994-95 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 3 110
Stealth
1991-96 3.0L V6 (DOHC) T195 Yes Yes 60,000 3 142
1991-93 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
1994-96 3.0L V6 (SOHC) T139 TCK139 4 60,000 3 110
Stratus
2000 2.0L 4-Cyl. (SOHC, VIN C) T245 Yes Yes 100,000 Federal 93
105,000 Calif. 93
1995-00 2.5L V6 T259 Yes Yes 60,000 3 108
024
1981-82 1.7L 4-Cyl. T017 TCK017 4 60,000 1 89
1981-82 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
400
1982-83 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
600
1983-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
2000 GTX (Canadian)
1989-92 2.0L 4-Cyl. (SOHC)
Camshaft T155 60,000 2 121
1
2
3

DODGE/PLYMOUTH
Light Trucks
Caravan
1982-88 2.2L 4-Cyl. T071 TCK071 4 60,000 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989-95 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1996-00 2.4L 4-Cyl. (DOHC, VIN B) T265 Yes 120,000 104
1987-93 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 110
1994-96 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 3 110
1997-00 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 3 110
Dakota
1987-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989-95 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
Mini Ram Van
1984-87 2.2L 4-Cyl. T071 TCK0714 60,000 1 101
1987 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1987-93 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 110
Raider
1989 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
Ram 50
1983-86 2.0L 4-Cyl. (SOHC)
Camshaft T089 60,000 2 121
1987-89 2.0L 4-Cyl. (SOHC)
Camshaft T158 TCK158A 4 60,000 2 121
1983-85 2.3L 4-Cyl. Diesel
Balance Shaft T092 Yes 50,000 2 138
Camshaft T091 Yes 50,000 2 138
1990-92 2.4L 4-Cyl.
Balance Shaft T159 TCK124 4 60,000 2 140
Camshaft T124 TCK124 4 60,000 2 140
1993 2.4L 4-Cyl.
Camshaft T229 60,000 2 140
1990-91 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
Scamp Pickup
1983 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
Light Trucks
Voyager
1982-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989-95 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1987-93 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 110
1994-96 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 3 110
1997-00 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 3 110
EAGLE
Medallion
1989 2.2L 4-Cyl. T140 60,000 1 156
1
2
3
EAGLE (Cont.)
Summit
1989-90 1.5L 4-Cyl. T128 TCK128 4 Yes 60,000 114
1991-96 1.5L 4-Cyl. T191 TCK191 4 60,000 114
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
1992-96 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 136
1993-96 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
Summit Wagon
1992-96 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
Talon
1993-94 1.8L 4-Cyl.
Camshaft T158 TCK158 4 60,000 2 128
1990-99 2.0L 4-Cyl. (DOHC)
Balance Shaft T168 TCK167 4 Yes 60,000 2 116
Camshaft T167 TCK167 4 Yes 60,000 2 116
Vision
1993-94 3.5L V6 T219 Yes 105,000 123
1995-97 3.5L V6 T255 Yes 105,000 123
Vista (Canadian)
1989-91 1.5L 4-Cyl. T128 TCK128 4 Yes 60,000 114
1992 1.5L 4-Cyl. T191 TCK191 4 60,000 114
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
1989 1.6L 4-Cyl. w/o Bal. Shaft T093 60,000 87
1989-91 2.0L 4-Cyl. (SOHC)
Camshaft T158 TCK158A 4 60,000 2 121
2000GTX (Canadian)
1989-93 2.0L 4-Cyl. (DOHC)
1989-92 2.0L 4-Cyl. (SOHC)
Camshaft T155 60,000 2 121
FIAT
Brava
1974-78 1.8L 4-Cyl. T020 Yes 25,000 158
1979-83 2.0L 4-Cyl. T068 Yes 30,000 160
Spider 2000
1979-82 2.0L 4-Cyl. T068 Yes 30,000 160
Strada
1979-82 1.5L 4-Cyl. T069 Yes 30,000 157
X1/9
1974-78 1.3L 4-Cyl. T018 Yes 36,000 157
1979-83 1.5L 4-Cyl. T069 Yes 30,000 157
1
2
3

FIAT (Cont.)
124 Series
1971-74 1.6L 4-Cyl. T020 Yes 25,000 158
1974-78 1.8L 4-Cyl. T020 Yes 25,000 158
128 Series
1973-79 1.3L 4-Cyl. T018 Yes 36,000 157
131 Series
1975-78 1.8L 4-Cyl. T020 Yes 25,000 158
FORD
Passenger Cars
Aspire
1994-97 1.3L 4-Cyl. T185 60,000 Federal 161
Contour
1995-97 2.0L 4-Cyl. (DOHC, VIN 3) T258 60,000 1 178
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) T294 Inspect at 120,000;
Replace if needed 180
Escort
1981-85 1.6L 4-Cyl. (SOHC) T067 TCK067 4 Yes Yes 60,000 165
1991-96 1.8L 4-Cyl. (DOHC) T179 TCK179 4 60,000 169
1985-90 1.9L 4-Cyl. T067 TCK067 4 Yes Yes 60,000 165
1991 1.9L 4-Cyl.
Before 3/25/1991 T067 TCK067 4 Yes Yes 60,000 165
After 3/26/1991 T194 TCK194 4 Yes Yes 60,000 165
1992-96 1.9L 4-Cyl. T194 TCK194 4 Yes Yes 60,000 165
1984-87 2.0L 4-Cyl. Diesel
Injection Pump T102 Yes Yes 100,000 2 172
1997-00 2.0L 4-Cyl. (SOHC, VIN P) T283 Inspect at 120,000;
2001 2.0L 4-Cyl. (SOHC, VIN P) T283 120,000 184
Escort Coupe & ZX2
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) T294 Inspect at 120,000;
2001 2.0L 4-Cyl. (DOHC, VIN 3) T294 120,000 180
EXP
1985-90 1.9L 4-Cyl. T067 TCK067 4 Yes Yes 60,000 165
Fairmont
1978-83 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Festiva
1988-89 1.3L 4-Cyl. T141 TCK141 4 60,000 161
1990-93 1.3L 4-Cyl. T185 60,000 161
Focus
2000 2.0L 4-Cyl. (DOHC, VIN 3) T294 Inspect at 120,000;
2001 2.0L 4-Cyl. (DOHC, VIN 3) T294 120,000 180
2000 2.0L 4-Cyl. (SOHC, VIN P) T283 Inspect at 120,000;
2001 2.0L 4-Cyl. (SOHC, VIN P) T283 120,000 184
Granada
1981-82 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
LTD
1983-86 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
1
2
3
FORD (Cont.)
Mustang
1974-91 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
1992 2.3L 4-Cyl.
Square Tooth Sprocket T014 TCK014 4 60,000 1 189
Round Tooth Sprocket T210 60,000 1 189
1993 2.3L 4-Cyl. T210 60,000 1 189
Pinto
1971-74 2.0L 4-Cyl. T013 60,000 1 168
1974-80 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Probe
1989-92 2.2L 4-Cyl. T134 TCK134 4 Yes 60,000 186
1993-97 2.0L 4-Cyl. T228 TCK228 4 Yes 60,000 Federal 186
1993-97 2.5L V6 T214 Yes 60,000 Federal 196
Taurus SHO
1989-95 3.0L V6 T248 100,000 200
1993-95 3.2L V6 T248 100,000 200
Tempo
1984-86 2.0L 4-Cyl. Diesel
Thunderbird
1983-88 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Light Trucks
Aerostar
1987 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Courier
1977-82 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Escape
2001 2.0L 4-Cyl. (DOHC) T294 120,000 175
Ranger
1983-88 2.0L 4-Cyl. T014 60,000 1 189
1983-91 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
1992 2.3L 4-Cyl.
Square Tooth Sprocket T014 TCK014 4 60,000 1 189
Round Tooth Sprocket T210 60,000 1 189
1993-94 2.3L 4-Cyl. T210 60,000 1 189
1995-97 2.3L 4-Cyl. T276 60,000 194
1985-87 2.3L 4-Cyl. Diesel
1998-00 2.5L 4-Cyl. T276 Inspect At 120,000;
Replace, if needed 195
2001 2.5L 4-Cyl. T276 120,000 195
G.M.C. (SEE CHEVROLET/G.M.C.)

GEO
Passenger Cars
Metro
1989-92 1.0L 3-Cyl. T166 60,000 211
1993 1.0L 3-Cyl.
4-Bolt Sprocket T166 60,000 211
5-Bolt Sprocket T241 60,000 211
1
2
3

GEO (Cont.)
Metro (Cont.)
1994-95 1.0L 3-Cyl. T241 60,000 211
1996 1.0L 3-Cyl. T194 TCK194 4 60,000 211
1997-00 1.0L 3-Cyl. T194 TCK194 4 100,000 211
1992-93 1.3L 4-Cyl. T095 60,000 213
1994 1.3L 4-Cyl. T243 60,000 213
1995-97 1.3L 4-Cyl. T272 60,000 213
Metro (Canadian)
1992-93 1.3L 4-Cyl. T095 60,000 213
1994 1.3L 4-Cyl. T243 60,000 213
Prizm
1937-97 1.6L 4-Cyl. (DOHC, VIN 6) T236 TCK236 4 Yes 60,000 207
Prizm GSI
1990-92 1.6L 4-Cyl. (DOHC) T176 60,000 203
Spectrum
1985 1.5L 4-Cyl. T118 Yes Yes 60,000 219
1986-87 1.5L 4-Cyl
Up To 6/30/1986 T118 Yes Yes 60,000 219
From 7/1/1986 T162 Yes Yes 60,000 219
1988-89 1.5L 4-Cyl. T162 Yes Yes 60,000 219
Storm
1990-91 1.6L 4-Cyl. (DOHC) T169 Yes 60,000 209
1990-93 1.6L 4-Cyl. (SOHC) T177 Yes Yes 30,000 205
1992-93 1.8L 4-Cyl. (DOHC) T205 Yes 60,000 209
Light Trucks
Tracker
1989-95 1.6L 4-Cyl. (8-Valve)
California T212 60,000 1 215
Except California T164 60,000 1 215
1994-98 1.6L 4-Cyl. (16-Valve)
1999-01 1.6L 4-Cyl. (16-Valve) T212 60,000 217
HONDA
Passenger Cars
Accord
1976-83 1.6L 4-Cyl. (SOHC) T041 Yes 60,000 1 253
1979-83 1.8L 4-Cyl. T041 Yes 60,000 1 263
1984-85 1.8L 4-Cyl. T094 TCK160 4 Yes 60,000 1 263
1986-89 2.0L 4-Cyl. T160 TCK160 4 Yes 60,000 1 269
1990-93 2.2L 4-Cyl. (SOHC)
Balance Shaft T186 TCK186 4 Yes Yes 90,000 2 278
Camshaft T187 TCK186 4 Yes Yes 90,000 2 278
1994 (EX) 2.2L 4-Cyl. (SOHC)
1994 (Exc. EX) 2.2L 4-Cyl. (SOHC)
1
2
3
HONDA (Cont.)
Accord (Cont.)
1995 (EX) 2.2L 4-Cyl. (SOHC)
Balance Shaft T186 TCK186 4 Yes Yes 90,000 2, Normal 278
60,000 2, Severe 278
Camshaft T244 TCK186 4 Yes Yes 90,000 2, Normal 278
60,000 2, Severe 278
1995 (Exc. EX) 2.2L 4-Cyl. (SOHC)
60,000 2, Severe 278
60,000 2, Severe 278
1996 2.2L 4-Cyl. (SOHC)
Balance Shaft T186 Yes Yes 90,000 2, Normal 278
60,000 2, Severe 278
Camshaft (w/o VTEC) T187 TCK186 4 Yes Yes 90,000 2, Normal 278
60,000 2, Severe 278
Camshaft (w/ VTEC) T244 TCK186 4 Yes Yes 90,000 2, Normal 278
60,000 2, Severe 278
1997 2.2L 4-Cyl. (SOHC)
Balance Shaft T186 Yes Yes 105,000 2, 3 278
Camshaft (w/o VTEC) T187 TCK186 4 Yes Yes 105,000 2, 3 278
Camshaft (w/ VTEC) T244 Yes Yes 105,000 2, 3 278
1998-01 2.3L 4-Cyl. (SOHC)
1996 2.7L V6 T263 Yes Yes 90,000 Normal 287
60,000 Normal 287
1997 2.7L V6 T263 Yes Yes 105,000 3 287
1998-01 3.0L V6 T286 Yes Yes 105,000 3 288
Civic
1973-79 1.2L 4-Cyl. T028 Yes 60,000 1 241
1980-83 1.3L 4-Cyl.
Canada T028 Yes 60,000 1 243
USA T073 Yes 60,000 1 243
1984-85 1.3L 4-Cyl. T099 Yes Yes 60,000 1 243
1986-87 1.3L 4-Cyl. T161 TCK161 4 Yes Yes 60,000 1 243
1980-83 1.5L 4-Cyl. T041 Yes 60,000 1 246
1984-85 1.5L 4-Cyl. T099 Yes Yes 60,000 1 246
1986-87 1.5L 4-Cyl. T161 TCK161 4 Yes Yes 60,000 1 246
1988-89 1.5L 4-Cyl. T143 TCK143 4 Yes Yes 60,000 1 246
1990-94 1.5L 4-Cyl. T143 TCK143 4 Yes Yes 90,000 246
1995 1.5L 4-Cyl. T143 TCK143 4 Yes Yes 90,000, Normal 246
60,000, Severe 246
1988-89 1.6L 4-Cyl. (SOHC) T145 Yes Yes 60,000 1 253
1991 1.6L 4-Cyl. (SOHC) T145 Yes Yes 90,000 253
1992
Except Si 1.6L 4-Cyl. (SOHC) T145 Yes Yes 90,000 253
Si 1.6L 4-Cyl. (SOHC) T224 Yes Yes 90,000 253
1995 1.6L 4-Cyl. (SOHC) T224 Yes Yes 90,000 Normal 253
60,000 Severe 253
60,000 Severe 257
1
2
3

HONDA (Cont.)
Civic (Cont.)
2001 1.7L 4-Cyl. (SOHC) T312 Yes 110,000 3 260
Civic CVCC
1975 1.5L 4-Cyl. T036 TCK036 4 Yes 60,000 1 246
1976-79 1.5L 4-Cyl. T041 Yes 60,000 1 246
Civic CRX
1984 1.3L 4-Cyl. T099 Yes Yes 60,000 1 243
1984-85 1.5L 4-Cyl. T099 Yes Yes 60,000 1 246
1986-87 1.5L 4-Cyl. T161 TCK1614 Yes Yes 60,000 1 246
Civic del Sol (Except VX)
1993-94 1.5L 4-Cyl. T143 TCK143 4 Yes Yes 90,000 246
1995 1.5L 4-Cyl. T143 TCK143 4 Yes Yes 90,000, Normal 246
60,000, Severe 246
60,000 Severe 253
60,000 Severe 257
1997 1.6L 4-Cyl. (SOHC) T224 Yes Yes 105,000 3 257
1994 1.6L 4-Cyl. (DOHC) T227 Yes Yes 90,000 251
1995-95 1.6L 4-Cyl. (DOHC) T227 Yes Yes 90,000 Normal 251
60,000 Severe 251
1997 1.6L 4-Cyl. (DOHC) T227 Yes Yes 105,000 3 251
Civic del Sol VX
1993-94 1.5L 4-Cyl. T223 Yes Yes 90,000 246
1995 1.5L 4-Cyl. T223 Yes Yes 90,000, Normal 246
60,000, Severe 246
Civic VX
1992-94 1.5L 4-Cyl. T223 Yes Yes 90,000 246
60,000, Severe 246
Prelude
1980-82 1.6L 4-Cyl. (SOHC) T041 Yes 60,000 1 253
1979-82 1.8L 4-Cyl. T041 Yes 60,000 1 263
1983-85 1.8L 4-Cyl. T094 TCK160 4 Yes Yes 60,000 1 263
1986-87 1.8L 4-Cyl. T160 TCK160 4 Yes Yes 60,000 1 263
1985 2.0L 4-Cyl. T094 TCK160 4 Yes 60,000 1 269
1986-87 2.0L 4-Cyl. (SOHC) T160 TCK160 4 Yes 60,000 1 269
1990 2.0L 4-Cyl. (SOHC) T144 Yes Yes 90,000 269
1988-89 2.0L 4-Cyl. (DOHC) T142 Yes Yes 60,000 1 271
1990-91 2.0L 4-Cyl. (DOHC) T141 Yes Yes 90,000 271
1990-91 2.1L 4-Cyl. (DOHC) T142 Yes Yes 90,000 271
1993-94 2.2L 4-Cyl. (DOHC)
1995-96 2.2L 4-Cyl. (DOHC)
60,000 2, Severe 273
60,000 2, Severe 273
1
2
3
HONDA (Cont.)
Prelude (Cont.)
1997-01 2.2L 4-Cyl. (DOHC)
Balance Shaft T186 TCK186 4 Yes Yes 105,000 2, 3 273
Camshaft T226 TCK186 4 Yes Yes 105,000 2, 3 273
1992-94 2.2L 4-Cyl. (SOHC)
1995-96 2.2L 4-Cyl. (SOHC)
60,000 2, Severe 278
60,000 2, Severe 278
1992-94 2.3L 4-Cyl. (DOHC)
1995-96 2.3L 4-Cyl. (DOHC)
Balance Shaft T186 Yes Yes 90,000 2, Normal 278
60,000 2, Severe 278
Camshaft T216 Yes Yes 90,000 2, Normal 278
60,000 2, Severe 278
Light Trucks
CR-V
1997-01 2.0L 4-Cyl. T184 Yes Yes 105,000 3 266
Odyssey
1995-96 2.2L 4-Cyl. (SOHC)
1997 2.2L 4-Cyl. (SOHC)
1998 2.3L 4-Cyl. (SOHC)
1999-01 3.5L V6 T286 Yes Yes 105,000 3 288
Passport
1994-96 2.6L 4-Cyl. T147 Yes 60,000 285
1994-97 3.2L V6 (SOHC) T221 Yes 60,000 28
1998-99 3.2L V6 (DOHC) T303 Yes 75,000 291
2000-01 3.2L V6 (DOHC) T303 Yes 105,000 3 291
HYUNDAI
Accent
1995-96 1.5L 4-Cyl. (DOHC) T282 Yes 60,000 293
1997 1.5L 4-Cyl. (DOHC) T282 Yes 60,000 3 293
1995-96 1.5L 4-Cyl. (SOHC) T191 TCK191 4 Yes 60,000 294
1997-01 1.5L 4-Cyl. (SOHC) T191 TCK191 4 60,000 3 294
2001 1.6L 4-Cyl. (DOHC) T282 Yes 60,000 3 296
Elantra
1992-95 1.6L 4-Cyl. (DOHC)
Balance Shaft T168 Yes 60,000 2
297
Camshaft T165 Yes 60,000 2
297
1993-95 1.8L 4-Cyl. (DOHC)
Balance Shaft T168 TCK167 4 Yes 60,000 2
297
Camshaft T167 TCK167 4 Yes 60,000 2
297
1
2
3

HYUNDAI (Cont.)
Elantra (Cont.)
1996-98 1.8L 4-Cyl. T278 Yes 60,000 3 301
1999-01 2.0L 4-Cyl. T284 Yes 60,000 3 301
Excel
1986-89 1.5L 4-Cyl. (SOHC) T073 Yes 60,000 294
Scoupe
Sonata
1992-98 2.0L 4-Cyl. (DOHC)
Balance Shaft T168 TCK167 4 Yes 60,000 2, 3
302
Camshaft T167 TCK167 4 Yes 60,000 2, 3
302
1989-91 2.4L 4-Cyl. (SOHC)
1990-98 3.0L V6 T139 TCK139 4 Yes 60,000 3 308
Tiburon
1997 1.8L 4-Cyl. T278 Yes 60,000 3 301
1999-01 2.0L 4-Cyl. T284 Yes 60,000 3 301
INFINITI
Passenger Cars
J30
1993 3.0L V6 T180 Yes 60,000 310
1994-97 3.0L V6 T251 Yes 60,000 310
M30
1990-92 3.0L V6 T104 Yes 60,000 313
Light Trucks
QX4
1997-01 3.3L V6 (SOHC) T249 105,000 456
ISUZU
Passenger Cars
I-Mark
1981-84 1.8L 4-Cyl. Diesel T076 Yes 60,000 318
1985-87 1.5L 4-Cyl.
Up To 6/30/86 T118 Yes Yes 60,000 219
From 7/1/86 T162 Yes Yes 60,000 219
1988-89 1.5L 4-Cyl. T162 Yes Yes 60,000 219
1989 1.6L 4-Cyl. (DOHC) T169 Yes Yes 60,000 315
Impulse
1985-89 2.0L 4-Cyl. Turbo T121 Yes 60,000 320
1988-89 2.3L 4-Cyl. T122 Yes 60,000 315
1990-92 1.6L 4-Cyl. (DOHC) T169 Yes 60,000 315
1991-93 1.6L 4-Cyl. Turbo T169 Yes Yes 60,000 315
1992 1.8L 4-Cyl. T205 Yes 60,000 315
Stylus
1991 1.6L 4-Cyl. (DOHC) T169 60,000 315
1991-93 1.6L 4-Cyl. (SOHC) T177 Yes 60,000 315
1992-93 1.8L 4-Cyl. T205 Yes 60,000 315
Light Trucks
Amigo
1998 2.2L 4-Cyl. T305 Yes Yes 75,000 325
1
2
3
ISUZU (Cont.)
Amigo (Cont.)
1999-00 2.2L 4-Cyl. T305 Yes Yes 100,000, Normal 325
75,000, Severe 325
1989-93 2.3L 4-Cyl. T122 Yes 60,000 320
1989-94 2.6L 4-Cyl. T147 Yes 60,000 320
1998 3.2L V6 T303 Yes 75,000 334
1999 3.2L V6 T303 Yes 100,000 Normal 334
75,000 Severe 334
Oasis
1996 2.2L 4-Cyl. (SOHC)
1997 2.2L 4-Cyl. (SOHC)
1998 2.3L 4-Cyl. (SOHC)
Pickup & PUP
1981-87 2.2L 4-Cyl. Diesel T075 Yes 60,000 323
1986-95 2.3L 4-Cyl. T122 Yes 60,000 320
1988-95 2.6L 4-Cyl. T147 Yes 60,000 320
Rodeo
1998 2.2L 4-Cyl. T305 Yes Yes 75,000 325
1999-00 2.2L 4-Cyl. T305 Yes Yes 100,000, Normal 325
75,000, Severe 325
60,000, Severe 325
1991-97 2.6L 4-Cyl. T147 Yes 60,000 320
1993-97 3.2L V6 (SOHC) T221 Yes 60,000 332
1998 3.2L V6 T303 Yes 75,000 334
1999-01 3.2L V6 T303 Yes 100,000 Normal 334
75,000 Severe 334
Trooper
1990-91 2.6L 4-Cyl. T147 Yes 60,000 320
1992-95 3.2L V6 (DOHC) T220 Yes 60,000 332
1992-97 3.2L V6 (SOHC) T221 Yes 60,000 332
1998 3.5L V6 T303 Yes 75,000 334
1999-01 3.5L V6 T303 Yes 100,000 Normal 334
75,000 Severe 334
Trooper II
1984-87 2.2L 4-Cyl. Diesel T075 Yes 60,000 323
1986-87 2.3L 4-Cyl. T122 Yes 60,000 320
1988-89 2.6L 4-Cyl. T147 Yes 60,000 320
VehiCROSS
1999-01 3.5L V6 T303 Yes 100,000 Normal 334
75,000 Severe 334
KIA
Passenger Cars
Sephia
1994-95 1.6L 4-Cyl. (SOHC) T185 Yes 105,000 (Calif.) 3 337
1994-95 1.6L 4-Cyl. (SOHC) T185 Yes 60,000 (Exc. Calif.) 337
1996-97 1.6L 4-Cyl. (DOHC) T179 TCK179 4 Yes 105,000 (Calif.) 3 336
1996-97 1.6L 4-Cyl. (DOHC) T179 TCK179 4 Yes 60,000 (Exc. Calif.) 336
1
2
3

KIA (Cont.)
Sephia (Cont.)
1995-97 1.8L 4-Cyl. (DOHC) T179 TCK179 4 Yes 105,000 (Calif.) 3 336
1995-97 1.8L 4-Cyl. (DOHC) T179 TCK179 4 Yes 60,000 (Exc. Calif.) 336
1998-01 1.8L 4-Cyl. (DOHC) T302 Yes 105,000 (Calif.) 3 339
1998-01 1.8L 4-Cyl. (DOHC) T302 Yes 60,000 (Exc. Calif.) 339
1996-97 1.8L 4-Cyl. (SOHC) T185 Yes 105,000 (Calif.) 3 337
1996-97 1.8L 4-Cyl. (SOHC) T185 Yes 60,000 (Exc. Calif.) 337
Spectra
Light Trucks
Sportage
1995 2.0L 4-Cyl. (SOHC) T264 Yes 105,000 (Calif.) 3 343
1995 2.0L 4-Cyl. (SOHC) T264 Yes 60,000 (Exc. Calif.) 343
LANCIA
Beta
1976-78 1.8L 4-Cyl. T020 Yes 25,000 344
LEXUS
ES250
1990-91 2.5L V6 T157 Yes 60,000 1, 3 345
ES300
1992-93 3.0L V6 T200 Yes 60,000 1, 3 345
1994-98 3.0L V6 T257 Yes 60,000 1, 3 345
1999-01 3.0L V6 T257 Yes 90,000 349
GS300
1993-97 3.0L 6-Cyl. T215 60,000 1, 3 353
1998-01 3.0L 6-Cyl. T215 90,000 355
GS400
1998-00 4.0L V8 T298 Yes 90,000 362
LS400
1990-94 4.0L V8 T190 Yes 60,000 1, 3 358
1995-97 4.0L V8 T190 Yes 90,000, Normal 358
60,000, Severe 358
1998-00 4.0L V8 T298 Yes 90,000 362
SC300
1993-97 3.0L 6-Cyl. T215 60,000 1, 3 353
1998-00 3.0L 6-Cyl. T215 90,000 355
SC400
1992-94 4.0L V8 T190 Yes 60,000 1, 3 358
1995-97 4.0L V8 T190 Yes 90,000, Normal 358
60,000, Severe 358
1998-00 4.0L V8 T298 Yes 90,000 362
Light Trucks
LX470
1998-01 4.7L V8 T298 Yes Yes 90,000 366
RX-300
1999-01 3.0L V6 T257 Yes 90,000 349
1
2
3
MAZDA
Passenger Cars
Miata & MX-5 Miata
1990-92 1.6L 4-Cyl. (DOHC) T179 TCK179 4 60,000 373
1993 1.6L 4-Cyl. (DOHC) T179 TCK179 4 60,000 Federal 373
105,000 Calif. 373
1994-96 1.8L 4-Cyl. (DOHC) T179 TCK179 4 60,000 Federal 376
105,000 Calif. 376
1997-00 1.8L 4-Cyl. (DOHC) T179 TCK179 4 105,000 3 376
1997-00 1.8L 4-Cyl. (DOHC) T179 TCK179 4 60,000 3 376
2001 1.8L 4-Cyl. (DOHC) T179 TCK179 4 60,000 376
Millenia
1995-96 2.3L V6 (Miller Cycle) T267 60,000 Federal 396
105,000 Calif. 396
1997-00 2.3L V6 (Miller Cycle) T267 105,000 3 396
1997-00 2.3L V6 (Miller Cycle) T267 60,000 3 396
1995-96 2.5L V6 T214 60,000 Federal 399
105,000 Calif. 399
1997-00 2.5L V6 T214 105,000 3 399
1997-00 2.5L V6 T214 60,000 3 399
2001 2.5L V6 T214 105,000 3 399
MX-3 (Includes Canadian)
1988-89 1.6L 4-Cyl. (DOHC) T149 60,000 373
105,000 Calif. 373
1992 1.6L 4-Cyl. (SOHC) T185 60,000 373
1993 1.6L 4-Cyl. (SOHC) T185 60,000 Federal 373
105,000 Calif. 373
1992 1.8L V6 T214 Yes 60,000 393
1993-95 1.8L V6 T214 Yes 60,000 Federal 393
105,000 Calif. 393
MX-6
1993 2.0L 4-Cyl. (DOHC) T228 TCK228 4 Yes 60,000 382
1994-96 2.0L 4-Cyl. (DOHC) T228 TCK228 4 Yes 60,000 Federal 382
105,000 Calif. 382
1997 2.0L 4-Cyl. (DOHC) T228 TCK228 4 Yes 105,000 3 382
1988-92 2.2L 4-Cyl. T134 TCK134 4 Yes 60,000 387
1993 2.5L V6 T214 60,000 399
1994-96 2.5L V6 T214 60,000 Federal 399
105,000 Calif. 399
1997 2.5L V6 T214 105,000 3 399
1997 2.5L V6 T214 60,000 3 399
Protege
1995-97 1.5L 4-Cyl. T266 60,000 (Ex. CA & MA) 370
1995-97 1.5L 4-Cyl. T266 105,000 (CA & MA) 3 370
1998 1.5L 4-Cyl.
Up To Eng. No. 19472 T266 60,000 (Ex. CA & MA) 370
105,000 (CA & MA) 3 370
From Eng. No. 19473 T308 60,000 (Ex. CA & MA) 370
105,000 (CA & MA) 3 370
1999-00 1.6L 4-Cyl. (DOHC) T308 60,000 3 371
2001 1.6L 4-Cyl. (DOHC) T308 105,000 3 371
1990-92 1.8L 4-Cyl. (DOHC) T179 60,000 373
105,000 Calif. 373
1
2
3

MAZDA (Cont.)
Protege (Cont.)
105,000 Calif. 376
1997-98 1.8L 4-Cyl. (DOHC) T179 TCK179 4 60,000 3 376
1997-98 1.8L 4-Cyl. (DOHC) T179 TCK179 4 105,000 3 376
1999-00 1.8L 4-Cyl. (DOHC) T316 60,000 3 380
1999-00 1.8L 4-Cyl. (DOHC) T316 105,000 3 380
1990-92 1.8L 4-Cyl. (SOHC) T185 60,000 373
1993-94 1.8L 4-Cyl. (SOHC) T185 60,000 Federal 373
105,000 Calif. 373
323
1988-89 1.6L 4-Cyl. (DOHC) T149 60,000 373
1986 1.6L 4-Cyl. (SOHC) T123 60,000 373
1987-89 1.6L 4-Cyl. (SOHC) T141 TCK141 4 60,000 373
1990-92 1.8L 4-Cyl. (SOHC) T185 60,000 373
1993-94 1.6L 4-Cyl. (SOHC) T185 60,000 Federal 373
105,000 Calif. 373
626
1983 2.0L 4-Cyl. (SOHC) T088 Yes 60,000 387
1984-85 2.0L 4-Cyl.
Square Tooth Sprocket T088 Yes 60,000 387
Round Tooth Sprocket T113 Yes 60,000 387
1986-87 2.0L 4-Cyl. T117 Yes 60,000 387
1984-85 2.0L 4-Cyl. Diesel
Injection Pump T102 Yes 100,000 389
1993 2.0L 4-Cyl. (DOHC) T228 TCK228 4 Yes 60,000 382
1994-96 2.0L 4-Cyl. (DOHC) T228 TCK228 4 Yes 60,000 Federal 382
105,000 Calif. 382
1997-00 2.0L 4-Cyl. (DOHC) T228 TCK228 4 Yes 105,000 3 382
1997-00 2.0L 4-Cyl. (DOHC) T228 TCK228 4 Yes 60,000 3 382
1988-92 2.2L 4-Cyl. T134 TCK134 4 Yes 60,000 387
1993 2.5L V6 T214 60,000 399
1994-96 2.5L V6 T214 60,000 Federal 399
105,000 Calif. 399
1997-00 2.5L V6 T214 105,000 3 399
1997-00 2.5L V6 T214 60,000 3 399
2001 2.5L V6 T214 105,000 3 399
929
1990-93 3.0L V6 (DOHC) T183 Yes 60,000 402
1994-95 3.0L V6 (DOHC) T183 Yes 60,000 Federal 402
105,000 Calif. 402
1988-91 3.0L V6 (SOHC) T146 TCK146 4 Yes 60,000 404
Light Trucks
B2000
1986 2.0L 4-Cyl. (SOHC)
Up To Chas. 568707 T113 Yes 60,000 387
From Chas. 568708 T117 Yes 60,000 387
1987 2.0L 4-Cyl. (SOHC) T117 Yes 60,000 387
B2200
1987-93 2.2L 4-Cyl. T134 TCK134 4 Yes 60,000 387
1
2
3
MAZDA (Cont.)
B2300
1994 2.3L 4-Cyl. T210 60,000 391
1997-95 2.3L 4-Cyl. T276 60,000 391
B2500
1998-00 2.5L 4-Cyl. T276 120,000 392
MPV
1988-93 3.0L V6 (SOHC) T146 TCK146 4 Yes 60,000 404
1994-96 3.0L V6 (SOHC) T146 TCK146 4 Yes 60,000 Federal 404
105,000 Calif. 404
1997-98 3.0L V6 (SOHC) T146 TCK146 4 Yes 105,000 3 404
1997-98 3.0L V6 (SOHC) T146 TCK146 4 Yes 60,000 3 404
Tribute
2001 2.0L 4-Cyl. (DOHC) T294 120,000 384
MERCURY
Passenger Cars
Bobcat
1974-80 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Capri
1972 1.6L 4-Cyl. T013 60,000 1 168
1971-74 2.0L 4-Cyl. T013 60,000 1 168
1991-94 1.6L 4-Cyl. (DOHC) T179 TCK179 4 60,000 163
1976-86 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Cougar
1981-86 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) T294 Inspect at 120,000,
2001 2.0L 4-Cyl. (DOHC, VIN 3) T294 120,000 180
LN7
1985-87 1.9L 4-Cyl. T067 TCK067 4 Yes Yes 60,000 165
1984-87 2.0L 4-Cyl. Diesel
Marquis
1983-86 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Mystique
1995-97 2.0L 4-Cyl. (DOHC, VIN 3) T258 60,000 1000 178
1998-00 2.0L 4-Cyl. (DOHC, VIN 3) T294 Inspect at 120,000,
Topaz
1984-86 2.0L 4-Cyl. Diesel
Tracer
1991-96 1.8L 4-Cyl. (DOHC) T179 TCK179 4 60,000 169
1991 1.9L 4-Cyl.
Before 3/25/1991 T067 TCK067 4 Yes Yes 60,000 165
After 3/26/1991 T194 TCK194 4 Yes Yes 60,000 165
1992-96 1.9L 4-Cyl. T194 TCK194 4 Yes Yes 60,000 165
1
2
3

MERCURY (Cont.)
Tracer (Cont.)
1997-00 2.0L 4-Cyl. (SOHC, VIN P) T283 Inspect at 120,000,
2001 2.0L 4-Cyl. (SOHC, VIN P) T283 120,000 184
Zephyr
1978-83 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
Light Trucks
Villager
1993 3.0L V6 (SOHC) T104 TCK104 4 Yes 105,000 198
1994-98 3.0L V6 (SOHC) T249 Yes 105,000 198
MERKUR
XR4Ti
1985-89 2.3L 4-Cyl. T014 TCK014 4 60,000 1 189
MITSUBISHI
Passenger Cars
Cordia & Tredia
1983-84 1.8L 4-Cyl.
Camshaft T089 60,000 2 411
1985-86 1.8L 4-Cyl.
Camshaft T089 60,000 2 411
1987-88 1.8L 4-Cyl.
Camshaft T158 TCK158 4 60,000 2 411
1984 2.0L 4-Cyl.
Camshaft T089 60,000 2 411
1985-86 2.0L 4-Cyl.
Camshaft T089 60,000 2 411
1987-88 2.0L 4-Cyl.
Camshaft T158 60,000 2 411
Diamante
1992-93 3.0L V6 (DOHC) T195 Yes Yes 60,000 142
1994-96 3.0L V6 (DOHC) T195 Yes Yes 60,000 3 142
1992-93 3.0L V6 (SOHC, 12-Valve) T139 TCK139 4 Yes 60,000 430
1994-96 3.0L V6 (SOHC, 12-Valve) T139 TCK139 4 Yes 60,000 Federal 430
100,000 Calif. 430
1997-01 3.5L V6 (SOHC) T287 Yes Yes 60,000 3 442
Eclipse
1990-94 1.8L 4-Cyl.
Camshaft T158 TCK158 4 60,000 2 128
1995-97 2.0L 4-Cyl. (Non-Turbo)
DOHC, VIN Y T246 Yes Yes 60,000 Federal 3 133
100,000 Calif. 3 133
1998-99 2.0L 4-Cyl. (Non-Turbo)
DOHC, VIN Y T246 Yes Yes 60,000 3 133
1
2
3
MITSUBISHI (Cont.)
Eclipse (Cont.)
1990-94 2.0L 4-Cyl. (DOHC)
1995-97 2.0L 4-Cyl. (DOHC) Turbo
Balance Shaft T168 TCK167 4 Yes 60,000 Federal 2, 3 414
100,000 Calif. 2, 3 414
Camshaft T167 TCK167 4 Yes 60,000 Federal 2, 3 414
100,000 Calif. 2, 3 414
1998-99 2.0L 4-Cyl. (DOHC) Turbo
Balance Shaft T168 TCK167 4 Yes 60,000 2, 3 414
100,000 2, 3 414
Camshaft T167 TCK167 4 Yes 60,000 2, 3 414
100,000 2, 3 414
1996 2.4L 4-Cyl. (SOHC, VIN G)
Balance Shaft T168 Yes 60,000 Federal 2 425
100,000 Calif.2 425
Camshaft T230 Yes 60,000 Federal 2 425
100,000 Calif.2 425
1997-98 2.4L 4-Cyl. (SOHC, VIN G)

Balance Shaft T168 Yes 60,000 2 , 3 425
Camshaft T230 Yes 60,000 2 , 3 425
2000-01 2.4L 4-Cyl. (SOHC, VIN G)
Camshaft T232 Yes 60,000 2 , 3 425
2000-01 3.0L V6 (SOHC, 24-Valve) T259 Yes Yes 60,000 3 435
Expo & Expo LRV
1992-93 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
1994 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 Federal 131
100,000 California 3 131
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 136
1993-95 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
Galant
1989-92 2.0L 4-Cyl.
Camshaft T155 TCK155 4 60,000 2 411
1993 2.0L 4-Cyl.
Camshaft T232 TCK232 4 60,000 2 411
1989-92 2.0L 4-Cyl. (DOHC)
1993 2.0L 4-Cyl. (DOHC)
1
2
3

MITSUBISHI (Cont.)
Galant (Cont.)
1994 2.4L 4-Cyl. (DOHC)
Balance Shaft T168 Yes 60,000 Federal 419
100,000 Calif. 419
Camshaft
Up To May, 1994 T256 TCK256 4 Yes 60,000 Federal 419
100,000 Calif. 419
From June, 1994 T230 Yes 60,000 Federal 419
100,000 Calif. 419
1995-96 2.4L 4-Cyl. (DOHC)
Balance Shaft T168 Yes 60,000 Federal 419
100,000 Calif. 419
Camshaft T230 Yes 60,000 Federal 419
100,000 Calif. 419
1985-87 2.4L 4-Cyl. (SOHC)
Camshaft T124 TCK124 4 60,000 2 422
1994-96 2.4L 4-Cyl. (SOHC, VIN G)
Balance Shaft T168 Yes 60,000 Federal 2 425
100,000 Calif.2 425
Camshaft T230 Yes 60,000 Federal 2 425
100,000 Calif.2 425
1997-98 2.4L 4-Cyl. (SOHC, VIN G)

Camshaft T230 Yes 60,000 2 , 3 425
1999-01 2.4L 4-Cyl. (SOHC, VIN G)
Camshaft T232 Yes 60,000 2 , 3 425
1988 3.0L V6 (SOHC, 12-Valve) T139 TCK139 4 Yes 60,000 430
Mirage
1985-86 1.5L 4-Cyl. T073 Yes 60,000 406
1987-90 1.5L 4-Cyl. T128 TCK128 4 Yes 60,000 406
1991-93 1.5L 4-Cyl. T191 TCK191 4 60,000 406
1994-96 1.5L 4-Cyl. T191 TCK191 4 Yes 60,000 Federal 406
60,000 Calif. 3 406
1997-01 1.5L 4-Cyl. T289 Yes 100,000 3 406
1997-01 1.5L 4-Cyl. T289 Yes 60,000 3 406
1985-88 1.6L 4-Cyl. (SOHC) T093 Yes 60,000 409
1989-92 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
1993 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
1994-96 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 Federal 131
100,000 Calif. 3 131
1997-00 1.8L 4-Cyl. T288 Yes 100,000 3 131
1997-00 1.8L 4-Cyl. T288 Yes 60,000 3 131
Precis
1987-89 1.5L 4-Cyl. T073 Yes 60,000 406
1990-93 1.5L 4-Cyl. T128 TCK128 4 Yes 60,000 406
Sigma
Tredia (See Cordia)
1
2
3
MITSUBISHI (Cont.)
3000GT
1991-93 3.0L V6 (DOHC) T195 Yes Yes 60,000 142
1992-98 3.0L V6 (DOHC) T195 Yes Yes 60,000 3 142
1997-98 3.0L V6 (SOHC, 12-Valve) T139 TCK139 4 Yes 60,000 3 430
Light Trucks
Montero
1994 3.0L V6 (SOHC, 12-Valve) T139 TCK139 4 Yes 60,000 Federal 430
100,000 Calif. 430
1995-96 3.0L V6 (SOHC, 24-Valve) T259 Yes Yes 60,000 Federal 435
100,000 Calif. 435
1994-96 3.5L V6 (DOHC) T253 Yes 60,000 Federal 439
100,000 Calif. 439
1997-00 3.5L V6 (SOHC) T287 Yes Yes 60,000 3 442
Montero Sport
1997-98 2.4L 4-Cyl. (SOHC, VIN G)
Camshaft T230 Yes 60,000 2 , 3 425
1999 2.4L 4-Cyl. (SOHC, VIN G)
Camshaft T232 Yes 60,000 2 , 3 425
1997-01 3.5L V6 (SOHC) T287 Yes Yes 60,000 3 442
Pickup
1983-86 2.0L 4-Cyl.
Camshaft T089 60,000 2 411
1987-89 2.0L 4-Cyl.
Camshaft T158 TCK158A 4 60,000 2 411
1983-86 2.3L 4-Cyl. Diesel
1990-92 2.4L 4-Cyl.
Camshaft T124 TCK124 4 60,000 2 140
1993-96 2.4L 4-Cyl.
Camshaft T229 60,000 2 140
1994 3.0L V6 (SOHC, 12-Valve) T139 TCK139 4 Yes 60,000 Federal 430
100,000 Calif. 430
Van
1987-90 2.4L 4-Cyl. (SOHC)
Camshaft T124 TCK124 4 60,000 2 422
NISSAN
Passenger Cars
Maxima
1985 3.0L V6 (SOHC) T104 TCK104 4 Yes 454
1996-91 3.0L V6 (SOHC) T104 TCK104 4 Yes 60,000 454
1
2
3

NISSAN (Cont.)
Maxima (Cont.)
1992-94 3.0L V6 (SOHC)
Square Tooth Sprocket T104 TCK104 4 Yes 60,000 454
Pulsar & Pulsar NX
1983-84 1.5L 4-Cyl. T077 TCK077 4 Yes 60,000 1 446
1987 1.6L 4-Cyl. (DOHC) T137 Yes 60,000 448
1988-89 1.8L 4-Cyl. (DOHC) T137 Yes 60,000 448
Sentra
1982-83 1.5L 4-Cyl. T077 TCK077 4 Yes 60,000 1 446
1983-87 1.7L 4-Cyl. Diesel
Injection Pump T097 Yes 60,000 1 450
Stanza
1982-85 2.0L 4-Cyl. T078 Yes 60,000 1 451
1986-89 2.0L 4-Cyl. T078 Yes 60,000 451
Stanza Wagon
1989-86 2.0L 4-Cyl T078 60,000 1 451
200SX
1984-85 1.8L 4-Cyl. (Turbo) T100 60,000 1 451
1986-87 1.8L 4-Cyl. (Turbo) T100 60,000 451
1984-85 2.0L 4-Cyl. T078 Yes 60,000 1 451
1986-88 2.0L 4-Cyl. T078 Yes 60,000 451
1987-88 3.0L V6 (SOHC) T104 TCK104 4 Yes 60,000 454
300ZX
1984-85 3.0L V6 (SOHC) T104 TCK104 4 Yes 60,000 1 454
1986-89 3.0L V6 (SOHC) T104 TCK104 4 Yes 60,000 454
1990-93 3.0L V6 (DOHC) T180 Yes 60,000 452
1994-96 3.0L V6 (DOHC) T251 Yes 60,000 452
310
1982 1.5L 4-Cyl. T077 TCK077 4 Yes 60,000 1 446
Light Trucks
Frontier
1999-01 3.3L V6 (SOHC) T249 105,000 456
Pathfinder
1986-92 3.0L V6 (SOHC) T104 TCK104 4 Yes 60,000 454
1993-94 3.0L V6 (SOHC)
1995-96 3.0L V6 (SOHC) T249 Yes 60,000 454
1999-00 3.3L V6 (SOHC) T249 Yes 105,000 456
Pickup
1986-92 3.0L V6 (SOHC) T104 TCK104 4 Yes 60,000 454
1993-94 3.0L V6 (SOHC)
1995-96 3.0L V6 (SOHC) T249 Yes 60,000 454
Quest
1993-94 3.0L V6 (SOHC)
1995-98 3.0L V6 (SOHC) T249 Yes 60,000 454
1999-01 3.3L V6 (SOHC) T249 105,000 456
1
2
3
NISSAN (Cont.)
Xterra
2000-01 3.3L V6 (SOHC) T249 105,000 456
OLDSMOBILE
Cutlass Supreme
1991-95 3.4L V6 T192 Yes Yes 60,000 238
1996 3.4L V6 T273 Yes Yes 60,000 238
Firenza
1982-86 1.8L 4-Cyl. T081 60,000 1 228
1987-88 2.0L 4-Cyl. T081 60,000 1 229
PEUGEOT
405
1989-91 1.9L 4-Cyl. (DOHC) T188 60,000 1 460
1991-89 1.9L 4-Cyl. (SOHC) T189 60,000 1 460
505
1986-91 2.2L 4-Cyl. (Exc. Turbo) T140 60,000 1 462
PLYMOUTH
Passenger Cars
Acclaim
1985-89 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1989-93 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 110
1994-95 3.0L V6 (SOHC) T139 TCK139 4 Yes 60,000 3 110
Arrow
1977-80 1.6L 4-Cyl.
Camshaft T013 60,000 2 85
Breeze
1996-00 2.0L 4-Cyl. (SOHC, VIN C) T245 Yes Yes 100,000 Federal 93
105,000 Calif. 93
105,000 Calif. 106
Caravelle
1983-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
Champ
1979-82 1.4L 4-Cyl. T073 Yes 60,000 83
1979-80 1.6L 4-Cyl.
Camshaft T013 60,000 2 85
Colt
1979-84 1.4L 4-Cyl. T073 Yes 60,000 83
1985-86 1.5L 4-Cyl. T073 Yes 60,000 114
1987-90 1.5L 4-Cyl. T128 TCK128 4 Yes 60,000 114
1991-94 1.5L 4-Cyl. T191 TCK191 4 60,000 114
1979-82 (FWD)1.6L 4-Cyl. w/o Bal. Shaft T064 60,000 87
1977-80 1.6L 4-Cyl.
Camshaft T013 60,000 2 85
1
2
3

PLYMOUTH (Cont.)
Colt (Cont.)
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
1989-90 1.8L 4-Cyl. (VIN T) T093 60,000 91
1992-94 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
Colt Vista (Includes Canadian)
1992-94 1.8L 4-Cyl. (VINs C & D) T201 Yes 60,000 131
1984-86 2.0L 4-Cyl. (SOHC)
Camshaft T089 60,000 2 121
1987-91 2.0L 4-Cyl. (SOHC)
Camshaft T158 TCK158A 4 60,000 2 121
1992 2.4L 4-Cyl.
Camshaft T204 60,000 2 136
1993 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
1994 2.4L 4-Cyl.
Camshaft T230 60,000 2 136
Colt 100 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
Colt 200 (Canadian)
1989-90 1.6L 4-Cyl. (DOHC) T165 Yes 60,000 125
Horizon
1978-83 1.7L 4-Cyl. T017 TCK017 4 60,000 1 89
1981-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989-90 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
Laser
1990-94 1.8L 4-Cyl.
Camshaft T158 TCK158 4 60,000 2 128
1990-94 2.0L 4-Cyl. (DOHC)
Neon
1995-99 2.0L 4-Cyl. (DOHC, VIN Y) T246 Yes Yes 105,000 133
1995-00 2.0L 4-Cyl. (SOHC, VIN C) T245 Yes Yes 105,000 93
Reliant
1981-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989 2.2L 4-Cyl. T153 TCK071 4 60,000 1 101
1986-87 2.5L 4-Cyl. T114 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1989 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
Sapporo
1977-80 1.6L 4-Cyl.
Camshaft T013 60,000 2 85
Sundance
1987-88 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
1989-94 2.2L 4-Cyl. T153 TCK153 4 60,000 1 101
1988 2.5L 4-Cyl. T132 60,000 1 101
1
2
3
PLYMOUTH (Cont.)
Sundance (Cont.)
1989-94 2.5L 4-Cyl. T153 TCK153 4 60,000 1 101
1992-93 3.0L V6 (SOHC) T139 TCK139 4 60,000 110
1994 3.0L V6 (SOHC) T139 TCK139 4 60,000 3 110
TC3
1981-82 1.7L 4-Cyl. T017 TCK017 4 60,000 1 89
1981-82 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
Turismo
1983 1.7L 4-Cyl. T017 TCK017 4 60,000 1 89
1983-87 2.2L 4-Cyl. T071 TCK071 4 60,000 1 101
Light Trucks
(See DODGE/PLYMOUTH Light Trucks)
PONTIAC
Passenger Cars
Acadian (Canadian)
1976 1.4L 4-Cyl. T037 60,000 1 221
1977 1.4L 4-Cyl. T039 60,000 1 221
1976 1.6L 4-Cyl. T037 60,000 1 221
1977-78 1.6L 4-Cyl. T039 60,000 1 221
1979-87 1.6L 4-Cyl. T061 60,000 1 221
1981-85 1.8L 4-Cyl. Diesel T076 Yes 60,000 1 226
Firefly (Canadian)
1985-88 1.0L 3-Cyl. T095 60,000 211
1989-91 1.0L 3-Cyl. T166 60,000 211
1994-95 1.0L 3-Cyl. T243 60,000 211
1996-97 1.0L 3-Cyl. T194 TCK194 4 60,000 211
1998-00 1.0L 3-Cyl. T194 TCK194 4 100,000 211
1995-97 1.3L 4-Cyl. T272 60,000 213
1998-00 1.3L 4-Cyl. T194 TCK194 4 100,000 213
Grand Am
1987-88 2.0L 4-Cyl. T081 Yes 60,000 1 229
1989 2.0L 4-Cyl. (Turbo) T163 TCK163 4
Yes 60,000 1 229
Grand Prix
1991-95 3.4L V6 T192 Yes Yes 60,000 238
1996 3.4L V6 T273 Yes Yes 60,000 238
J2000
1982 1.8L 4-Cyl. T081 Yes 60,000 1 228
LeMans
1988-89 1.6L 4-Cyl. Yes 60,000 1 223
1990 1.6L 4-Cyl.
With Tensioner T203 Yes Yes 60,000 1 223
Without Tensioner T148 Yes Yes 60,000 1 223
1991-93 1.6L 4-Cyl. T203 Yes Yes 60,000 1 223
1989 2.0L 4-Cyl.
First Design T081 Yes 60,000 1 229
Second Design T163 TCK163 4
Yes 60,000 1 229
1990 2.0L 4-Cyl. T163 TCK163 4 Yes 60,000 1 229
Sunbird
1985-86 1.8L 4-Cyl. T081 Yes 60,000 1 228
1987-88 2.0L 4-Cyl. T081 Yes 60,000 1 229
1989-94 2.0L 4-Cyl. T163 TCK163 4 Yes 60,000 1 229
Sunburst (Canadian)
1985-88 1.5L 4-Cyl. T162 Yes Yes 60,000 219
1
2
3

PONTIAC (Cont.)
T1000
1981-82 1.6L 4-Cyl. T061 60,000 1 221
1000
1983-87 1.6L 4-Cyl. T061 60,000 1 221
2000
1983 1.8L 4-Cyl. T081 Yes 60,000 1 228
2000 Sunbird
1984 1.8L 4-Cyl. T081 Yes 60,000 1 228
Light Trucks
Sunrunner (Canadian)
1989-95 1.6L 4-Cyl. (8-Valve)
California T212 60,000 1 215
Except California T164 60,000 1 215
1994-98 1.6L 4-Cyl. (16-Valve)
PORSCHE
924
1977-82 2.0L 4-Cyl. T017 Yes 45,000 463
1987-88 2.5L 4-Cyl.
928
1978-82 4.5L V8 T196 Yes 60,000 467
1983-84 4.5L V8 T196 Yes 60,000 467
1985-91 5.0L V8 T196 Yes 60,000 467
1992-95 5.4L V8 T196 Yes 60,000 467
944
1983-89 2.5L 4-Cyl.
1989 2.7L 4-Cyl.
1989-91 3.0L 4-Cyl.
944S & 944 Turbo
1987-88 2.5L 4-Cyl.
968
1992-95 3.0L 4-Cyl.
RENAULT
Alliance & Encore
1985-87 1.7L 4-Cyl. T119 Yes 60,000 1 470
Fuego & Sportwagon
1984-86 2.2L 4-Cyl. T140 60,000 1 472
1
2
3
SAAB
900
1994-97 2.5L V6 T285 Yes 60,000 474
9000
1995-97 3.0L V6 T285 Yes 60,000 474
SATURN
L Series
2000-01 3.0L V6 (DOHC) T285 Yes Yes 100,000 235
STERLING
825
1987-88 2.5L V6 T129 Yes 60,000 1 475
827
1989-91 2.7L V6 T129 Yes 60,000 1 475
SUBARU
Coupe
1985-89 1.8L 4-Cyl.
Right Hand Belt T300 TCK299 4 52,000 2 478
Left Hand Belt T299 TCK299 4 52,000 2 478
Impreza & Outback Sport
1993 1.8L 4-Cyl. T172 TCK172 4 60,000 480
1994 1.8L 4-Cyl. T254 60,000 480
1995-97 1.8L 4-Cyl. T254 60,000 Federal 480
105,000 Calif. 480
1995-98 2.2L 4-Cyl. T254 60,000 Federal 480
105,000 Calif. 480
1999-01 2.2L 4-Cyl. (SOHC) T304 105,000 482
1996-97 2.5L 4-Cyl. (DOHC) T277 Yes 60,000 484
1998-99 2.5L 4-Cyl. (DOHC) T277 Yes 105,000 484
Justy
1987-95 1.2L 3-Cyl. T135 60,000 477
Legacy & Outback
1990-93 2.2L 4-Cyl. T172 TCK172 4 60,000 480
1994 2.2L 4-Cyl. T254 60,000 480
1995-98 2.2L 4-Cyl. T254 60,000 Federal 480
105,000 Calif. 480
1999-01 2.2L 4-Cyl. (SOHC) T304 105,000 482
1996-97 2.5L 4-Cyl. (DOHC) T277 Yes 60,000 484
1998-99 2.5L 4-Cyl. (DOHC) T277 Yes 105,000 484
2000-01 2.5L 4-Cyl. (SOHC) T307 105,000 482
Loyale
1990-94 1.8L 4-Cyl.
RX
1985-89 1.8L 4-Cyl.
Sedan & Station Wagon
1985-89 1.8L 4-Cyl.
1
2
3

SUBARU (Cont.)
SVX
1992-94 3.3L 6-Cyl. T209 60,000 491
1995-97 3.3L 6-Cyl. T209 60,000 Federal 491
105,000 Calif. 491
XT
1985-91 1.8L 4-Cyl.
XT6
1988-91 2.7L 6-Cyl.
Right Hand Belt T150 60,000 2 487
Left Hand Belt T151 60,000 2 487
Light Trucks
Forester
1998 2.5L 4-Cyl. (DOHC) T277 Yes 105,000 484
1999-01 2.5L 4-Cyl. (SOHC) T304 105,000 482
SUZUKI
Passenger Cars
Esteem
1995-00 1.6L 4-Cyl. T212 60,000 497
Esteem (Canadian)
2001 1.6L 4-Cyl. T212 60,000 497
Swift
1989-92 1.3L 4-Cyl. (DOHC) T171 Yes 60,000 1 492
1993-94 1.3L 4-Cyl. (DOHC) T171 Yes 60,000 492
1989-92 1.3L 4-Cyl. (SOHC) T095 60,000 1 494
1993 1.3L 4-Cyl. (SOHC) T095 60,000 494
1994 1.3L 4-Cyl. (SOHC) T243 60,000 494
1995-97 1.3L 4-Cyl. (SOHC) T272 60,000 494
1998-01 1.3L 4-Cyl. (SOHC) T194 TCK194A 4 60,000 494
Light Trucks
Samurai
1985-92 1.3L 4-Cyl. (SOHC) T095 60,000 1 494
1993 1.3L 4-Cyl. (SOHC) T095 60,000 494
1994 1.3L 4-Cyl. (SOHC)
VIN R4100375 & Earlier T095 60,000 494
From VIN R4100376 T243 60,000 494
1995 1.3L 4-Cyl. T243 60,000 494
Sidekick
1989 1.3L 4-Cyl. (SOHC) T095 60,000 1 494
1989-91 1.6L 4-Cyl. T164 60,000 1 497
1992 1.6L 4-Cyl.
Convertible T164 60,000 1 497
Hardtop T212 60,000 1 497
1993-95 1.6L 4-Cyl.
Convertible T164 60,000 497
Hardtop T212 60,000 497
1996-98 1.6L 4-Cyl. T212 60,000 497
Vitara
1999-01 1.6L 4-Cyl. T212 60,000 497
X-90
1996-98 1.6L 4-Cyl. T212 60,000 497
1
2
3
TOYOTA
Passenger Cars
Avalon
1995-97 3.0L V6 T257 Yes 60,000, Severe 543
1998-01 3.0L V6 T257 90,000 547
Camry
1984-85 1.8L 4-Cyl. Diesel T098 60,000 516
1983-85 2.0L 4-Cyl. T087 TCK087 4 Yes 60,000 1 518
1986 2.0L 4-Cyl. T087 TCK087 4 Yes 60,000, Severe 518
1987-91 2.0L 4-Cyl. T199 TCK199 4 Yes 60,000, Severe 518
1998-01 2.2L 4-Cyl. T199 TCK199 4 90,000 525
1988-91 2.5L V6 T157 Yes 60,000, Severe 543
1992-93 3.0L V6 T200 Yes 60,000, Severe 543
1995-97 3.0L V6 T257 Yes 60,000, Severe 543
1998-01 3.0L V6 T257 90,000 547
Camry Solara
1999-01 2.2L 4-Cyl. T199 TCK199 4 90,000 525
1998-01 3.0L V6 T257 90,000 547
Celica, Celica GT & ST
1990-92 1.6L 4-Cyl. (DOHC, 4A-F) T036 TCK036 4 60,000, Severe 512
1993 1.6L 4-Cyl. (DOHC, 4A-F) T239 60,000, Severe 512
1994-97 1.8L 4-Cyl. (7A-FE) T235 60,000, Severe 512
1986 2.0L 4-Cyl. T087 TCK087 4 Yes 60,000, Severe 518
1990-93 2.0L 4-Cyl. T125 Yes 60,000, Severe 518
1998-01 2.2L 4-Cyl. T199 TCK199 4 Yes 90,000 525
Celica GTS
1986-88 2.0L 4-Cyl. T125 Yes 60,000, Severe 518
Celica Supra
1982-83 2.8L 6-Cyl. T074 60,000, Severe 533
1984-86 2.8L 6-Cyl. T101 60,000, Severe 533
Corolla
1983-85 1.6L 4-Cyl. (SOHC) T070 TCK070 4 60,000 1 509
1986-88 1.6L 4-Cyl. (SOHC) T070 TCK070 4 60,000, Severe 509
1984-85 1.8L 4-Cyl. Diesel T098 60,000 516
1993-97 1.8L 4-Cyl. (7A-FE) T235 60,000, Severe 512
Corolla FX & FX-16
1986-88 1.6L 4-Cyl. T070 TCK070 4 60,000, Severe 509
1985 1.6L 4-Cyl. (4A-GE) T112 60,000 1 506
1986-88 1.6L 4-Cyl. (4A-GE) T112 60,000, Severe 506
Corolla GTS
1989-91 1.6L 4-Cyl. (4A-GE/GELC) T176 60,000, Severe 506
Corolla SR5
1985 1.6L 4-Cyl. T070 TCK070 4 60,000 1 509
1986-88 1.6L 4-Cyl. T070 TCK070 4 60,000, Severe 509
Corolla Tercel
1980-82 1.5L 4-Cyl. T070 TCK070 4 60,000 1 499
Cressida
1983 2.8L 6-Cyl. T074 60,000, Severe 533
1984-88 2.8L 6-Cyl. T101 60,000, Severe 533
1
2
3

TOYOTA (Cont.)
Cressida (Cont.)
1989-91 3.0L 6-Cyl. T126 60,000, Severe 535
1992 3.0L 6-Cyl. T237 60,000, Severe 535
MR2
1985 1.6L 4-Cyl. (4A-GE) T112 60,000 1 506
1986-88 1.6L 4-Cyl. (4A-GE) T112 60,000, Severe 506
1989 1.6L 4-Cyl. (4A-GE) T176 60,000, Severe 506
1991-95 2.0L 4-Cyl. T125 Yes 60,000, Severe 518
Paseo
1992-97 1.5L 4-Cyl. (5E-FE) T208 60,000, Severe 504
1998 1.5L 4-Cyl. (5E-FE) T208 90,000, Severe 504
1999 1.5L 4-Cyl. (5E-FE) T208 90,000 504
Supra
1986-90 3.0L 6-Cyl. (7M-GE) T126 60,000, Severe 535
1991-92 3.0L 6-Cyl. (7M-GE) T237 60,000, Severe 535
1993-97 3.0L 6-Cyl. (2JZ) T215 60,000, Severe 537
1998 3.0L 6-Cyl. (2JZ) T215 90,000, Severe 539
Tercel
1983-86 1.5L 4-Cyl. (3A-C)) T070 TCK070 4 60,000 1 499
1987 1.5L 4-Cyl. (Sedan, 3E) T136 Yes 60,000, Severe 501
1988-94 1.5L 4-Cyl. (3E) T233 TCK233 4 Yes 60,000, Severe 501
1995-97 1.5L 4-Cyl. (5E-FE) T208 60,000, Severe 504
1998 1.5L 4-Cyl. (5E-FE) T208 90,000, Severe 504
1999 1.5L 4-Cyl. (5E-FE) T208 90,000 504
Tercel Wagon
1987-88 1.5L 4-Cyl. (3A-C) T070 TCK070 4 60,000, Severe 499
Light Trucks
Highlander
2001 3.0L V6 T257 90,000 547
Land Cruiser
1998-01 4.7L V8 T298 Yes Yes 90,000 366
Pickup
1981 2.2L 4-Cyl. Diesel T079 Yes 100,000 529
1982 2.2L 4-Cyl. Diesel
Up To May 31 T079 Yes 100,000 529
From June 1 T084 Yes 100,000 529
1983 2.2L 4-Cyl. Diesel T084 Yes 100,000 529
1984-87 2.4L 4-Cyl. Diesel T084 Yes 100,000 531
1988-92 3.0L V6 (3V-ZE) T154 Yes 60,000, Severe 552
RAV4
1996-97 2.0L 4-Cyl. T199 Yes 60,000, Severe 523
1998 2.0L 4-Cyl. T199 Yes 90,000, Severe 523
1999-00 2.0L 4-Cyl. T199 Yes 90,000 523
Sienna
1998-01 3.0L V6 T257 90,000 547
Tacoma
1995-97 3.4L V6 T271 Yes 60,000, Severe 555
1999-01 3.4L V6 T271 Yes 90,000 555
Tundra
2000-01 3.4L V6 T271 Yes 90,000 555
2000-01 4.7L V8 T298 Yes Yes 90,000 366
1
2
3
TOYOTA (Cont.)
T100
1995-97 3.4L V6 T271 Yes 60,000, Severe 555
1998 3.4L V6 T271 Yes 90,000 555
4Runner
1996-97 3.4L V6 T271 Yes 60,000, Severe 555
1999-01 3.4L V6 T271 Yes 90,000 555
VOLKSWAGEN
Passenger Cars
Beetle (New Beetle)
1999-01 1.8L 4-Cyl. (APH & AWV) T306 Yes Yes 105,000 561
1998-00 2.0L 4-Cyl. (AEG) T296 Yes Yes 60,000 1 583
2001 2.0L 4-Cyl. (AEG) T296 Yes Yes 105,000 583
1998-01 1.9L 4-Cyl. Diesel (ALH) T301 Yes 60,000 (Man. Trans.) 578
40,000 (Auto. Trans.) 578
Cabrio
1995-01 2.0L 4-Cyl. (ABA) T262 Yes 60,000 1 581
1999 2.0L 4-Cyl. (AEG) T296 Yes Yes 60,000 1 583
Cabriolet
1985-89 1.8L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1985-93 1.8L 4-Cyl. (SOHC) T017 TCK017 4
60,000 1 569
Corrado
1990-92 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
Dasher
1974-75 1.5L 4-Cyl. T017 TCK017 4 60,000 1 558
1979-80 1.5L 4-Cyl. Diesel T043 Yes 60,000 1 559
1976-80 1.6L 4-Cyl. T017 TCK017 4 60,000 1 558
1981 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
Fox
1987-93 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
Golf
1985-87 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
1985-89 1.8L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1985-92 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
1993-96 1.9L 4-Cyl. Diesel
AAZ, AHU & 1Z Engines T242 Yes 60,000 573
40,000 (Auto. Trans.) 578
1993-99 2.0L 4-Cyl. (ABA) T262 Yes 60,000 1 581
1999 2.0L 4-Cyl. (AEG) T296 Yes Yes 60,000 1 583
2000 2.0L 4-Cyl. (AEG) T296 Yes Yes 60,000 1 583
Golf (Canadian)
1988-92 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
1993-95 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
1995 2.0L 4-Cyl. (ABA) T262 Yes 60,000 1 581
GTI
1985-89 1.8L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1985-92 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
1990-92 2.0L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1996-99 2.0L 4-Cyl. (ABA) T262 Yes 60,000 1 581
1999 2.0L 4-Cyl. (AEG) T296 Yes Yes 60,000 1 583
1
2
3

VOLKSWAGEN (Cont.)
GTI (Canadian)
1993-95 2.0L 4-Cyl. (ABA) T262 Yes 60,000 1 581
Jetta
1980 1.6L 4-Cyl. T017 TCK017 4 60,000 1 558
1981-86 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
1989-92 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
1981-84 1.7L 4-Cyl. T017 TCK017 4 60,000 1 558
1985-89 1.8L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1984-92 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
1993-98 1.9L 4-Cyl. Diesel
AAZ, AHU & 1Z Engines T242 Yes 60,000 573
40,000 (Auto. Trans.) 578
1990-92 2.0L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1993-99 2.0L 4-Cyl. (ABA) T262 Yes 60,000 1 581
1999-00 2.0L 4-Cyl. (AEG) T296 Yes Yes 60,000 1 583
Jetta (Canadian)
1993-95 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
Passat
1998-99 1.8L 4-Cyl. (AEB & ATW)
152 Tooth Belt T291 Yes Yes 90,000 564
2000-01 1.8L 4-Cyl. (AUG & AWM)
1990-92 2.0L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1993-96 2.0L 4-Cyl. (ABA) T262 Yes 60,000 1 581
1998 2.8L V6 T297 Yes Yes 90,000 585
1999 2.8L V6 T297 Yes Yes 75,000 585
2000-01 2.8L V6 T297 Yes Yes 105,000 585
Passat (Canadian)
1992-94 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
Quantum
1982-86 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
1982-83 1.7L 4-Cyl. T017 TCK017 4 60,000 1 558
1985 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
1984-85 2.1L 5-Cyl.
.70 Belt Width T127 Yes 60,000 1 79
.75 Belt Width T065 Yes 60,000 1 79
1983-86 2.2L 5-Cyl.
.70 Belt Width T127 Yes 60,000 1 79
.75 Belt Width T065 Yes 60,000 1 79
1987-88 2.2L 5-Cyl. T127 Yes 60,000 1 79
Rabbit
1975-79 1.5L 4-Cyl. T017 TCK017 4 60,000 1 558
1977-80 1.5L 4-Cyl. Diesel T043 Yes 60,000 1 559
1980 1.6L 4-Cyl. T017 TCK017 4 60,000 1 558
1981-84 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
1981-84 1.7L 4-Cyl. T017 TCK017 4 60,000 1 558
1983-84 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
Scirocco
1978 1.5L 4-Cyl. T017 TCK017 4 60,000 1 558
1976-80 1.6L 4-Cyl. T017 TCK017 4 60,000 1 558
1981-83 1.7L 4-Cyl. T017 TCK017 4 60,000 1 558
1
2
3
VOLKSWAGEN (Cont.)
Scirocco (Cont.)
1985-89 1.8L 4-Cyl. (DOHC) T292 Yes 60,000 1 571
1983-89 1.8L 4-Cyl. (SOHC) T017 TCK017 4 60,000 1 569
Light Trucks
Pickup & Rabbit Pickup
1980 1.5L 4-Cyl. Diesel T043 Yes 60,000 1 559
1980 1.6L 4-Cyl. T017 TCK017 4 60,000 1 558
1981-83 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
1981-83 1.7L 4-Cyl. T017 TCK017 4 60,000 1 558
Vanagon
1982 1.6L 4-Cyl. Diesel T043 Yes 60,000 1 559
VOLVO
C70, S70 & V70
1998 2.3L 5-Cyl.
To Eng. VIN 1266127 T252 Yes Yes 70,000 598
From Eng. VIN 1266128 T311 Yes Yes 70,000 598
1999-01 2.3L 5-Cyl.
To Eng. VIN 1266127 T252 Yes Yes 105,000 3 598
From Eng. VIN 1266128 T311 Yes Yes 105,000 3 598
1998 2.4L 5-Cyl.
To Eng. VIN 1266127 T252 Yes Yes 70,000 598
1999-01 2.4L 5-Cyl.
Coupe
1991 2.3L 4-Cyl. T032 TCK032 4 Yes 50,000 593
DL & GL
1980-83 2.1L 4-Cyl. T032 TCK032 4 Yes 40,000 592
1982-85 2.3L 4-Cyl. T032 TCK032 4 Yes 40,000 592
1980-84 2.4L 6-Cyl. Diesel
GLE (Canadian)
1984 2.1L 4-Cyl. T032 TCK032 4 Yes 40,000 592
GLT
1981-83 2.1L 4-Cyl. T032 TCK032 4 Yes 40,000 592
GLT (Canadian)
1983 2.3L 4-Cyl. T032 TCK032 4 Yes 40,000 592
GT Turbo
1984-85 2.1L 4-Cyl. T032 TCK032 4 Yes 40,000 592
S40 & V40
2000-01 1.9L 4-Cyl. Turbo
Up Eng. VIN 1219110 T252 Yes Yes 105,000 587
S60
2001 2.3L 5-Cyl.
2001 2.4L 5-Cyl.
1
2
3

VOLVO (Cont.)
S90 & V90
1997-98 2.9L 6-Cyl. T270 Yes Yes 70,000 600
240
1986-92 2.3L 4-Cyl. T032 TCK032 4 Yes 50,000 593
1993 2.3L 4-Cyl. T234 Yes 50,000 593
242, 244 & 245
1976-79 2.1L 4-Cyl. T032 TCK032 4 Yes 40,000 592
740
1986-92 2.3L 4-Cyl. T032 TCK032 4 Yes 50,000 593
1985-86 2.4L 6-Cyl. Diesel
740 (Canadian)
1986-88 2.3L 4-Cyl. (B234, DOHC)
1989 2.3L 4-Cyl. (B234, DOHC)
Automatic Tensioner
Manual Tensioner
1990 2.3L 4-Cyl. (B234, DOHC)
760
1985-90 2.3L 4-Cyl. T032 TCK032 Yes 50,000 593
1985 2.4L 6-Cyl. Diesel
760 GLE
1984 2.3L 4-Cyl. T032 TCK032 Yes 40,000 592
1983-84 2.4L 6-Cyl. Diesel
780
198-90 2.3L 4-Cyl. T032 TCK032 Yes 50,000 593
850
1994 2.3L 5-Cyl. Turbo
Up To Eng. No. 131034 T217 Yes Yes 50,000 3 600
From Eng. No. 131035 T252 Yes Yes 70,000 3 600
Up To Eng. No. 131034 T217 Yes Yes 50,000 3 600
From Eng. No. 131035 T252 Yes Yes 70,000 3 600
850 (Canadian)
1996 2.3L 5-Cyl. Turbo T252 Yes Yes 70,000 600
Up To Eng. No. 131034 T217 Yes Yes 70,000 600
From Eng. No. 131035 T269 Yes Yes 70,000 600
1
2
3
VOLVO (Cont.)
940
1991-92 2.3L 4-Cyl. T032 TCK032 Yes 50,000 592
1993 2.3L 4-Cyl. T234 Yes 50,000 592
1994-95 2.3L 4-Cyl. (B230FT) T234 Yes 50,000 w/o EGR 593
100,000 w/ EGR 593
940 (Canadian)
1991-92 2.3L 4-Cyl. (B234, DOHC)
960
1992 2.9L 6-Cyl. T217 Yes Yes 30,000 3 600
1993 2.9L 6-Cyl. T252 Yes Yes 50,000 600
1994 2.9L 6-Cyl. T252 Yes Yes 50,000 600
1995-97 2.9L 6-Cyl. T270 Yes Yes 70,000 600
YUGO
GV Series
1986-89 1.1L 4-Cyl. T018 Yes 60,000 1 604
1987 1.3L 4-Cyl. T018 Yes 60,000 1 604
1
2
3
Changeover Listing
Automotive Timing Belt Numbers
Showing Competitive Numbers with Corresponding Gates Belt Numbers
The Gates numbers shown in the following listings were determined by comparing the applications and physical characteristics of the product. This is a guide for
changing over stocks to Gates numbers, and does not mean that the competitive number shown will fit all applications recommended for the Gates number. If a custom-
er asks for a product to replace a product of another brand, do not use this list. Ask for the make, model, year and engine size on which it is to be used, and refer
to the alphabetical listing to determine the proper replacement.
Competitive Gates Competitive Gates Competitive Gates Competitive Gates Competitive Gates
No. No. No. No. No. No. No. No. No. No.
ACDELCO ACDELCO - Cont. ACDELCO - Cont. ACDELCO - Cont. ATLAS (CANADA) - Cont.
TB013 .............. T013 TB139 .............. T139 TB218 .............. T218 TB301 .............. T301 TB1054 ............ T160
TB067 .............. T067 TB155 .............. T155 TB235 .............. T235 88921005......... T316 TB6408 ............ T020
TB068 .............. T068 TB157 .............. T157 TB236 .............. T236 88925830......... T270 TB6409 ............ T039
TB069 .............. T069 TB158 .............. T158 TB237 .............. T237 ATLAS TB6410 ............ T032
TB070 .............. T070 TB159 .............. T159 TB239 .............. T239 TB6411 ............ T041
TB071 .............. T071 TB160 .............. T160 TB240 .............. T240 689900............. T067 TB6412 ............ T062
TB073 .............. T073 TB161 .............. T161 TB241 .............. T241 689901............. T071 TB6415 ............ T028
TB074 .............. T074 TB162 .............. T162 TB242 .............. T242 689902............. T014 TB6416 ............ T064
TB075 .............. T075 TB163 .............. T163 TB243 .............. T243 689903............. T061 TB6417 ............ T065
TB076 .............. T076 TB164 .............. T164 TB244 .............. T244 689904............. T017 TB6418 ............ T061
TB077 .............. T077 TB165 .............. T165 TB245 .............. T245 689905............. T081 TB6419 ............ T073
TB078 .............. T078 TB166 .............. T166 TB246 .............. T246 689906............. T070 TB6424 ............ T069
TB079 .............. T079 TB167 .............. T167 TB247 .............. T247 689907............. T089 TB6425 ............ T070
TB081 .............. T081 TB168 .............. T168 TB248 .............. T248 689908............. T077 TB6426 ............ T068
TB082 .............. T082 TB169 .............. T169 TB249 .............. T249 689909............. T094 TB6427 ............ T071
TB083 .............. T083 TB170 .............. T170 TB251 .............. T251 ATLAS (CANADA) TB6428 ............ T067
TB084 .............. T084 TB171 .............. T171 TB252 .............. T252 TB6429 ............ T076
TB1001 ............ T121 TB6430 ............ T075
TB087 .............. T087 TB172 .............. T172 TB253 .............. T253 TB1002 ............ T127
TB088 .............. T088 TB173 .............. T173 TB254 .............. T254 TB6431 ............ T078
TB1003 ............ T128 TB6432 ............ T077
TB089 .............. T089 TB174 .............. T174 TB255 .............. T255 TB1004 ............ T101
TB090 .............. T090 TB176 .............. T176 TB256 .............. T256 TB6433 ............ T043
TB1005 ............ T125 TB6434 ............ T074
TB091 .............. T091 TB177 .............. T177 TB257 .............. T257 TB1006 ............ T126
TB092 .............. T092 TB178 .............. T178 TB258 .............. T258 TB6435 ............ T081
TB1007 ............ T130 TB6436 ............ T088
TB093 .............. T093 TB179 .............. T179 TB259 .............. T259 TB1008 ............ T129 TB6437 ............ T087
TB113 .............. T113 TB194 .............. T194 TB278 .............. T278 TB1026 ............ T141
TB114 .............. T114 TB195 .............. T195 TB279 .............. T279 TB1027 ............ T123 AUTOZONE (See GOOD-
TB117 .............. T117 TB196 .............. T196 TB280 .............. T280 TB1028 ............ T090 YEAR)
TB118 .............. T118 TB197 .............. T197 TB281 .............. T281 TB1031 ............ T113
TB119 .............. T119 TB198 .............. T198 TB282 .............. T282 TB1032 ............ T132
TB120 .............. T120 TB199 .............. T199 TB283 .............. T283 TB1033 ............ T142 AVON AUTO
TB121 .............. T121 TB200 .............. T200 TB284 .............. T284 TB1034 ............ T143 B0100 .............. T100
TB122 .............. T122 TB201 .............. T201 TB285 .............. T285 TB1035 ............ T144 B0101 .............. T101
TB123 .............. T123 TB203 .............. T203 TB286 .............. T286 TB1036 ............ T145 B0102 .............. T102
TB124 .............. T124 TB204 .............. T204 TB287 .............. T287 TB1037 ............ T146 B0103 .............. T103
TB125 .............. T125 TB205 .............. T205 TB288 .............. T288 TB1038 ............ T147 B0104 .............. T104
TB126 .............. T126 TB206 .............. T206 TB289 .............. T289 TB1039 ............ T148 B0114 .............. T114
TB127 .............. T127 TB207 .............. T207 TB290 .............. T290 TB1040 ............ T149 B0118 .............. T162
TB128 .............. T128 TB208 .............. T208 TB291 .............. T291 TB1041 ............ T150 B013 ................ T013
TB129 .............. T129 TB209 .............. T209 TB292 .............. T292 TB1042 ............ T151 B014 ................ T014
TB130 .............. T130 TB210 .............. T210 TB293 .............. T293 TB1044 ............ T102 B017 ................ T017
TB131 .............. T131 TB211 .............. T211 TB294 .............. T294 TB1045 ............ T103 B018 ................ T018
TB132 .............. T132 TB212 .............. T212 TB295 .............. T295 TB1047 ............ T124 B020 ................ T020
TB134 .............. T134 TB213 .............. T213 TB296 .............. T296 TB1048 ............ T154 B028 ................ T028
TB135 .............. T135 TB214 .............. T214 TB297 .............. T297 TB1049 ............ T155 B032 ................ T032
TB136 .............. T136 TB215 .............. T215 TB298 .............. T298 TB1051 ............ T157 B036 ................ T036
TB137 .............. T137 TB216 .............. T216 TB299 .............. T299 TB1052 ............ T158 B037 ................ T037
TB138 .............. T138 TB217 .............. T217 TB300 .............. T300 TB1053 ............ T159 B039 ................ T039
Changeover Listing - Timing Belts
AVON AUTO - Cont. BANDO - Cont. BECK ARNLEY - Cont. BORG WARNER BORG WARNER - Cont.
B041 ................ T041 315AL075 ........ T028 026-0232.......... T129 TB013 .............. T013 TB155 .............. T155
B043 ................ T043 326AHL125...... T075 026-0233.......... T139 TB014 .............. T014 TB157 .............. T157
B061 ................ T061 330AL075 ........ T070 026-0234.......... T146 TB017 .............. T017 TB158 .............. T158
B062 ................ T062 345AL075 ........ T073 026-0235.......... T148 TB018 .............. T018 TB159 .............. T159
B063 ................ T073 398AL075 ........ T077 026-0236.......... T292 TB020 .............. T020 TB160 .............. T160
B064 ................ T064 458AL075 ........ T013 026-0237.......... T170 TB028 .............. T028 TB161 .............. T161
B065 ................ T065 89ZA19 ............ T095 026-0238.......... T143 TB029 .............. T104 TB162 .............. T162
B067 ................ T067 94ZA19 ............ T036 026-0239.......... T131 TB032 .............. T032 TB163 .............. T163
B068 ................ T068 97ZA25 ............ T067 026-0240.......... T144 TB036 .............. T036 TB164 .............. T164
B069 ................ T069 99ZA15 ............ T037 026-0242.......... T142 TB037 .............. T037 TB165 .............. T165
B070 ................ T070 99ZA19 ............ T039 026-0243.......... T135 TB039 .............. T039 TB166 .............. T166
B071 ................ T071 BAP-GEON 026-0244.......... T179 TB041 .............. T041 TB167 .............. T167
B074 ................ T074 026-0245.......... T147 TB042 .............. T068 TB168 .............. T168
B075 ................ T075 54-70301.......... T062 TB043 .............. T043 TB169 .............. T169
54-70302.......... T073 026-0246.......... T126 TB170 .............. T170
B076 ................ T076 026-0247.......... T136 TB061 .............. T061
B077 ................ T077 54-70303.......... T064 TB062 .............. T062 TB171 .............. T171
54-70901.......... T041 026-0248.......... T125 TB172 .............. T172
B078 ................ T078 026-0249.......... T164 TB063 .............. T073
B079 ................ T079 54-70902.......... T028 TB064 .............. T064 TB177 .............. T177
B081 ................ T081 54-70904.......... T073 026-0250.......... T166 TB065 .............. T065 TB178 .............. T178
B082 ................ T082 54-71501.......... T070 026-0251.......... T165 TB067 .............. T067 TB179 .............. T179
B083 ................ T083 54-72001.......... T017 026-0252.......... T130 TB068 .............. T068 TB183 .............. T183
B084 ................ T084 54-72100.......... T065 026-0253.......... T121 TB069 .............. T069 TB184 .............. T184
B087 ................ T087 54-76000.......... T020 026-0255.......... T167 TB070 .............. T070 TB185 .............. T185
B088 ................ T088 54-76300.......... T069 026-0256.......... T043 TB071 .............. T071 TB186 .............. T186
B089 ................ T089 54-76301.......... T018 026-0258.......... T197 TB073 .............. T073 TB187 .............. T187
B090 ................ T090 54-77801.......... T014 026-0259.......... T137 TB074 .............. T074 TB191 .............. T191
B091 ................ T091 54-77802.......... T067 026-0260.......... T171 TB075 .............. T075 TB192 .............. T192
B092 ................ T092 54-79800.......... T013 026-0261.......... T177 TB076 .............. T076 TB194 .............. T194
B093 ................ T093 BECK ARNLEY 026-0262.......... T179 TB077 .............. T077 TB195 .............. T195
B094 ................ T094 026-0263.......... T103 TB078 .............. T078 TB199 .............. T199
B095 ................ T095 026-0018.......... T028 026-0264.......... T102 TB079 .............. T079 TB200 .............. T200
B096 ................ T096 026-0026.......... T020 026-0265.......... T157 TB081 .............. T081 TB201 .............. T201
B099 ................ T099 026-0034.......... T020 026-0266.......... T159 TB082 .............. T082 TB202 .............. T248
026-0042.......... T018 026-0267.......... T151 TB083 .............. T083 TB204 .............. T204
BALKAMP 026-0067.......... T036 TB206 .............. T206
026-0268.......... T182 TB084 .............. T084
9-013................ T013 026-0075.......... T041 026-0269.......... T184 TB208 .............. T208
026-0083.......... T013 TB087 .............. T087
9-014................ T014 026-0270.......... T181 TB088 .............. T088 TB210 .............. T210
9-017................ T017 026-0091.......... T014 026-0271.......... T155 TB214 .............. T214
026-0109.......... T032 TB089 .............. T089
9-018................ T018 026-0272.......... T144 TB090 .............. T090 TB228 .............. T228
9-020................ T020 026-0117.......... T065 026-0273.......... T178 TB233 .............. T233
026-0125.......... T068 TB091 .............. T091
9-028................ T028 026-0274.......... T104 TB092 .............. T092 TB235 .............. T235
9-032................ T032 026-0133.......... T062 TB236 .............. T236
026-0158.......... T064 026-0275.......... T150 TB093 .............. T093
9-036................ T036 026-0276.......... T187 TB094 .............. T094 TB237 .............. T237
9-037................ T037 026-0174.......... T069 T219................. T219
9-039................ T039 026-0175.......... T070 026-0277.......... T180 TB095 .............. T095
026-0176.......... T017 026-0278.......... T186 TB096 .............. T096 BRYCO
9-041................ T041
9-043................ T043 026-0177.......... T043 026-0279.......... T176 TB098 .............. T098 B013 ................ T013
9-061................ T061 026-0178.......... T083 026-0280.......... T191 TB099 .............. T099 B014 ................ T014
9-062................ T062 026-0179.......... T073 026-0281.......... T174 TB100 .............. T100 B017 ................ T017
9-063................ T073 026-0180.......... T082 026-0282.......... T183 TB101 .............. T101 B028 ................ T028
9-064................ T064 026-0182.......... T088 026-0283.......... T154 TB102 .............. T102 B036 ................ T036
9-065................ T065 026-0183.......... T078 026-0284.......... T168 TB103 .............. T103 B041 ................ T041
9-067................ T067 026-0184.......... T077 026-0285.......... T173 TB104 .............. T104 B043 ................ T043
9-068................ T068 026-0185.......... T089 026-0286.......... T172 TB106 .............. T106 B062 ................ T062
9-069................ T069 026-0186.......... T090 026-0288.......... T152 TB107 .............. T107 B064 ................ T064
9-070................ T070 026-0187.......... T092 026-0289.......... T189 TB110 .............. T196 B067 ................ T067
9-071................ T071 026-0188.......... T091 026-0290.......... T188 TB112 .............. T112 B070 ................ T070
9-073................ T073 026-0189.......... T084 026-0293.......... T198 TB113 .............. T113 B071 ................ T071
9-074................ T074 026-0190.......... T074 026-0294.......... T208 TB114 .............. T114 B073 ................ T073
9-075................ T075 026-0191.......... T087 026-0295.......... T211 TB115 .............. T299 B074 ................ T074
9-076................ T076 026-0192.......... T079 026-0296.......... T201 TB116 .............. T300 B075 ................ T075
9-077................ T077 026-0193.......... T076 026-0297.......... T204 TB117 .............. T117 B076 ................ T076
9-078................ T078 026-0194.......... T075 026-0298.......... T218 TB118 .............. T118 B077 ................ T077
9-079................ T079 026-0195.......... T107 026-0299.......... T216 TB119 .............. T119 B078 ................ T078
9-081................ T081 026-0196.......... T093 026-0300.......... T203 TB121 .............. T121 B079 ................ T079
9-082................ T082 026-0197.......... T096 026-0301.......... T212 TB122 .............. T122 B087 ................ T087
9-083................ T083 026-0198.......... T106 026-0302.......... T193 TB123 .............. T123 B088 ................ T088
9-084................ T084 026-0199.......... T140 026-0303.......... T185 TB124 .............. T124 B089 ................ T089
9-087................ T087 026-0201.......... T196 026-0304.......... T221 TB125 .............. T125 B090 ................ T090
9-088................ T088 026-0202.......... T100 026-0305.......... T220 TB126 .............. T126 B091 ................ T091
9-089................ T089 026-0205.......... T097 026-0306.......... T194 TB127 .............. T127 B092 ................ T092
9-090................ T090 026-0206.......... T101 026-0307.......... T224 TB128 .............. T128 B093 ................ T093
9-091................ T091 026-0207.......... T095 026-0308.......... T226 TB129 .............. T129 B094 ................ T094
9-092................ T092 026-0208.......... T161 026-0309.......... T223 TB130 .............. T130 B095 ................ T095
9-093................ T093 026-0209.......... T160 026-0310.......... T227 TB131 .............. T131 B096 ................ T096
9-094................ T094 026-0210.......... T120 026-0311.......... T214 TB132 .............. T132 B099 ................ T099
9-095................ T095 026-0212.......... T300 TB133 .............. T292 B100 ................ T100
026-0213.......... T299 026-0312.......... T209 TB134 .............. T134 B101 ................ T101
9-096................ T096 026-0314.......... T229
9-098................ T098 026-0215.......... T158 TB135 .............. T135 B102 ................ T102
026-0216.......... T104 026-0316.......... T230 TB136 .............. T136 B103 ................ T103
9-099................ T099 026-0317.......... T232
9-100................ T100 026-0217.......... T112 TB137 .............. T137 B104 ................ T104
9-101................ T101 026-0218.......... T293 026-0318.......... T217 TB138 .............. T138 B112 ................ T112
026-0219.......... T119 026-0319.......... T195 TB139 .............. T139 B113 ................ T113
BANDO 026-0220.......... T138 026-0320.......... T234 TB140 .............. T140 B114 ................ T114
100ZA19 .......... T061 026-0221.......... T071 026-0322.......... T235 TB141 .............. T141 B115 ................ T299
109ZA19 .......... T088 026-0222.......... T162 026-0323.......... T252 TB142 .............. T142 B116 ................ T300
111ZA19 .......... T121 026-0223.......... T113 026-0324.......... T241 TB143 .............. T143 B117 ................ T117
113ZA19 .......... T065 026-0224.......... T117 026-0325.......... T236 TB144 .............. T144 B118 ................ T118
118ZA19 .......... T069 026-0225.......... T149 026-0326.......... T262 TB145 .............. T145 B121 ................ T121
121ZA19 .......... T017 026-0226.......... T141 026-0327.......... T228 TB146 .............. T146 B122 ................ T122
124ZA25 .......... T071 026-0228.......... T122 026-0329.......... T252 TB147 .............. T147 B123 ................ T123
135ZA25 .......... T043 026-0229.......... T124 026-0334.......... T249 TB148 .............. T148 B124 ................ T124
142ZA25 .......... T074 026-0230.......... T128 141-1156.......... 6414 TB153 .............. T153 B126 ................ T126
206AL050 ........ T062 026-0231.......... T134 141-1164.......... 6413 TB154 .............. T154 B127 ................ T127
BRYCO - Cont. CARQUEST - Cont. CARQUEST - Cont. CLEVELAND MOTIVE - Cont. CLOYES GEAR - Cont.
B128 ................ T128 T130................. T130 T227................. T227 B081 ................ T081 B150 ................ T150
B130 ................ T130 T131................. T131 T228................. T228 CLOYES GEAR B151 ................ T151
B132 ................ T132 T132................. T132 T229................. T229 B152 ................ T152
B133 ................ T292 T134................. T134 T230................. T230 B013 ................ T013 B153 ................ T153
B134 ................ T134 T135................. T135 T232................. T232 B014 ................ T014 B154 ................ T154
B136 ................ T136 T136................. T136 T233................. T233 B017 ................ T017 B155 ................ T155
B137 ................ T137 T137................. T137 T234................. T234 B018 ................ T018 B157 ................ T157
B138 ................ T138 T138................. T138 T235................. T235 B020 ................ T020 B158 ................ T158
B139 ................ T139 T139................. T139 T236................. T236 B028 ................ T028 B159 ................ T159
B141 ................ T141 T140................. T140 T237................. T237 B032 ................ T032 B160 ................ T160
B142 ................ T142 T141................. T141 T239................. T239 B036 ................ T036 B161 ................ T161
B143 ................ T143 T142................. T142 T240................. T240 B037 ................ T037 B162 ................ T162
B144 ................ T144 T143................. T143 T241................. T241 B039 ................ T039 B163 ................ T163
B145 ................ T145 T144................. T144 T242................. T242 B041 ................ T041 B164 ................ T164
B146 ................ T146 T145................. T145 T243................. T243 B043 ................ T043 B165 ................ T165
B147 ................ T147 T146................. T146 T244................. T244 B061 ................ T061 B166 ................ T166
B149 ................ T149 T147................. T147 T245................. T245 B062 ................ T062 B167 ................ T167
B153 ................ T153 T148................. T148 T246................. T246 B063 ................ T073 B168 ................ T168
B154 ................ T154 T149................. T149 T247................. T247 B064 ................ T064 B169 ................ T169
B155 ................ T155 T150................. T150 T248................. T248 B065 ................ T065 B170 ................ T170
B157 ................ T157 T151................. T151 T249................. T249 B067 ................ T067 B171 ................ T171
B158 ................ T158 T152................. T152 T251................. T251 B068 ................ T068 B172 ................ T172
B159 ................ T159 T153................. T153 T252................. T252 B069 ................ T069 B174 ................ T174
B160 ................ T160 T154................. T154 T253................. T253 B070 ................ T070 B176 ................ T176
B161 ................ T161 T155................. T155 T254................. T254 B071 ................ T071 B177 ................ T177
B162 ................ T162 T157................. T157 T255................. T255 B073 ................ T073 B178 ................ T178
B164 ................ T164 T158................. T158 T256................. T256 B074 ................ T074 B179 ................ T179
B165 ................ T165 T159................. T159 T257................. T257 B075 ................ T075 B180 ................ T180
B167 ................ T167 T160................. T160 T258................. T258 B076 ................ T076 B181 ................ T181
B168 ................ T168 T161................. T161 T259................. T259 B077 ................ T077 B182 ................ T182
B169 ................ T169 T162................. T162 T260................. T260 B078 ................ T078 B183 ................ T183
B176 ................ T176 T163................. T163 T262................. T262 B079 ................ T079 B184 ................ T184
B177 ................ T177 T164................. T164 T263................. T263 B081 ................ T081 B185 ................ T185
B179 ................ T179 T165................. T165 T264................. T264 B082 ................ T082 B186 ................ T186
B182 ................ T182 T166................. T166 T265................. T265 B083 ................ T083 B187 ................ T187
B184 ................ T184 T266................. T266 B084 ................ T084
T167................. T167 B087 ................ T087 B189 ................ T189
B185 ................ T185 T168................. T168 T267................. T267 B190 ................ T190
B186 ................ T186 T269................. T269 B088 ................ T088
T169................. T169 B089 ................ T089 B191 ................ T191
B187 ................ T187 T170................. T170 T271................. T271 B192 ................ T192
B191 ................ T191 T272................. T272 B090 ................ T090
T171................. T171 B091 ................ T091 B193 ................ T193
B194 ................ T194 T172................. T172 T273................. T273 B194 ................ T194
B195 ................ T195 T276................. T276 B092 ................ T092
B199 ................ T199 T173................. T173 B093 ................ T093 B195 ................ T195
T174................. T174 T277................. T277 B196 ................ T196
B201 ................ T201 T278................. T278 B094 ................ T094
B204 ................ T204 T176................. T176 B095 ................ T095 B199 ................ T199
T177................. T177 T279................. T279 B201 ................ T201
B208 ................ T208 T280................. T280 B096 ................ T096
B210 ................ T210 T178................. T178 B097 ................ T097 B203 ................ T203
T179................. T179 T281................. T281 B204 ................ T204
B223 ................ T223 T282................. T282 B098 ................ T098
B224 ................ T224 T180................. T180 B099 ................ T099 B205 ................ T205
T181................. T181 T283................. T283 B206 ................ T206
B227 ................ T227 T284................. T284 B100 ................ T100
B228 ................ T228 T182................. T182 B101 ................ T101 B208 ................ T208
T183................. T183 T285................. T285 B209 ................ T209
B229 ................ T229 T286................. T286 B102 ................ T102
B230 ................ T230 T184................. T184 T287................. T287 B103 ................ T103 B210 ................ T210
B235 ................ T235 T185................. T185 T288................. T288 B104 ................ T104 B211 ................ T211
B236 ................ T236 T186................. T186 T289................. T289 B106 ................ T106 B212 ................ T212
B237 ................ T237 T187................. T187 T290................. T290 B107 ................ T107 B214 ................ T214
B258 ................ T258 T188................. T188 T291................. T291 B108 ................ T293 B216 ................ T216
T115................. T299 T189................. T189 T292................. T292 B112 ................ T112 B219 ................ T219
54700............... T095 T190................. T190 T293................. T293 B113 ................ T113 C013 ................ T013
54742............... T075 T191................. T191 T294................. T294 B114 ................ T114 C014 ................ T014
54754............... T112 T192................. T192 T295................. T295 B115 ................ T299 C017 ................ T017
54755............... T176 T193................. T193 T296................. T296 B116 ................ T300 C018 ................ T018
54788............... T076 T194................. T194 T297................. T297 B117 ................ T117 C020 ................ T020
T195................. T195 T298................. T298 B118 ................ T118 C028 ................ T028
CARQUEST T196................. T196 B119 ................ T119 C032 ................ T032
T299................. T299
T013................. T013 T197................. T197 T300................. T300 B121 ................ T121 C037 ................ T037
T014................. T014 T198................. T198 T301................. T301 B122 ................ T122 C039 ................ T039
T096................. T096 T199................. T199 T302................. T302 B123 ................ T123 C041 ................ T041
T097................. T097 T200................. T200 T303................. T303 B124 ................ T124 C042 ................ T068
T098................. T098 T201................. T201 T304................. T304 B125 ................ T125 C043 ................ T043
T099................. T099 T203................. T203 T305................. T305 B126 ................ T126 C061 ................ T061
T100................. T100 T204................. T204 T306................. T306 B127 ................ T127 C062 ................ T062
T101................. T101 T205................. T205 6421................. 6421 B128 ................ T128 C063 ................ T073
T102................. T102 T206................. T206 B129 ................ T129 C064 ................ T064
T103................. T103 T207................. T207 CHIEF B130 ................ T130 C065 ................ T065
T104................. T104 T208................. T208 TB401 .............. T014 B131 ................ T131 C067 ................ T067
T106................. T106 T209................. T209 TB402 .............. T013 B132 ................ T132 C068 ................ T068
T107................. T107 T210................. T210 TB403 .............. T037 B133 ................ T292 C069 ................ T069
T112................. T112 T211................. T211 TB404 .............. T017 B134 ................ T134 C070 ................ T070
T113................. T113 T212................. T212 TB409 .............. T039 B135 ................ T135 C071 ................ T071
T114................. T114 T213................. T213 TB411 .............. T041 B136 ................ T136 C074 ................ T074
T117................. T117 T214................. T214 TB415 .............. T028 B137 ................ T137 C075 ................ T075
T118................. T118 T215................. T215 B138 ................ T138 C076 ................ T076
T119................. T119 T216................. T216 CLEVELAND MOTIVE B139 ................ T139 C077 ................ T077
T120................. T120 T217................. T217 B013 ................ T013 B140 ................ T140 C078 ................ T078
T121................. T121 T218................. T218 B014 ................ T014 B141 ................ T141 C081 ................ T081
T122................. T122 T219................. T219 B037 ................ T037 B142 ................ T142 C087 ................ T087
T123................. T123 T220................. T220 B043 ................ T043 B143 ................ T143 C088 ................ T088
T124................. T124 T221................. T221 B068 ................ T068 B144 ................ T144 C093 ................ T093
T125................. T125 T222................. T222 B074 ................ T074 B145 ................ T145 C094 ................ T094
T126................. T126 T223................. T223 B075 ................ T075 B146 ................ T146 C095 ................ T095
T127................. T127 T224................. T224 B076 ................ T076 B147 ................ T147 C099 ................ T099
T128................. T128 T225................. T225 B077 ................ T077 B148 ................ T148 C104 ................ T104
T129................. T129 T226................. T226 B078 ................ T078 B149 ................ T149 C112 ................ T112
CONTINENTAL CONTITECH - Cont. CONTITECH - Cont. DAYCO - Cont. DAYCO - Cont.

6585901........... T065 TB124 .............. T124 TB232 .............. T232 95074............... T074 95176............... T176
6585902........... T017 TB125 .............. T125 TB233 .............. T233 95075............... T075 95177............... T177
6585910........... T013 TB126 .............. T126 TB235 .............. T235 95076............... T076 95178............... T178
6585911........... T082 TB127 .............. T127 TB236 .............. T236 95077............... T077 95179............... T179
6585912........... T083 TB128 .............. T128 TB239 .............. T239 95078............... T078 95180............... T180
6585913........... T032 TB129 .............. T129 TB240 .............. T240 95079............... T079 95181............... T181
6585914........... T043 TB130 .............. T130 TB241 .............. T241 95081............... T081 95182............... T182
6585916........... T018 TB131 .............. T131 TB252 .............. T252 95082............... T082 95183............... T183
6585918........... T020 TB133 .............. T292 CY-LENT 95083............... T083 95184............... T184
6585921........... T068 TB134 .............. T134 95084............... T084 95185............... T185
6585924........... T078 TB135 .............. T135 C013 ................ T013 95087............... T087 95186............... T186
6585929........... T064 TB136 .............. T136 C014 ................ T014 95088............... T088 95187............... T187
6585933........... T062 TB137 .............. T137 C017 ................ T017 95089............... T089 95188............... T188
6585934........... T073 TB138 .............. T138 C018 ................ T018 95090............... T090 95190............... T190
6585935........... T077 TB139 .............. T139 C020 ................ T020 95091............... T091 95191............... T191
6585939........... T028 TB140 .............. T140 C028 ................ T028 95092............... T092 95192............... T192
6585943........... T041 TB141 .............. T141 C032 ................ T032 95093............... T093 95193............... T193
6585945........... T069 TB142 .............. T142 C037 ................ T037 95094............... T094 95194............... T194
6585949........... T070 TB143 .............. T143 C039 ................ T039 95095............... T095 95195............... T195
6589089........... T131 TB144 .............. T144 C041 ................ T041 95096............... T096 95196............... T196
6589092........... T084 TB145 .............. T145 C043 ................ T043 95097............... T097 95197............... T197
6589095........... T107 TB146 .............. T146 C061 ................ T061 95098............... T098 95198............... T198
6589100........... T081 TB147 .............. T147 C062 ................ T062 95099............... T099 95199............... T199
6589103........... T106 TB148 .............. T148 C063 ................ T073 95100............... T100 95200............... T200
6598500........... T062 TB150 .............. T150 C064 ................ T064 95101............... T101 95201............... T201
6598506........... T028 TB151 .............. T151 C065 ................ T065 95102............... T102 95202............... T248
6598512........... T073 TB152 .............. T152 C067 ................ T067 95103............... T103 95203............... T203
6598513........... T041 TB154 .............. T154 C069 ................ T069 95104............... T104 95204............... T204
6598519........... T077 TB155 .............. T155 C070 ................ T070 95106............... T106 95205............... T205
6598521........... T088 TB157 .............. T157 C071 ................ T071 95107............... T107 95206............... T206
6598523........... T069 TB158 .............. T158 C073 ................ T073 95108............... T293 95207............... T207
6598530........... T087 TB159 .............. T159 C075 ................ T075 95110............... T196 95208............... T208
6598534........... T075 TB160 .............. T160 C076 ................ T076 95112............... T112 95210............... T210
6598550........... T094 TB162 .............. T162 C077 ................ T077 95113............... T113 95211............... T211
6598551........... T293 TB163 .............. T163 C078 ................ T078 95114............... T114 95212............... T212
6598554........... T196 TB164 .............. T164 C081 ................ T081 95115............... T299 95214............... T214
CONTITECH TB165 .............. T165 DAYCO 95116............... T300 95215............... T215
TB014 .............. T014 TB166 .............. T166 A206L050 ........ T062 95117............... T117 95216............... T216
TB017 .............. T017 TB167 .............. T167 A234L075 ........ T073 95118............... T118 95217............... T217
TB018 .............. T018 TB168 .............. T168 A315L075 ........ T028 95119............... T119 95218............... T218
TB032 .............. T032 TB169 .............. T169 A356L075 ........ T041 95120............... T120 95219............... T219
TB036 .............. T036 TB170 .............. T170 A371L059 ........ T037 95121............... T121 95220............... T220
TB041 .............. T041 TB171 .............. T171 A375L075 ........ T061 95122............... T122 95221............... T221
TB043 .............. T043 TB172 .............. T172 A450L075 ........ T064 95123............... T123 95223............... T223
TB061 .............. T061 TB173 .............. T173 A453L075 ........ T017 95124............... T124 95224............... T224
TB063 .............. T073 TB174 .............. T174 A457L075 ........ T013 95125............... T125 95225............... T225
TB064 .............. T064 TB176 .............. T176 A484L088 ........ T014 95126............... T126 95226............... T226
TB065 .............. T065 TB177 .............. T177 A547L075 ........ T020 95127............... T127 95227............... T227
TB068 .............. T068 TB178 .............. T178 94011............... T092 95128............... T128 95228............... T228
TB069 .............. T069 TB179 .............. T179 94075............... T070 95129............... T129 95229............... T229
TB070 .............. T070 TB180 .............. T180 94078............... T203 95130............... T130 95230............... T230
TB074 .............. T074 TB181 .............. T181 94080............... T203 95131............... T131 95232............... T232
TB075 .............. T075 TB182 .............. T182 94098............... T089 95132............... T132 95233............... T233
TB076 .............. T076 TB183 .............. T183 94100............... T090 95133............... T292 95234............... T234
TB077 .............. T077 TB184 .............. T184 94123............... T117 95134............... T134 95235............... T235
TB078 .............. T078 TB185 .............. T185 94133............... T128 95135............... T135 95236............... T236
TB079 .............. T079 TB186 .............. T186 94165............... T146 95136............... T136 95237............... T237
TB081 .............. T081 TB187 .............. T187 94169............... T148 95137............... T137 95240............... T240
TB082 .............. T082 TB188 .............. T188 94185............... T163 95138............... T138 95241............... T241
TB083 .............. T083 TB189 .............. T189 94266............... T091 95139............... T139 95244............... T244
TB084 .............. T084 TB190 .............. T190 94283............... T124 95140............... T140 95245............... T245
TB087 .............. T087 TB191 .............. T191 94284............... T185 95141............... T141 95246............... T246
TB088 .............. T088 TB193 .............. T193 94293............... T165 95142............... T142 95247............... T247
TB089 .............. T089 TB195 .............. T195 94294............... T179 95143............... T143 95248............... T248
TB090 .............. T090 TB196 .............. T196 94340............... T155 95144............... T144 95249............... T249
TB091 .............. T091 TB197 .............. T197 94341............... T139 95145............... T145 95251............... T251
TB092 .............. T092 TB198 .............. T198 94350............... T167 95146............... T146 95252............... T252
TB093 .............. T093 TB199 .............. T199 94351............... T168 95147............... T147 95253............... T253
TB094 .............. T094 TB200 .............. T200 94430............... T155 95148............... T148 95254............... T254
TB095 .............. T095 TB201 .............. T201 95013............... T013 95150............... T150 95255............... T255
TB096 .............. T096 TB203 .............. T203 95014............... T014 95151............... T151 95257............... T257
TB097 .............. T097 TB204 .............. T204 95017............... T017 95152............... T152 95258............... T258
TB098 .............. T098 TB205 .............. T205 95018............... T018 95153............... T153 95259............... T259
TB099 .............. T099 TB208 .............. T208 95020............... T020 95154............... T154 95262............... T262
TB100 .............. T100 TB209 .............. T209 95028............... T028 95155............... T155 95263............... T263
TB101 .............. T101 TB210 .............. T210 95032............... T032 95157............... T157 95264............... T264
TB102 .............. T102 TB211 .............. T211 95036............... T036 95158............... T158 95265............... T265
TB103 .............. T103 TB212 .............. T212 95037............... T037 95159............... T159 95266............... T266
TB104 .............. T104 TB213 .............. T213 95039............... T039 95160............... T160 95269............... T269
TB106 .............. T106 TB214 .............. T214 95041............... T041 95161............... T161 95271............... T271
TB107 .............. T107 TB215 .............. T215 95042............... T068 95162............... T162 95272............... T272
TB108 .............. T293 TB216 .............. T216 95043............... T043 95163............... T163 95273............... T273
TB110 .............. T196 TB217 .............. T217 95061............... T061 95164............... T164 95276............... T276
TB112 .............. T112 TB218 .............. T218 95062............... T062 95165............... T165 95277............... T277
TB113 .............. T113 TB220 .............. T220 95063............... T073 95166............... T166 95278............... T278
TB115 .............. T299 TB221 .............. T221 95064............... T064 95167............... T167 95281............... T281
TB116 .............. T300 TB222 .............. T222 95065............... T065 95168............... T168 95283............... T283
TB117 .............. T117 TB224 .............. T224 95067............... T067 95169............... T169 95284............... T284
TB118 .............. T118 TB225 .............. T225 95068............... T068 95170............... T170 95286............... T286
TB119 .............. T119 TB227 .............. T227 95069............... T069 95171............... T171 95287............... T287
TB121 .............. T121 TB228 .............. T228 95070............... T070 95172............... T172 95288............... T288
TB122 .............. T122 TB229 .............. T229 95071............... T071 95173............... T173 95289............... T289
TB123 .............. T123 TB230 .............. T230 95073............... T073 95174............... T174 95291............... T291
DAYCO - Cont. DURKEE-ATWOOD - Cont. DYNAGEAR - Cont. ELGIN MACH. - Cont. FEDERAL MOGUL - Cont.
95292............... T292 88144............... T144 TB095 .............. T095 LB-074 ............. T074 LB163 .............. T163
95293............... T293 88146............... T146 TB096 .............. T096 LB-075 ............. T075 LB164 .............. T164
95294............... T294 88153............... T153 TB098 .............. T098 LB-076 ............. T076 LB165 .............. T165
95295............... T295 88157............... T157 TB099 .............. T099 LB-077 ............. T077 LB166 .............. T166
95296............... T296 88158............... T158 TB100 .............. T100 LB-078 ............. T078 LB167 .............. T167
95298............... T298 88159............... T159 TB101 .............. T101 LB-081 ............. T081 LB168 .............. T168
95299............... T299 88160............... T160 TB102 .............. T102 LB-088 ............. T088 LB169 .............. T169
95300............... T300 88161............... T161 TB103 .............. T103 LB-093 ............. T093 LB170 .............. T170
95302............... T302 88162............... T162 TB104 .............. T104 FEDERAL MOGUL LB172 .............. T254
95303............... T303 88163............... T163 TB106 .............. T106 LB176 .............. T176
95304............... T304 88165............... T165 TB107 .............. T107 LB013 .............. T013 LB177 .............. T177
88170............... T170 TB108 .............. T293 LB014 .............. T014 LB179 .............. T179
DURKEE-ATWOOD LB020 .............. T020
DYNAFLEX (See DAYCO) TB110 .............. T196 LB180 .............. T180
24-436PD......... T018 TB112 .............. T112 LB028 .............. T028 LB183 .............. T183
24-457PD......... T017 TB113 .............. T113 LB032 .............. T032 LB184 .............. T184
24-542PD......... T020 DYNAGEAR TB114 .............. T114 LB036 .............. T036 LB185 .............. T185
28-457PD......... T013 TB115 .............. T299 LB037 .............. T037 LB186 .............. T186
28-487PD......... T014 B013 ................ T013 TB116 .............. T300 LB039 .............. T039 LB187 .............. T187
88013............... T013 B014 ................ T014 TB117 .............. T117 LB041 .............. T041 LB193 .............. T193
88014............... T014 B017 ................ T017 TB118 .............. T118 LB043 .............. T043 LB194 .............. T194
88017............... T017 B018 ................ T018 TB119 .............. T119 LB061 .............. T061 LB202 .............. T248
88018............... T018 B020 ................ T020 TB121 .............. T121 LB062 .............. T062 LB210 .............. T210
88020............... T020 B028 ................ T028 TB122 .............. T122 LB064 .............. T064
88028............... T028 B032 ................ T032 TB123 .............. T123 LB065 .............. T065 FIRESTONE
88032............... T032 B037 ................ T037 TB124 .............. T124 LB067 .............. T067 51309510......... T017
88037............... T037 B039 ................ T039 TB125 .............. T125 LB069 .............. T069 51309618......... T061
88039............... T039 B041 ................ T041 TB126 .............. T126 LB070 .............. T070 51309677......... T067
88041............... T041 B043 ................ T043 TB127 .............. T127 LB071 .............. T071 51309693......... T071
88042............... T068 B061 ................ T061 TB128 .............. T128 LB073 .............. T073 51309766......... T081
88043............... T043 B062 ................ T062 TB129 .............. T129 LB074 .............. T074
88046............... T013 B063 ................ T073 TB130 .............. T130 LB075 .............. T075 FRESHSTART (See GOOD-
88047............... T014 B064 ................ T064 TB131 .............. T131 LB076 .............. T076 YEAR)
88050............... T018 B065 ................ T065 TB132 .............. T132 LB077 .............. T077
88052............... T020 B067 ................ T067 TB133 .............. T292 LB078 .............. T078
88057............... T037 B068 ................ T068 LB081 .............. T081 GATES (CANADA)
TB134 .............. T134
88058............... T039 B069 ................ T069 TB135 .............. T135 LB082 .............. T082 T013................. T013
88060............... T017 B070 ................ T070 TB136 .............. T136 LB083 .............. T083 T014................. T014
88061............... T061 B071 ................ T071 TB137 .............. T137 LB087 .............. T087 T017................. T017
88062............... T062 B074 ................ T074 TB138 .............. T138 LB088 .............. T088 T018................. T018
88063............... T073 B075 ................ T075 TB139 .............. T139 LB089 .............. T089 T020................. T020
88064............... T064 B076 ................ T076 TB140 .............. T140 LB090 .............. T090 T028................. T028
88065............... T065 B077 ................ T077 TB141 .............. T141 LB093 .............. T093 T032................. T032
88067............... T067 B078 ................ T078 TB142 .............. T142 LB094 .............. T094 T036................. T036
88069............... T069 B081 ................ T081 TB143 .............. T143 LB095 .............. T095 T037................. T037
88070............... T070 B087 ................ T087 TB144 .............. T144 LB099 .............. T099 T039................. T039
88071............... T071 B088 ................ T088 TB145 .............. T145 LB101 .............. T101 T041................. T041
88074............... T074 B093 ................ T093 TB146 .............. T146 LB102 .............. T102 T043................. T043
88075............... T075 B094 ................ T094 TB147 .............. T147 LB103 .............. T103 T061................. T061
88076............... T076 B095 ................ T095 TB148 .............. T148 LB104 .............. T104 T062................. T062
88077............... T077 B099 ................ T099 TB149 .............. T149 LB107 .............. T107 T063................. T073
88078............... T078 B104 ................ T104 TB150 .............. T150 LB108 .............. T293 T064................. T064
88079............... T079 B112 ................ T112 TB151 .............. T151 LB110 .............. T196 T065................. T065
88081............... T081 TB013 .............. T013 TB152 .............. T152 LB112 .............. T112 T067................. T067
88082............... T082 TB014 .............. T014 TB153 .............. T153 LB113 .............. T113 T068................. T068
88083............... T083 TB017 .............. T017 TB154 .............. T154 LB114 .............. T114 T069................. T069
88084............... T084 TB018 .............. T018 TB155 .............. T155 LB115 .............. T299 T070................. T070
88087............... T087 TB020 .............. T020 TB157 .............. T157 LB116 .............. T300 T071................. T071
88088............... T088 TB028 .............. T028 TB158 .............. T158 LB117 .............. T117 T073................. T073
88089............... T089 TB029 .............. T104 TB159 .............. T159 LB118 .............. T162 T074................. T074
88090............... T090 TB032 .............. T032 TB160 .............. T160 LB119 .............. T119 T075................. T075
88091............... T091 TB036 .............. T036 TB161 .............. T161 LB122 .............. T122 T076................. T076
88092............... T092 TB037 .............. T037 TB162 .............. T162 LB124 .............. T124 T077................. T077
88093............... T093 TB039 .............. T039 TB163 .............. T163 LB125 .............. T125 T078................. T078
88094............... T094 TB041 .............. T041 TB164 .............. T164 LB126 .............. T237 T079................. T079
88095............... T095 TB043 .............. T043 TB165 .............. T165 LB128 .............. T128 T081................. T081
88099............... T099 TB061 .............. T061 TB166 .............. T166 LB129 .............. T129 T082................. T082
88100............... T100 TB062 .............. T062 TB167 .............. T167 LB130 .............. T130 T083................. T083
88101............... T101 TB063 .............. T073 TB168 .............. T168 LB131 .............. T131 T084................. T084
88102............... T102 TB064 .............. T064 TB169 .............. T169 LB132 .............. T132 T087................. T087
88104............... T104 TB065 .............. T065 LB133 .............. T292 T088................. T088
88106............... T106 TB067 .............. T067 ELGIN MACH. LB134 .............. T134 T089................. T089
88107............... T107 TB068 .............. T068 LB-013 ............. T013 LB135 .............. T135 T090................. T090
88112............... T112 TB069 .............. T069 LB-014 ............. T014 LB136 .............. T233 T091................. T091
88113............... T113 TB070 .............. T070 LB-017 ............. T017 LB138 .............. T199 T092................. T092
88114............... T114 TB071 .............. T071 LB-018 ............. T018 LB139 .............. T139 T093................. T093
88115............... T299 TB073 .............. T073 LB-020 ............. T020 LB141 .............. T141 T094................. T094
88116............... T300 TB074 .............. T074 LB-028 ............. T028 LB142 .............. T142 T095................. T095
88117............... T117 TB075 .............. T075 LB-032 ............. T032 LB143 .............. T143 T096................. T096
88118............... T118 TB076 .............. T076 LB-036 ............. T036 LB144 .............. T144 T097................. T097
88121............... T121 TB077 .............. T077 LB-037 ............. T037 LB145 .............. T145 T098................. T098
88122............... T122 TB078 .............. T078 LB-039 ............. T039 LB146 .............. T146 T099................. T099
88124............... T124 TB079 .............. T079 LB-041 ............. T041 LB147 .............. T147 T100................. T100
88125............... T125 TB081 .............. T081 LB-043 ............. T043 LB148 .............. T148 T101................. T101
88126............... T126 TB082 .............. T082 LB-061 ............. T061 LB149 .............. T149 T102................. T102
88127............... T127 TB083 .............. T083 LB-062 ............. T062 LB152 .............. T152 T103................. T103
88130............... T130 TB084 .............. T084 LB-063 ............. T073 LB153 .............. T153 T104................. T104
88131............... T131 TB087 .............. T087 LB-064 ............. T064 LB154 .............. T154 T106................. T106
88132............... T132 TB088 .............. T088 LB-065 ............. T065 LB155 .............. T155 T107................. T107
88133............... T292 TB089 .............. T089 LB-067 ............. T067 LB157 .............. T157 T108................. T293
88134............... T134 TB090 .............. T090 LB-068 ............. T068 LB158 .............. T158 T110................. T196
88136............... T136 TB091 .............. T091 LB-069 ............. T069 LB159 .............. T159 T112................. T112
88138............... T138 TB092 .............. T092 LB-070 ............. T070 LB160 .............. T160 T113................. T113
88141............... T141 TB093 .............. T093 LB-071 ............. T071 LB161 .............. T161 T114................. T114
88143............... T143 TB094 .............. T094 LB-073 ............. T073 LB162 .............. T162 T115................. T299
GATES (CANADA) - Cont. GATES (CANADA) - Cont. GATES (CANADA) - Cont. GOODYEAR - Cont. GOODYEAR - Cont.
T116................. T300 T212................. T212 T310................. T310 CD-168 ............ T168 CD-263 ............ T263
T117................. T117 T213................. T213 T311................. T311 CD-169 ............ T169 CD-264 ............ T264
T118................. T118 T214................. T214 T312................. T312 CD-17 .............. T017 CD-265 ............ T265
T119................. T119 T215................. T215 T315................. T315 CD-170 ............ T170 CD-266 ............ T266
T120................. T120 T216................. T216 T316................. T316 CD-171 ............ T171 CD-267 ............ T267
T121................. T121 T217................. T217 T317................. T317 CD-172 ............ T172 CD-269 ............ T269
T122................. T122 T218................. T218 T318................. T318 CD-173 ............ T173 CD-271 ............ T271
T123................. T123 T219................. T219 6401................. T014 CD-174 ............ T174 CD-272 ............ T272
T124................. T124 T220................. T220 6402................. T013 CD-176 ............ T176 CD-273 ............ T273
T125................. T125 T221................. T221 6403................. T037 CD-177 ............ T177 CD-276 ............ T276
T126................. T126 T222................. T222 6404................. T017 CD-178 ............ T178 CD-277 ............ T277
T127................. T127 T223................. T223 6406................. T018 CD-179 ............ T179 CD-278 ............ T278
T128................. T128 T224................. T224 6408................. T020 CD-18 .............. T018 CD-279 ............ T279
T129................. T129 T225................. T225 6409................. T039 CD-180 ............ T180 CD-28 .............. T028
T130................. T130 T226................. T226 6410................. T032 CD-181 ............ T181 CD-280 ............ T280
T131................. T131 T227................. T227 6411................. T041 CD-182 ............ T182 CD-281 ............ T281
T132................. T132 T228................. T228 6412................. T062 CD-183 ............ T183 CD-282 ............ T282
T133................. T292 T229................. T229 6413................. 6413 CD-184 ............ T184 CD-283 ............ T283
T134................. T134 T230................. T230 6414................. 6414 CD-185 ............ T185 CD-284 ............ T284
T135................. T135 T232................. T232 6415................. T028 CD-186 ............ T186 CD-285 ............ T285
T136................. T136 T233................. T233 6416................. T064 CD-187 ............ T187 CD-286 ............ T286
T137................. T137 T234................. T234 6417................. T065 CD-188 ............ T188 CD-287 ............ T287
T138................. T138 T235................. T235 6418................. T061 CD-189 ............ T189 CD-288 ............ T288
T139................. T139 T236................. T236 6419................. T073 CD-190 ............ T190 CD-289 ............ T289
T140................. T140 T237................. T237 6421................. 6421 CD-191 ............ T191 CD-290 ............ T290
T141................. T141 T239................. T239 6424................. T069 CD-192 ............ T192 CD-291 ............ T291
T142................. T142 T240................. T240 6425................. T070 CD-193 ............ T193 CD-292 ............ T292
T143................. T143 T241................. T241 6426................. T068 CD-194 ............ T194 CD-293 ............ T293
T144................. T144 T242................. T242 6427................. T071 CD-195 ............ T195 CD-294 ............ T294
T145................. T145 T243................. T243 6428................. T067 CD-196 ............ T196 CD-295 ............ T295
T146................. T146 T244................. T244 6429................. T076 CD-197 ............ T197 CD-296 ............ T296
T147................. T147 T245................. T245 6430................. T075 CD-198 ............ T198 CD-297 ............ T297
T148................. T148 T246................. T246 6431................. T078 CD-199 ............ T199 CD-298 ............ T298
T149................. T149 T247................. T247 6432................. T077 CD-20 .............. T020 CD-299 ............ T299
T150................. T150 T248................. T248 6433................. T043 CD-200 ............ T200 CD-300 ............ T300
T151................. T151 T249................. T249 6434................. T074 CD-201 ............ T201 CD-301 ............ T301
T152................. T152 T251................. T251 GOODYEAR CD-202 ............ T248 CD-302 ............ T302
T153................. T153 T252................. T252 CD-100 ............ T100 CD-203 ............ T203 CD-303 ............ T303
T154................. T154 T253................. T253 CD-101 ............ T101 CD-204 ............ T204 CD-304 ............ T304
T155................. T155 T254................. T254 CD-104 ............ T104 CD-205 ............ T205 CD-305 ............ T305
T157................. T157 T255................. T255 CD-106 ............ T106 CD-206 ............ T206 CD-306 ............ T306
T158................. T158 T256................. T256 CD-112 ............ T112 CD-207 ............ T207 CD-32 .............. T032
T159................. T159 T257................. T257 CD-113 ............ T113 CD-208 ............ T208 CD-36 .............. T036
T160................. T160 T258................. T258 CD-114 ............ T114 CD-209 ............ T209 CD-37 .............. T037
T161................. T161 T259................. T259 CD-115 ............ T299 CD-210 ............ T210 CD-39 .............. T039
T162................. T162 T260................. T260 CD-116 ............ T300 CD-211 ............ T211 CD-41 .............. T041
T163................. T163 T262................. T262 CD-117 ............ T117 CD-212 ............ T212 CD-42 .............. T068
T164................. T164 T263................. T263 CD-118 ............ T118 CD-213 ............ T213 CD-43 .............. T043
T165................. T165 T264................. T264 CD-122 ............ T122 CD-214 ............ T214 CD-61 .............. T061
T166................. T166 T265................. T265 CD-124 ............ T124 CD-215 ............ T215 CD-62 .............. T062
T167................. T167 T266................. T266 CD-125 ............ T125 CD-216 ............ T216 CD-63 .............. T073
T168................. T168 T267................. T267 CD-126 ............ T126 CD-217 ............ T217 CD-64 .............. T064
T169................. T169 T269................. T269 CD-127 ............ T127 CD-218 ............ T218 CD-65 .............. T065
T170................. T170 T270................. T270 CD-128 ............ T128 CD-219 ............ T219 CD-67 .............. T067
T171................. T171 T271................. T271 CD-129 ............ T129 CD-220 ............ T220 CD-69 .............. T069
T172................. T172 T272................. T272 CD-13 .............. T013 CD-221 ............ T221 CD-70 .............. T070
T173................. T173 T273................. T273 CD-130 ............ T130 CD-222 ............ T222 CD-71 .............. T071
T174................. T174 T274................. T274 CD-131 ............ T131 CD-223 ............ T223 CD-74 .............. T074
T176................. T176 T275................. T275 CD-132 ............ T132 CD-224 ............ T224 CD-77 .............. T077
T177................. T177 T276................. T276 CD-133 ............ T292 CD-225 ............ T225 CD-78 .............. T078
T178................. T178 T277................. T277 CD-134 ............ T134 CD-226 ............ T226 CD-81 .............. T081
T179................. T179 T278................. T278 CD-136 ............ T136 CD-227 ............ T227 CD-87 .............. T087
T180................. T180 T279................. T279 CD-137 ............ T137 CD-228 ............ T228 CD-88 .............. T088
T181................. T181 T280................. T280 CD-138 ............ T138 CD-229 ............ T229 CD-89 .............. T089
T182................. T182 T281................. T281 CD-139 ............ T139 CD-230 ............ T230 CD-90 .............. T090
T183................. T183 T282................. T282 CD-14 .............. T014 CD-232 ............ T232 CD-91 .............. T091
T184................. T184 T283................. T283 CD-140 ............ T140 CD-233 ............ T233 CD-92 .............. T092
T185................. T185 T284................. T284 CD-141 ............ T141 CD-234 ............ T234 CD-93 .............. T093
T186................. T186 T285................. T285 CD-142 ............ T142 CD-235 ............ T235 CD-94 .............. T094
T187................. T187 T286................. T286 CD-143 ............ T143 CD-236 ............ T236 CD-95 .............. T095
T188................. T188 T287................. T287 CD-144 ............ T144 CD-237 ............ T237 CD-99 .............. T099
T189................. T189 T288................. T288 CD-145 ............ T145 CD-239 ............ T239 40013............... T013
T190................. T190 T289................. T289 CD-146 ............ T146 CD-240 ............ T240 40014............... T014
T191................. T191 T290................. T290 CD-147 ............ T147 CD-241 ............ T241 40017............... T017
T192................. T192 T291................. T291 CD-148 ............ T148 CD-242 ............ T242 40018............... T018
T193................. T193 T292................. T292 CD-149 ............ T149 CD-243 ............ T243 40020............... T020
T194................. T194 T293................. T293 CD-150 ............ T150 CD-244 ............ T244 40028............... T028
T195................. T195 T294................. T294 CD-151 ............ T151 CD-245 ............ T245 40032............... T032
T196................. T196 T295................. T295 CD-152 ............ T152 CD-246 ............ T246 40036............... T036
T197................. T197 T296................. T296 CD-153 ............ T153 CD-247 ............ T247 40037............... T037
T198................. T198 T297................. T297 CD-154 ............ T154 CD-248 ............ T248 40039............... T039
T199................. T199 T298................. T298 CD-155 ............ T155 CD-249 ............ T249 40041............... T041
T200................. T200 T299................. T299 CD-157 ............ T157 CD-251 ............ T251 40042............... T068
T201................. T201 T300................. T300 CD-158 ............ T158 CD-252 ............ T252 40043............... T043
T203................. T203 T301................. T301 CD-159 ............ T159 CD-253 ............ T253 40046............... T013
T204................. T204 T302................. T302 CD-160 ............ T160 CD-254 ............ T254 40047............... T014
T205................. T205 T303................. T303 CD-161 ............ T161 CD-255 ............ T255 40050............... T018
T206................. T206 T304................. T304 CD-162 ............ T162 CD-256 ............ T256 40052............... T020
T207................. T207 T305................. T305 CD-163 ............ T163 CD-257 ............ T257 40057............... T037
T208................. T208 T306................. T306 CD-164 ............ T164 CD-258 ............ T258 40058............... T039
T209................. T209 T307................. T307 CD-165 ............ T165 CD-259 ............ T259 40060............... T017
T210................. T210 T308................. T308 CD-166 ............ T166 CD-260 ............ T260 40061............... T061
T211................. T211 T309................. T309 CD-167 ............ T167 CD-262 ............ T262 40062............... T062
GOODYEAR - Cont. GOODYEAR - Cont. HOOF PRODUCTS - Cont. LAZORLITE - Cont. MCQUAY-NORRIS - Cont.
40063............... T073 40183............... T183 HB076.............. T076 L55-4855.......... T142 TC043.............. T043
40064............... T064 40184............... T184 HB077.............. T077 L55-4863.......... T143 TC061.............. T061
40065............... T065 40185............... T185 HB078.............. T078 L55-4880.......... T167 TC062.............. T062
40067............... T067 40186............... T186 HB079.............. T079 L55-4898.......... T165 TC063.............. T073
40069............... T069 40187............... T187 HB081.............. T081 L55-4901.......... T164 TC064.............. T064
40070............... T070 40190............... T190 HB082.............. T082 L55-4910.......... T150 TC065.............. T065
40071............... T071 40191............... T191 HB083.............. T083 L55-4928.......... T151 TC067.............. T067
40074............... T074 40192............... T192 HB084.............. T084 L55-4936.......... T166 TC068.............. T068
40075............... T075 40193............... T193 HB087.............. T087 L55-4944.......... T113 TC069.............. T069
40076............... T076 40194............... T194 HB088.............. T088 L55-4952.......... T157 TC070.............. T070
40077............... T077 40195............... T195 HB089.............. T089 L55-4960.......... T154 TC071.............. T071
40078............... T078 40198............... T198 HB090.............. T090 L55-4979.......... T125 TC074.............. T074
40079............... T079 40199............... T199 HB091.............. T091 U55-4359 ......... T069 TC075.............. T075
40081............... T081 40200............... T200 HB092.............. T092 U55-4367 ......... T018 TC076.............. T076
40082............... T082 40201............... T201 HB093.............. T093 U55-4375 ......... T068 TC077.............. T077
40083............... T083 40202............... T248 HB094.............. T094 U55-4383 ......... T020 TC078.............. T078
40084............... T084 40203............... T203 HB095.............. T095 U55-4405 ......... T017 TC081.............. T081
40087............... T087 40204............... T204 HB096.............. T096 U55-4413 ......... T065 TC087.............. T087
40088............... T088 40205............... T205 HB099.............. T099 U55-4421 ......... T127 TC088.............. T088
40089............... T089 40208............... T208 HB100.............. T100 U55-4430 ......... T083 TC089.............. T089
40090............... T090 40210............... T210 HB102.............. T102 U55-4448 ......... T032 MELLING AUTOMOTIVE
40091............... T091 40211............... T211 HB103.............. T103 U55-4456 ......... T082
40092............... T092 40212............... T212 HB104.............. T104 U55-4464 ......... T043 B0100 .............. T100
40093............... T093 40214............... T214 HB114.............. T114 U55-4545 ......... T082 B0101 .............. T101
40094............... T094 40215............... T215 HB115.............. T299 U55-4553 ......... T083 B0102 .............. T102
40095............... T095 40216............... T216 HB116.............. T300 U55-4561 ......... T293 B0103 .............. T103
40099............... T099 40217............... T217 HB118.............. T118 U55-4570 ......... T107 B0104 .............. T104
40100............... T100 40219............... T219 HB121.............. T121 U55-4588 ......... T119 B0106 .............. T106
40101............... T101 40220............... T220 HB122.............. T122 U55-4871 ......... T292 B0107 .............. T107
40102............... T102 40221............... T221 HB127.............. T127 B0108 .............. T293
40223............... T223 HB128.............. T128 LEMPCO B0112 .............. T176
40103............... T103 B0113 .............. T113
40104............... T104 40224............... T224 LAZORLITE TB013 .............. T013
40106............... T106 40226............... T226 TB014 .............. T014 B0114 .............. T114
40107............... T107 40227............... T227 L55-4014.......... T013 TB017 .............. T017 B0115 .............. T299
40112............... T176 40228............... T228 L55-4022.......... T062 TB018 .............. T018 B0116 .............. T300
40230............... T230 L55-4030.......... T064 TB028 .............. T028 B0117 .............. T117
40113............... T113 L55-4049.......... T028 B0118 .............. T162
40114............... T114 40233............... T233 TB037 .............. T037
40234............... T234 L55-4057.......... T041 TB039 .............. T039 B0119 .............. T119
40115............... T299 L55-4065.......... T041 B0121 .............. T121
40116............... T300 40235............... T235 TB041 .............. T041
40236............... T236 L55-4081.......... T073 TB063 .............. T073 B0122 .............. T122
40117............... T117 L55-4103.......... T078 B0123 .............. T123
40118............... T118 40237............... T237 TB064 .............. T064
40239............... T239 L55-4111.......... T077 TB071 .............. T071 B0124 .............. T124
40119............... T119 40240............... T240 L55-4120.......... T074 B0125 .............. T125
40121............... T121 TB112 .............. T112
40241............... T241 L55-4138.......... T079 B0126 .............. T126
40122............... T122 40244............... T244 L55-4154.......... T088 LINK-BELT B0127 .............. T127
40123............... T123 40245............... T245 L55-4162.......... T089 B0128 .............. T128
40124............... T124 B013 ................ T013
40246............... T246 L55-4170.......... T090 B014 ................ T014 B0129 .............. T129
40125............... T125 40247............... T247 L55-4189.......... T092 B013 ................ T013
40126............... T126 B037 ................ T037
40248............... T248 L55-4200.......... T070 B0130 .............. T130
40127............... T127 40249............... T249 L55-4219.......... T075 MBL THREE STARS B0131 .............. T131
40128............... T128 40252............... T252 L55-4227.......... T076 100ZA19 .......... T061 B0132 .............. T132
40129............... T129 40255............... T255 L55-4235.......... T117 106ZA19 .......... T077 B0133 .............. T292
40130............... T130 40257............... T257 L55-4243.......... T093 109ZA19 .......... T088 B0134 .............. T134
40131............... T131 40258............... T258 L55-4251.......... T091 113ZA19 .......... T065 B0135 .............. T135
40132............... T132 40259............... T259 L55-4260.......... T095 116ZA19 .......... T018 B0136 .............. T136
40133............... T292 40262............... T262 L55-4286.......... T104 118ZA19 .......... T069 B0137 .............. T137
40134............... T134 40263............... T263 L55-4294.......... T101 120ZA19 .......... T064 B0138 .............. T138
40136............... T136 40265............... T265 L55-4308.......... T084 121ZA19 .......... T017 B0139 .............. T139
40137............... T137 40266............... T266 L55-4316.......... T087 122ZA19 .......... T013 B014 ................ T014
40138............... T138 40271............... T271 L55-4324.......... T094 123ZA19 .......... T032 B0140 .............. T140
40139............... T139 40272............... T272 L55-4332.......... T099 124ZA25 .......... T071 B0141 .............. T141
40140............... T140 40273............... T273 L55-4405.......... T017 129ZA22 .......... T014 B0142 .............. T142
40141............... T141 40276............... T276 L55-4472.......... T300 134ZA30 .......... T076 B0143 .............. T143
40142............... T142 40283............... T283 L55-4480.......... T299 134ZB301 ........ T076 B0144 .............. T144
40143............... T143 40292............... T292 L55-4499.......... T112 135ZB25 .......... T043 B0145 .............. T145
40144............... T144 40299............... T299 L55-4502.......... T161 139ZA25 .......... T087 B0146 .............. T146
40145............... T145 40300............... T300 L55-4510.......... T118 142ZA25 .......... T074 B0147 .............. T147
40146............... T146 L55-4529.......... T104 146ZA19 .......... T020 B0148 .............. T148
40147............... T147 HOOF PRODUCTS L55-4537.......... T137 B0149 .............. T149
148ZA19 .......... T068
40148............... T148 HB013.............. T013 L55-4596.......... T149 55ZA13 ............ T062 B0150 .............. T150
40152............... T152 HB014.............. T014 L55-4600.......... T141 84ZA19 ............ T028 B0151 .............. T151
40153............... T153 HB017.............. T017 L55-4618.......... T141 87ZA34 ............ T075 B0152 .............. T152
40154............... T154 HB018.............. T018 L55-4626.......... T117 87ZB34 ............ T075 B0153 .............. T153
40155............... T155 HB020.............. T020 L55-4634.......... T134 88ZA19 ............ T070 B0154 .............. T154
40157............... T157 HB028.............. T028 L55-4642.......... T128 92ZA19 ............ T073 B0155 .............. T155
40158............... T158 HB032.............. T032 L55-4650.......... T124 95ZA19 ............ T041 B0157 .............. T157
40159............... T159 HB036.............. T036 L55-4669.......... T139 97ZA25 ............ T067 B0158 .............. T158
40160............... T160 HB037.............. T037 L55-4677.......... T103 98ZA19 ............ T078 B0159 .............. T159
40161............... T161 HB039.............. T039 L55-4685.......... T135 99ZA15 ............ T037 B0160 .............. T160
40162............... T162 HB041.............. T041 L55-4693.......... T136 99ZA19 ............ T039 B0161 .............. T161
40163............... T163 HB042.............. T068 L55-4707.......... T126 B0162 .............. T162
40164............... T164 HB043.............. T043 L55-4715.......... T098 MCQUAY-NORRIS B0163 .............. T163
40165............... T165 HB061.............. T061 L55-4723.......... T138 TC013.............. T013 B0164 .............. T164
40166............... T166 HB062.............. T062 L55-4731.......... T130 TC014.............. T014 B0165 .............. T165
40167............... T167 HB063.............. T073 L55-4740.......... T129 TC017.............. T017 B0166 .............. T166
40168............... T168 HB064.............. T064 L55-4758.......... T145 TC018.............. T018 B0167 .............. T167
40169............... T169 HB065.............. T065 L55-4766.......... T122 TC020.............. T020 B0168 .............. T168
40170............... T170 HB067.............. T067 L55-4774.......... T121 TC028.............. T028 B0169 .............. T169
40172............... T172 HB069.............. T069 L55-4782.......... T148 TC032.............. T032 B017 ................ T017
40176............... T176 HB070.............. T070 L55-4790.......... T138 TC036.............. T036 B0170 .............. T170
40177............... T177 HB071.............. T071 L55-4812.......... T146 TC037.............. T037 B0171 .............. T171
40178............... T178 HB073.............. T073 L55-4820.......... T159 TC039.............. T039 B0172 .............. T172
40179............... T179 HB074.............. T074 L55-4839.......... T168 TC041.............. T041 B0174 .............. T174
40180............... T180 HB075.............. T075 L55-4847.......... T144 TC042.............. T068 B0176 .............. T176
MELLING AUTOMOTIVE MICROTEST - Cont. MIGHTY - Cont. NAPA - Cont. NAPA - Cont.
- Cont. 9-067................ T067 CD81................ T081 25-90097.......... T097 25-90440.......... T081
B0177 .............. T177 9-071................ T071 CD82................ T082 25-90130.......... T013 25-90450.......... T088
B0178 .............. T178 MIGHTY CD83................ T083 25-90140.......... T014 25-90460.......... T087
B0179 .............. T179 CD84................ T084 25-90150.......... T032 25-90470.......... T093
B018 ................ T018 CD100.............. T100 CD87................ T087 25-90160.......... T041 25-90480.......... T094
B0180 .............. T180 CD101.............. T101 CD88................ T088 25-90166.......... T166 25-90490.......... T104
B0181 .............. T181 CD102.............. T102 CD89................ T089 25-90167.......... T167 25-90510.......... T100
B0182 .............. T182 CD103.............. T103 CD90................ T090 25-90168.......... T168 25-90520.......... T084
B0183 .............. T183 CD104.............. T104 CD91................ T091 25-90169.......... T169 25-90530.......... T099
B0184 .............. T184 CD111.............. T140 CD92................ T092 25-90170.......... T017 25-90540.......... T098
B0185 .............. T185 CD112.............. T176 CD93................ T093 25-90171.......... T171 25-90550.......... T082
B0186 .............. T186 CD113.............. T113 CD94................ T094 25-90172.......... T172 25-90560.......... T083
B0187 .............. T187 CD114.............. T114 CD95................ T095 25-90173.......... T173 25-90570.......... T095
B0189 .............. T189 CD115.............. T299 CD99................ T099 25-90174.......... T174 25-90590.......... T112
B0191 .............. T191 CD116.............. T300 25-90176.......... T176 25-90600.......... T089
B0192 .............. T192 CD117.............. T117 MITSUBOSHI
25-90177.......... T177 25-90610.......... T118
B0193 .............. T193 CD118.............. T118 106ZA19 .......... T077 25-90178.......... T178 25-90620.......... T079
B0194 .............. T194 CD119.............. T119 111ZA19 .......... T121 25-90179.......... T179 25-90630.......... T122
B0195 .............. T195 CD121.............. T121 116ZA19 .......... T018 25-90180.......... T018 25-90640.......... T121
B0199 .............. T199 CD122.............. T122 120ZA19 .......... T064 25-90181.......... T181 25-90650.......... T127
B020 ................ T020 CD123.............. T123 122ZA19 .......... T013 25-90182.......... T182 25-90670.......... T101
B0202 .............. T248 CD124.............. T124 123ZA19 .......... T032 25-90183.......... T183 25-90680.......... T125
B0203 .............. T203 CD125.............. T125 127ZA25 .......... T079 25-90184.......... T184 25-90690.......... T126
B0204 .............. T204 CD126.............. T126 129ZA22 .......... T014 25-90185.......... T185 25-90700.......... T130
B0205 .............. T205 CD127.............. T127 134ZB30 .......... T076 25-90186.......... T186 25-90710.......... T129
B0208 .............. T208 CD128.............. T128 139ZA25 .......... T087 25-90187.......... T187 25-90720.......... T106
B0210 .............. T210 CD129.............. T129 146ZA19 .......... T020 25-90188.......... T188 25-90730.......... T114
B0216 .............. T216 CD13................ T013 148ZA19 .......... T068 25-90189.......... T189 25-90740.......... T300
B0219 .............. T219 CD130.............. T130 55ZA13 ............ T062 25-90191.......... T191 25-90750.......... T299
B0223 .............. T223 CD131.............. T131 55ZB13 ............ T090 25-90192.......... T192 25-90760.......... T091
B0224 .............. T224 CD132.............. T132 83ZB19 ............ T092 25-90193.......... T193 25-90770.......... T092
B0226 .............. T226 CD133.............. T292 84ZA19 ............ T028 25-90194.......... T194 25-90780.......... T117
B0228 .............. T228 CD134.............. T134 87ZB34 ............ T075 25-90195.......... T195 25-90790.......... T119
B0229 .............. T229 CD135.............. T135 88ZA19 ............ T070 25-90196.......... T196 25-90800.......... T292
B0230 .............. T230 CD136.............. T136 89ZA19 ............ T095 25-90197.......... T197 25-90810.......... T134
B0232 .............. T232 CD137.............. T137 92ZA19 ............ T073
CD138.............. T138 25-90198.......... T198 25-90820.......... T135
B0233 .............. T233 94ZA19 ............ T036 25-90199.......... T199 25-90830.......... T136
B0237 .............. T237 CD139.............. T139 95ZA19 ............ T041
CD14................ T014 25-90200.......... T020 25-90840.......... T137
B0239 .............. T239 98ZA19 ............ T078 25-90201.......... T201 25-90850.......... T138
B028 ................ T028 CD141.............. T141
CD142.............. T142 MOPAR 25-90202.......... T248 25-90860.......... T139
B029 ................ T104 25-90203.......... T203 25-90870.......... T140
B032 ................ T032 CD143.............. T143 BTC-13 ............ T013
B036 ................ T036 CD144.............. T144 25-90204.......... T204 25-90880.......... T131
BTC-14 ............ T014 25-90205.......... T205 25-90890.......... T141
B037 ................ T037 CD145.............. T145 BTC-37 ............ T037
B039 ................ T039 CD146.............. T146 25-90206.......... T206 25-90900.......... T123
BTC-39 ............ T020 25-90208.......... T208 25-90910.......... T090
B041 ................ T041 CD147.............. T147 B0040013 ........ T013
B042 ................ T068 CD148.............. T148 25-90209.......... T209 25-90920.......... T293
B0040017 ........ T017 25-90210.......... T039 25-90930.......... T196
B043 ................ T043 CD153.............. T153 B0040062 ........ T062
B061 ................ T061 CD154.............. T154 25-90211.......... T211 25-90940.......... T113
B0040063 ........ T073 25-90212.......... T212 25-90950.......... T132
B062 ................ T062 CD155.............. T155 B0040064 ........ T064
B063 ................ T073 CD157.............. T157 25-90213.......... T213 25-90960.......... T142
B0040071 ........ T071 25-90214.......... T214 25-90970.......... T143
B064 ................ T064 CD158.............. T158
B065 ................ T065 CD159.............. T159 MOTORCRAFT 25-90215.......... T215 25-90980.......... T144
B067 ................ T067 CD160.............. T160 CET13.............. T013 25-90216.......... T216 25-90990.......... T145
B069 ................ T069 CD161.............. T161 CET135............ T135 25-90217.......... T217 25-91000.......... T146
B070 ................ T070 CD162.............. T162 CET14.............. T014 25-90218.......... T218 25-91001.......... T147
B071 ................ T071 CD163.............. T163 CET17.............. T017 25-90219.......... T219 25-91002.......... T148
B074 ................ T074 CD164.............. T164 CET207............ T207 25-90220.......... T062 25-91003.......... T149
B075 ................ T075 CD165.............. T165 CET230............ T230 25-90221.......... T221 25-91004.......... T150
B076 ................ T076 CD166.............. T166 CET257............ T257 25-90222.......... T222 25-91005.......... T151
B077 ................ T077 CD167.............. T167 CET262............ T262 25-90223.......... T223 25-91006.......... T152
B078 ................ T078 CD17................ T017 CET263............ T263 25-90224.......... T224 25-91007.......... T102
B079 ................ T079 CD176.............. T176 CET264............ T264 25-90225.......... T225 25-91008.......... T103
B081 ................ T081 CD18................ T018 CET265............ T265 25-90226.......... T226 25-91009.......... T107
B082 ................ T082 CD185.............. T185 CET271............ T271 25-90227.......... T227 25-91010.......... T124
B083 ................ T083 CD186.............. T186 CET272............ T272 25-90228.......... T228 25-91011.......... T154
B084 ................ T084 CD187.............. T187 CET273............ T273 25-90229.......... T229 25-91012.......... T155
B087 ................ T087 CD191.............. T191 CET277............ T277 25-90230.......... 6413 25-91014.......... T157
B088 ................ T088 CD20................ T020 CET278............ T278 25-90232.......... T232 25-91015.......... T158
B089 ................ T089 CD208.............. T208 CET279............ T279 25-90233.......... T233 25-91016.......... T159
B090 ................ T090 CD210.............. T210 CET28.............. T028 25-90234.......... T234 25-91017.......... T160
B091 ................ T091 CD28................ T028 CET280............ T280 25-90235.......... T235 25-91018.......... T161
B092 ................ T092 CD32................ T032 CET281............ T281 25-90236.......... T236 25-91019.......... T162
B093 ................ T093 CD36................ T036 CET282............ T282 25-90237.......... T237 25-91020.......... T163
B094 ................ T094 CD37................ T037 CET284............ T284 25-90239.......... T239 25-91021.......... T164
B095 ................ T095 CD39................ T039 CET285............ T285 25-90240.......... 6414 25-91022.......... T165
B096 ................ T096 CD41................ T041 CET286............ T286 25-90250.......... T028 25-91023.......... T153
B097 ................ T097 CD42................ T068 CET287............ T287 25-90260.......... T061 25-91120.......... T120
B098 ................ T098 CD43................ T043 CET288............ T288 25-90270.......... T064 25-91170.......... T170
B099 ................ T099 CD61................ T061 CET289............ T289 25-90280.......... T065 25-91180.......... T180
CD62................ T062 CET290............ T290 25-90290.......... T073 25-91190.......... T190
MICROTEST CD63................ T073 25-90310.......... T069 25-91200.......... T200
CET291............ T291
9-013................ T013 CD64................ T064 CET37.............. T037 25-90320.......... T036 25-91210.......... T210
9-014................ T014 CD65................ T065 CET39.............. T039 25-90330.......... T070 25-91220.......... T220
9-017................ T017 CD67................ T067 CET41.............. T041 25-90340.......... T068 25-91230.......... T230
9-018................ T018 CD69................ T069 CET61.............. T061 25-90350.......... T071 25-91240.......... T240
9-020................ T020 CD70................ T070 CET67.............. T067 25-90360.......... T067 25-99000.......... 6421
9-028................ T028 CD71................ T071 CET70.............. T070 25-90370.......... T037 250000............. 6421
9-039................ T039 CD74................ T074 CET71.............. T071 25-90380.......... T076 250013............. T013
9-041................ T041 CD75................ T075 CET94.............. T094 25-90390.......... T075 250014............. T014
9-061................ T061 CD76................ T076 25-90400.......... T078 250017............. T017
9-063................ T073 CD77................ T077 NAPA 25-90410.......... T077 250018............. T018
9-064................ T064 CD78................ T078 25-90073.......... T073 25-90420.......... T043 250020............. T020
9-065................ T065 CD79................ T079 25-90096.......... T096 25-90430.......... T074 250028............. T028
NAPA - Cont. NAPA - Cont. NAPA - Cont. PERFECT CIRCLE PERFECTION AM - Cont.
250032............. T032 250159............. T159 250256............. T256 9-100................ T100 037................... T037
250036............. T036 250160............. T160 250257............. T257 9-101................ T101 039................... T039
250037............. T037 250161............. T161 250258............. T258 9-102................ T102 PROVEN VALU
250039............. T039 250162............. T162 250259............. T259 9-103................ T103
250041............. T041 250163............. T163 250260............. T260 9-104................ T104 TB-013............. T013
250043............. T043 250164............. T164 250262............. T262 9-13.................. T013 TB-014............. T014
250061............. T061 250165............. T165 250263............. T263 9-14.................. T014 TB-017............. T017
250062............. T062 250166............. T166 250264............. T264 9-17.................. T017 TB-018............. T018
250064............. T064 250167............. T167 250265............. T265 9-18.................. T018 TB-020............. T020
250065............. T065 250168............. T168 250266............. T266 9-20.................. T020 TB-028............. T028
250067............. T067 250169............. T169 250267............. T267 9-28.................. T028 TB-032............. T032
250068............. T068 250170............. T170 9-32.................. T032 TB-036............. T036
250269............. T269 TB-037............. T037
250069............. T069 250171............. T171 250270............. T270 9-36.................. T036
250070............. T070 250172............. T172 9-37.................. T037 TB-039............. T039
250271............. T271 9-39.................. T039 TB-041............. T041
250071............. T071 250173............. T173 250272............. T272
250073............. T073 250174............. T174 9-41.................. T041 TB-043............. T043
250273............. T273 9-43.................. T043 TB-061............. T061
250074............. T074 250176............. T176 250274............. T274
250075............. T075 250177............. T177 9-61.................. T061 TB-062............. T062
250076............. T076 250178............. T178 250275............. T275 9-62.................. T062 TB-063............. T073
250077............. T077 250179............. T179 250276............. T276 9-63.................. T073 TB-064............. T064
250078............. T078 250180............. T180 250277............. T277 9-64.................. T064 TB-065............. T065
250079............. T079 250181............. T181 250278............. T278 9-65.................. T065 TB-067............. T067
250081............. T081 250182............. T182 250279............. T279 9-67.................. T067 TB-068............. T068
250082............. T082 250183............. T183 250280............. T280 9-69.................. T069 TB-069............. T069
250083............. T083 250184............. T184 250281............. T281 9-70.................. T070 TB-070............. T070
250084............. T084 250185............. T185 250282............. T282 9-71.................. T071 TB-071............. T071
250087............. T087 250186............. T186 250283............. T283 9-74.................. T074 TB-073............. T073
250088............. T088 250187............. T187 250284............. T284 9-75.................. T075 TB-074............. T074
250089............. T089 250188............. T188 250285............. T285 9-76.................. T076 TB-075............. T075
250090............. T090 250189............. T189 250286............. T286 9-77.................. T077 TB-076............. T076
250091............. T091 250190............. T190 250287............. T287 9-78.................. T078 TB-077............. T077
250092............. T092 250191............. T191 250288............. T288 9-79.................. T079 TB-078............. T078
250093............. T093 250192............. T192 250289............. T289 9-81.................. T081 TB-079............. T079
250094............. T094 250193............. T193 250290............. T290 9-84.................. T084 TB-081............. T081
250095............. T095 250194............. T194 250291............. T291 9-87.................. T087 TB-082............. T082
250096............. T096 250195............. T195 250292............. T292 9-88.................. T088 TB-083............. T083
250097............. T097 250196............. T196 250293............. T293 9-89.................. T089 TB-084............. T084
250098............. T098 250197............. T197 250294............. T294 9-90.................. T090 TB-087............. T087
250099............. T099 250198............. T198 250295............. T295 9-91.................. T091 TB-088............. T088
250100............. T100 250199............. T199 9-92.................. T092 TB-089............. T089
250296............. T296 9-93.................. T093 TB-090............. T090
250101............. T101 250200............. T200 250297............. T297 9-94.................. T094 TB-091............. T091
250102............. T102 250201............. T201 250298............. T298 9-96.................. T096 TB-092............. T092
250103............. T103 250202............. T248 250299............. T299 9-98.................. T098 TB-093............. T093
250104............. T104 250203............. T203 250300............. T300 9-99.................. T099 TB-094............. T094
250106............. T106 250204............. T204 250301............. T301 TB-095............. T095
250107............. T107 250205............. T205 250302............. T302 PERFECTION AM
TB-096............. T096
250108............. T293 250206............. T206 250303............. T303 B0101 .............. T101 TB-098............. T098
250112............. T112 250207............. T207 250304............. T304 B0102 .............. T102 TB-099............. T099
250113............. T113 250208............. T208 250305............. T305 B0103 .............. T103 TB-100............. T100
250114............. T114 250209............. T209 250306............. T306 B0104 .............. T104 TB-101............. T101
250115............. T299 250210............. T210 250307............. T307 B0114 .............. T114 TB-102............. T102
250116............. T300 250211............. T211 250308............. T308 B0118 .............. T162 TB-103............. T103
250117............. T117 250212............. T212 250309............. T309 B013 ................ T013 TB-104............. T104
250118............. T118 250213............. T213 250310............. T310 B014 ................ T014 TB-112............. T112
250119............. T119 250214............. T214 B017 ................ T017 TB-113............. T113
250120............. T120 250215............. T215 250311............. T311
250312............. T312 B018 ................ T018 TB-114............. T114
250121............. T121 250216............. T216 B020 ................ T020 TB-115............. T299
250122............. T122 250217............. T217 250315............. T315
250316............. T316 B028 ................ T028 TB-116............. T300
250123............. T123 250218............. T218 B032 ................ T032 TB-117............. T117
250124............. T124 250219............. T219 250317............. T317 B036 ................ T036
250318............. T318 TB-118............. T118
250125............. T125 250220............. T220 B037 ................ T037 TB-119............. T119
250126............. T126 250221............. T221 PAREX TRANS. PARTS B039 ................ T039 TB-121............. T121
250127............. T127 250222............. T222 B041 ................ T041 TB-122............. T122
250128............. T128 250223............. T223 013................... T013 B043 ................ T043
018................... T018 TB-123............. T123
250129............. T129 250224............. T224 B061 ................ T061 TB-125............. T125
250130............. T130 250225............. T225 020................... T020 B062 ................ T062 TB-126............. T126
250131............. T131 250226............. T226 028................... T028 B063 ................ T073 TB-127............. T127
250132............. T132 250227............. T227 032................... T032 B064 ................ T064 TB-128............. T128
250133............. T292 250228............. T228 037................... T037 B065 ................ T065 TB-129............. T129
250134............. T134 250229............. T229 041................... T041 B067 ................ T067 TB-130............. T130
250135............. T135 250230............. T230 043................... T043 B069 ................ T069 TB-134............. T134
250136............. T136 250232............. T232 062................... T062 B070 ................ T070 TB-139............. T139
250137............. T137 250233............. T233 065................... T065 B071 ................ T071
250138............. T138 250234............. T234 067................... T067 B074 ................ T074 REPCOPARTS
250139............. T139 250235............. T235 068................... T068 B075 ................ T075 4013................. T013
250140............. T140 250236............. T236 069................... T069 B076 ................ T076 4014................. T014
250141............. T141 250237............. T237 070................... T070 B077 ................ T077 4017................. T017
250142............. T142 250239............. T239 071................... T071 B078 ................ T078 4018................. T018
250143............. T143 250240............. T240 074................... T074 B081 ................ T081 4020................. T020
250144............. T144 250241............. T241 075................... T075 B082 ................ T082 4028................. T028
250145............. T145 250242............. T242 076................... T076 B083 ................ T083 4029................. T104
250146............. T146 250243............. T243 077................... T077 B087 ................ T087 4032................. T032
250147............. T147 250244............. T244 078................... T078 B088 ................ T088 4036................. T036
250148............. T148 250245............. T245 081................... T081 B089 ................ T089 4037................. T037
250149............. T149 250246............. T246 087................... T087 B090 ................ T090 4039................. T039
250150............. T150 250247............. T247 088................... T088 B093 ................ T093 4041................. T041
250151............. T151 250248............. T248 093................... T093 B094 ................ T094 4042................. T068
250152............. T152 250249............. T249 094................... T094 B095 ................ T095 4043................. T043
250153............. T153 250251............. T251 095................... T095 B099 ................ T099 4061................. T061
250154............. T154 250252............. T252 099................... T099 013................... T013 4065................. T065
250155............. T155 250253............. T253 104................... T104 014................... T014 4070................. T070
250157............. T157 250254............. T254 017................... T017 4071................. T071
250158............. T158 250255............. T255 PEP BOYS (See DAYCO) 018................... T020 4073................. T073
REPCOPARTS - Cont. REPUBLIC PARTS - Cont. SEALED POWER SEALED POWER - Cont. T.R.W. - Cont.
4074................. T074 R-028 ............... T028 222-100............ T100 222088............. T088 LB104 .............. T104
4077................. T077 R-032 ............... T032 222-13.............. T013 222089............. T158 LB112 .............. T112
4078................. T078 R-036 ............... T036 222-14.............. T014 222090............. T159 LB113 .............. T113
4079................. T079 R-037 ............... T037 222-17.............. T017 222093............. T093 LB114 .............. T114
4081................. T081 R-039 ............... T039 222-18.............. T018 222094............. T160 LB115 .............. T299
4082................. T082 R-041 ............... T041 222-20.............. T020 222095............. T095 LB116 .............. T300
4083................. T083 R-042 ............... T068 222-28.............. T028 222099............. T161 LB117 .............. T117
4084................. T084 R-043 ............... T043 222-32.............. T032 222101............. T101 LB118 .............. T162
4089................. T089 R-061 ............... T061 222-36.............. T036 222102............. T102 LB119 .............. T119
4091................. T091 R-062 ............... T062 222-37.............. T037 222103............. T103 LB121 .............. T121
4092................. T092 R-063 ............... T073 222-39.............. T039 222104............. T104 LB122 .............. T122
4093................. T093 R-064 ............... T064 222-41.............. T041 222107............. T107 LB123 .............. T123
4094................. T094 R-065 ............... T065 222-42.............. T068 222108............. T293 LB124 .............. T124
4095................. T095 R-067 ............... T067 222-43.............. T043 222110............. T196 LB125 .............. T125
4096................. T096 R-068 ............... T068 222-61.............. T061 222112............. T176 LB126 .............. T237
4097................. T097 R-069 ............... T069 222-62.............. T062 222113............. T113 LB128 .............. T128
4098................. T098 R-070 ............... T070 222-63.............. T073 222114............. T114 LB129 .............. T129
4099................. T099 R-071 ............... T071 222-64.............. T064 222115............. T299 LB13 ................ T013
4100................. T100 R-073 ............... T073 222-65.............. T065 222116............. T300 LB130 .............. T130
4101................. T101 R-074 ............... T074 222-67.............. T067 222117............. T117 LB132 .............. T132
4102................. T102 R-075 ............... T075 222-69.............. T069 222118............. T162 LB134 .............. T134
4103................. T103 R-076 ............... T075 222-70.............. T070 222119............. T119 LB136 .............. T233
4104................. T104 R-077 ............... T077 222-71.............. T071 222122............. T122 LB137 .............. T137
4106................. T106 R-078 ............... T078 222-73.............. T073 222124............. T124 LB138 .............. T199
REPUBLIC R-079 ............... T079 222-74.............. T074 222125............. T125 LB139 .............. T139
R-081 ............... T081 222-75.............. T075 222126............. T237 LB14 ................ T014
R0112 .............. T176 222-76.............. T076 222128............. T128
R0113 .............. T113 R-084 ............... T084 222129............. T129 LB141 .............. T141
R-087 ............... T087 222-77.............. T077 LB142 .............. T142
R0114 .............. T114 222-78.............. T078 222130............. T130
R0115 .............. T299 R-088 ............... T088 222131............. T131 LB143 .............. T143
R-089 ............... T089 222-81.............. T081 LB144 .............. T144
R0116 .............. T300 222-87.............. T087 222132............. T132
R0117 .............. T117 R-090 ............... T090 222133............. T292 LB146 .............. T146
R-091 ............... T091 222-88.............. T088 LB148 .............. T148
R0118 .............. T162 222-89.............. T089 222134............. T134
R0119 .............. T119 R-092 ............... T092 222135............. T135 LB149 .............. T149
R-093 ............... T093 222-90.............. T090 LB150 .............. T150
R0122 .............. T122 222-91.............. T091 222136............. T233
R0124 .............. T124 R-094 ............... T094 222-92.............. T092 222138............. T199 LB151 .............. T151
R0125 .............. T125 R-095 ............... T095 222-93.............. T093 222139............. T139 LB153 .............. T153
R0126 .............. T126 R-096 ............... T096 222-94.............. T094 222141............. T141 LB155 .............. T155
R0127 .............. T127 R-098 ............... T098 222-95.............. T095 222142............. T142 LB157 .............. T157
R0128 .............. T128 R-099 ............... T099 222-99.............. T161 222143............. T143 LB158 .............. T158
R0129 .............. T129 ROCKHILL 222B160 .......... T160 222144............. T144 LB159 .............. T159
R0130 .............. T130 222B161 .......... T161 222145............. T145 LB160 .............. T160
R0132 .............. T132 TB-100............. T100 222146............. T146 LB161 .............. T161
R0133 .............. T292 TB-101............. T101 222B162 .......... T162
222B163 .......... T163 222147............. T147 LB163 .............. T163
R0134 .............. T134 TB-102............. T102 222148............. T148 LB164 .............. T164
R0135 .............. T135 TB-103............. T103 222B164 .......... T164
222B165 .......... T165 222152............. T152 LB165 .............. T165
R0136 .............. T233 TB-104............. T104 222153............. T153 LB166 .............. T166
R0138 .............. T138 TB-112............. T176 222B166 .......... T166
222B167 .......... T167 222154............. T154 LB167 .............. T167
R0139 .............. T139 TB-118............. T118 222155............. T155 LB168 .............. T168
R0141 .............. T141 TB-13 ............... T013 222B168 .......... T168
222B169 .......... T169 222157............. T157 LB169 .............. T169
R0142 .............. T142 TB-14 ............... T014 222158............. T158 LB17 ................ T017
R0143 .............. T143 222B170 .......... T170 222159............. T159
TB-17 ............... T017 222B172 .......... T254 LB18 ................ T018
R0144 .............. T144 TB-18 ............... T018 LB20 ................ T020
R0145 .............. T145 222B177 .......... T177 SUNOCO
TB-20 ............... T020 222B179 .......... T179 LB28 ................ T028
R0146 .............. T146 TB-28 ............... T028 TB063 .............. T073 LB32 ................ T032
R0147 .............. T147 222B180 .......... T180 TB070 .............. T070
TB-32 ............... T032 222B183 .......... T183 LB36 ................ T036
R0148 .............. T148 TB-36 ............... T036 TB077 .............. T077 LB37 ................ T037
R0153 .............. T153 222B184 .......... T184 TB401 .............. T014
TB-37 ............... T037 222B185 .......... T185 LB39 ................ T039
R0154 .............. T154 TB-39 ............... T039 TB402 .............. T013 LB41 ................ T041
R0157 .............. T157 222B186 .......... T186 TB403 .............. T037
TB-41 ............... T041 222B187 .......... T187 LB43 ................ T043
R0158 .............. T158 TB-43 ............... T043 TB404 .............. T017 LB61 ................ T061
R0159 .............. T159 222B193 .......... T193 TB409 .............. T039
TB-61 ............... T061 222B194 .......... T194 LB62 ................ T062
R0160 .............. T160 TB-62 ............... T062 TB411 .............. T041 LB63 ................ T073
R0161 .............. T161 222B202 .......... T248 TB415 .............. T028
TB-63 ............... T073 222B210 .......... T210 LB64 ................ T064
R0162 .............. T162 TB-64 ............... T064 TB418 .............. T061 LB65 ................ T065
R0163 .............. T163 222013............. T013 TB428 .............. T067
R0164 .............. T164 TB-65 ............... T065 222014............. T014 T1043............... T043 LB67 ................ T067
R0166 .............. T166 TB-67 ............... T067 222017............. T017 T1064............... T064 LB68 ................ T068
R0167 .............. T167 TB-68 ............... T068 222018............. T018 T1071............... T071 LB69 ................ T069
R0168 .............. T168 TB-69 ............... T069 222020............. T020 T1081............... T081 LB70 ................ T070
R0169 .............. T169 TB-70 ............... T070 222028............. T028 LB71 ................ T071
TB-71 ............... T071 222032............. T032 T.R.W. LB73 ................ T073
R0170 .............. T170
R0176 .............. T176 TB-73 ............... T073 222036............. T036 LB042 .............. T068 LB74 ................ T074
R0177 .............. T177 TB-74 ............... T074 222037............. T037 LB074 .............. T074 LB75 ................ T075
R0179 .............. T179 TB-75 ............... T075 222039............. T039 LB075 .............. T075 LB76 ................ T076
R0184 .............. T184 TB-76 ............... T076 222041............. T041 LB077 .............. T077 LB77 ................ T077
R0185 .............. T185 TB-77 ............... T077 222043............. T043 LB078 .............. T078 LB78 ................ T078
R0186 .............. T186 TB-78 ............... T078 222061............. T061 LB079 .............. T079 LB79 ................ T079
R0187 .............. T187 TB-79 ............... T079 222062............. T062 LB081 .............. T081 LB81 ................ T081
R082 ................ T082 TB-81 ............... T081 222063............. T073 LB082 .............. T082 LB82 ................ T082
R083 ................ T083 TB-82 ............... T082 222064............. T064 LB083 .............. T083 LB83 ................ T083
TB-83 ............... T083 222065............. T065 LB084 .............. T084 LB84 ................ T084
REPUBLIC PARTS TB-84 ............... T084 222067............. T067 LB087 .............. T087 LB87 ................ T087
R-0100............. T100 TB-87 ............... T087 222069............. T069 LB088 .............. T088 LB88 ................ T088
R-0101............. T101 TB-88 ............... T088 222070............. T070 LB090 .............. T090 LB89 ................ T158
R-0102............. T102 TB-89 ............... T158 222071............. T071 LB091 .............. T091 LB90 ................ T159
R-0103............. T103 TB-90 ............... T159 222074............. T074 LB092 .............. T092 LB91 ................ T091
R-0104............. T104 TB-91 ............... T091 222075............. T075 LB093 .............. T093 LB92 ................ T092
R-0112............. T112 TB-92 ............... T092 222076............. T076 LB094 .............. T094 LB93 ................ T093
R-013 ............... T013 TB-93 ............... T093 222077............. T077 LB095 .............. T095 LB94 ................ T160
R-014 ............... T014 TB-94 ............... T094 222078............. T078 LB100 .............. T100 LB95 ................ T095
R-017 ............... T017 TB-95 ............... T095 222082............. T082 LB101 .............. T101 LB96 ................ T096
R-018 ............... T018 TB-98 ............... T098 222083............. T083 LB102 .............. T102 LB98 ................ T098
R-020 ............... T020 TB-99 ............... T161 222087............. T087 LB103 .............. T103 LB99 ................ T161
TEXACO ULTRALAST - Cont. UNIROYAL - Cont. VERA - Cont. VERA - Cont.

TB401 .............. T014 B167 ................ T167 A423L075 ........ T065 45-00955.......... T041 45-02215.......... T128
TB402 .............. T013 B168 ................ T168 A435L075 ........ T018 45-01051.......... T082 45-05074.......... T168
TB403 .............. T037 B172 ................ T172 A442L075 ........ T069 45-01069.......... T083 WESTERN AUTO
TB404 .............. T017 B177 ................ T177 A443L075 ........ T069 45-01127.......... T076
TB409 .............. T039 B179 ................ T179 A450L075 ........ T064 45-01135.......... T075 74-2736-2 ........ T067
TB411 .............. T041 B184 ................ T184 A450L075S ...... T093 45-01150.......... T078 74-2737-0 ........ T061
TB415 .............. T028 B185 ................ T185 A453L075 ........ T017 45-01168.......... T077 74-2738-8 ........ T039
ULTRALAST B186 ................ T186 A457L075 ........ T013 45-01176.......... T074 74-2739-6 ........ T037
B187 ................ T187 A457L075S ...... T158 45-01200.......... T107 74-2741-2 ........ T013
B013 ................ T013 B191 ................ T191 A461L075 ........ T032 45-01226.......... T158 74-2742-0 ........ T014
B014 ................ T014 B194 ................ T194 A465L100 ........ T071 45-01234.......... T091 74-2743-8 ........ T017
B017 ................ T017 B199 ................ T199 A483L087 ........ T014 45-01267.......... T106 74-2744-6 ........ T071
B028 ................ T028 B233 ................ T233 A484L088 ........ T014 45-01275.......... T196
B032 ................ T032 B236 ................ T236 WOLVERINE
A502L118B ...... T076 45-01283.......... T088
B036 ................ T036 B32 .................. T032 A506L100B ...... T043 45-01291.......... T087 TB013 .............. T013
B037 ................ T037 TB063 .............. T073 A521L100 ........ T087 45-01325.......... T104 TB014 .............. T014
B039 ................ T039 TB070 .............. T070 A532L100 ........ T074 45-01341.......... T099 TB017 .............. T017
B041 ................ T041 TB077 .............. T077 A547L075 ........ T020 45-01366.......... T094 TB018 .............. T018
B043 ................ T043 TB401 .............. T014 A555L075 ........ T068 45-01382.......... T093 TB020 .............. T020
B061 ................ T061 TB402 .............. T013 45-01408.......... T062 TB028 .............. T028
B064 ................ T064 TB403 .............. T037 UNOCAL
45-01424.......... T100 TB032 .............. T032
B067 ................ T067 TB404 .............. T017 TB063 .............. T073 45-01440.......... T103 TB036 .............. T036
B070 ................ T070 TB409 .............. T039 TB070 .............. T070 45-01481.......... T090 TB037 .............. T037
B071 ................ T071 TB411 .............. T041 TB077 .............. T077 45-01499.......... T092 TB039 .............. T039
B073 ................ T073 TB415 .............. T028 TB401 .............. T014 45-01580.......... T127 TB041 .............. T041
B074 ................ T074 TB418 .............. T061 TB402 .............. T013 45-01614.......... T293 TB043 .............. T043
B077 ................ T077 TB428 .............. T067 TB403 .............. T037 45-01622.......... T292 TB061 .............. T061
B078 ................ T078 T013................. T013 TB404 .............. T017 45-01630.......... T118 TB062 .............. T062
B081 ................ T081 T014................. T014 TB409 .............. T039 45-01648.......... T095 TB063 .............. T073
B087 ................ T087 T017................. T017 TB411 .............. T041 45-01655.......... T137 TB064 .............. T064
B088 ................ T088 T028................. T028 TB415 .............. T028 45-01663.......... T300 TB067 .............. T067
B089 ................ T089 T032................. T032 TB418 .............. T061 45-01671.......... T299
B090 ................ T090 TB069 .............. T069
T037................. T037 TB428 .............. T067 45-01689.......... T131 TB070 .............. T070
B094 ................ T094 T039................. T039 T013................. T013 45-01697.......... T135
B095 ................ T095 TB071 .............. T071
T041................. T041 T014................. T014 45-01705.......... T136 TB073 .............. T073
B099 ................ T099 T043................. T043 T017................. T017
B101 ................ T101 45-01713.......... T176 TB077 .............. T077
T061................. T061 T028................. T028 45-01721.......... T126 TB078 .............. T078
B104 ................ T104 T063................. T073 T032................. T032
B112 ................ T112 45-01739.......... T101 TB081 .............. T081
T064................. T064 T037................. T037 45-01754.......... T138 TB095 .............. T095
B113 ................ T113 T067................. T067 T039................. T039
B114 ................ T114 45-01762.......... T129 WORLD PARTS
T070................. T070 T041................. T041 45-01770.......... T071
B116 ................ T300 T071................. T071 T043................. T043
B117 ................ T117 45-01788.......... T122 W11-600 .......... T018
T073................. T073 T061................. T061 45-01796.......... T141 W11-601 .......... T020
B118 ................ T118 T077................. T077 T063................. T073
B122 ................ T122 45-01804.......... T134 W11-631 .......... T075
T081................. T081 T064................. T064 45-01812.......... T113 W11-636 .......... T013
B124 ................ T124 T087................. T087 T067................. T067
B125 ................ T125 45-01820.......... T117 W11-639 .......... T013
T089................. T089 T070................. T070 W11-640 .......... T076
B126 ................ T126 T092................. T092 T071................. T071 45-01838.......... T124
B128 ................ T128 T094................. T094 T073................. T073 45-01853.......... T121 W11-643 .......... T017
B129 ................ T129 T099................. T099 T077................. T077 45-01861.......... T140 W11-644 .......... 6413
B130 ................ T130 T1043............... T043 T081................. T081 45-01879.......... T147 W11-645 .......... T020
B132 ................ T132 T1064............... T064 T094................. T094 45-01887.......... T102 W11-651 .......... T028
B134 ................ T134 T1071............... T071 T1043............... T043 45-01895.......... T119 W11-654 .......... T041
B136 ................ T136 T1081............... T081 T1064............... T064 45-01911.......... T152 W11-655 .......... T014
B138 ................ T138 T115................. T299 T1071............... T071 45-01945.......... T187 W11-657 .......... T036
B139 ................ T139 T203................. T203 T1081............... T081 45-01952.......... T186 W11-658 .......... T032
B141 ................ T141 T210................. T210 45-01960.......... T143 W11-659 .......... T043
B142 ................ T142 VERA 45-01978.......... T145 W11-660 .......... T064
T228................. T228
B143 ................ T143 A326L134B ...... T075 45-01986.......... T144 W11-661 .......... T062
B145 ................ T145 UNIROYAL 45-00070.......... T062 45-01994.......... T142 W11-665 .......... T070
B146 ................ T146 A206L050 ........ T062 45-00096.......... T062 45-02009.......... T124 W11-669 .......... T073
B147 ................ T147 A206L050S ...... T090 45-00724.......... T028 45-02017.......... T169 W11-670 .......... T065
B148 ................ T148 A315L075 ........ T028 45-00732.......... T036 45-02025.......... T149 W11-673 .......... T068
B153 ................ T153 A326L134B ...... T075 45-00740.......... T020 45-02033.......... T146 W16-801 .......... T079
B154 ................ T154 A330L075 ........ T070 45-00773.......... T032 45-02041.......... T155 W16-802 .......... T084
B155 ................ T155 A345L075 ........ T073 45-00781.......... T018 45-02066.......... T167 W16-803 .......... T078
B157 ................ T157 A356L075 ........ T041 45-00799.......... T014 45-02074.......... T168 W16-804 .......... T087
B158 ................ T158 A363L100 ........ T067 45-00807.......... T013 45-02082.......... T139 W16-805 .......... T101
B159 ................ T159 A367L075 ........ T078 45-00815.......... T043 45-02090.......... T300 W16-807 .......... T090
B160 ................ T160 A371L060 ........ T037 45-00823.......... T017 45-02108.......... T299 W16-808 .......... T158
B161 ................ T161 A371L075 ........ T039 45-00849.......... T065 45-02116.......... T164 W16-811 .......... T083
B162 ................ T162 A375L075 ........ T061 45-00856.......... T069 45-02124.......... T157 W16-812 .......... T082
B163 ................ T163 A397L075 ........ T077 45-00864.......... T070 45-02140.......... T199 W16-814 .......... T299
B164 ................ T164 A408L075 ........ T088 45-00930.......... T073 45-02157.......... T154 W16-815 .......... T094
B166 ................ T166 A416L075R...... T081 45-00948.......... T064 45-02199.......... T127 W16-816 .......... T300
Manufacturers Part Numbers
Automotive Timing Belts
Showing Factory Part Numbers for Automotive Timing Belts
With the Corresponding Gates Replacement Numbers
Mfr. Gates Mfr. Gates Mfr. Gates Mfr. Gates Mfr. Gates
Part No. No. Part No. No. Part No. No. Part No. No. Part No. No.
ADO41407 ................. T090 FS0212205................. T228 MD100619.................. T064 028109119M .............. T242 13028AA102 .............. T172
AD041407 .................. T090 F0BZ 6268 A ............. T185 MD100620.................. T013 028109119P............... T242 13028AA120 .............. T209
A326L134B ................ T075 F1ZZ 6268 A ............. T210 MD100632.................. T062 034109119 ................. T127 13028AA150 .............. T254
BNP2955.................... T028 F17E 6268 AA........... T210 MD100679.................. T139 034109119A............... T197 13028AA170 .............. T300
BPY112205 ................ T185 F2CE 6268 AA .......... T194 MD100814.................. T128 03510911 ................... T065 13028AA181 .............. T304
BP0112205 ................ T185 F2Y112205................. T134 MD102248.................. T093 035109119 ................. T065 13028AA21A .............. T307
BP0112205A .............. T185 F20212205 ................. T134 MD102249.................. T158 038109119 ................. T301 13028D0100............... T100
BP0112205B .............. T185 F20312205 ................. T134 MD106103.................. T159 038109119B............... T301 13028D1700............... T078
BP0212205 ................ T185 F21012205 ................. T134 MD110029.................. T167 038109119D............... T301 13028D4200............... T137
BP0212205A .............. T185 F3BZ 6268 A ............. T185 MD110041.................. T165 048109119D............... T262 13028D4210............... T137
B10112205A .............. T141 F3CZ 6268 A............. T179 MD110709.................. T124 054109119A............... T197 13028D4211............... T137
B59712205................. T179 F3DZ 6268 A............. T248 MD111427.................. T139 054109119E............... T225 13028KA021 .............. T135
B6S712205A .............. T179 F3XY 6268 A............. T104 MD113561.................. T064 054109119H............... T225 13028V4000............... T017
B6S712205B .............. T179 F32Z 6268 A.............. T228 MD113562.................. T013 056109119A............... T017 13028V4310............... T093
B6S712205C.............. T179 F32Z 6268 B.............. T214 MD113563.................. T073 058109119A............... T291 13028V5100............... T104
B6S712205C (KIA) .... T179 F37E 6268 AA........... T210 MD113564.................. T128 06A109119C .............. T296 13028V5200............... T104
B6S712205D.............. T179 F4BZ 6268 A ............. T185 MD113790.................. T158 06B109119A .............. T306 13028V5201............... T104
B6Y212205 ................ T141 F4XY 6268 A............. T249 MD115977.................. T168 06B109119B .............. T306 13028V5210............... T104
B63012205................. T141 F42Z 6268 A.............. T228 MD120487.................. T155 068109119 ................. T043 13028V5220............... T104
B63012205A .............. T123 F47E 6268 AA........... T210 MD133115.................. T167 068109119A............... T043 13028V5221............... T104
B63012205B .............. T123 F47Z 6268 B.............. T210 MD133116.................. T165 068109119E............... T043 130280B700............... T249
B63012205C .............. T123 F5RZ 6268 A............. T258 MD134377.................. T091 069109119A............... T083 130280B785............... T249
B63012205D .............. T141 F57E 6268 AA........... T276 MD13805.................... T093 069130113A............... T082 1302810M00 .............. T077
B63012205E .............. T141 F57E 6268 BB........... T276 MD140070.................. T195 074109119 ................. T170 1302811M00 .............. T077
B63212205................. T141 F57Z 6268 A.............. T276 MD140227.................. T155 075RH200 .................. T082 1302811M10 .............. T077
B632122050............... T141 F7CZ 6268 AA........... T283 MD140228.................. T158 075109119B............... T083 1302812C00............... T100
B66012205................. T149 F8CZ 6268 AA........... T294 MD140229.................. T124 077109119B............... T207 1302812G00 .............. T104
B66012205B .............. T149 F80112205 ................. T077 MD145713.................. T167 077109119C............... T297 1302816A01............... T096
B66012205C .............. T149 F80212205 ................. T077 MD145714.................. T165 077109119D............... T207 1302816A10............... T096
C3905942................... T165 F9JY 6268 A.............. T179 MD145716.................. T168 077109119E............... T207 1302816E00............... T104
DBP4131.................... T099 GC01201200.............. T068 MD145813.................. T191 078109119A............... T218 1302816E10............... T104
DBP9289.................... T099 GC01201201.............. T068 MD152243.................. T159 078109119C............... T297 1302816V00............... T180
D1FZ 6268 A............. T013 GTB1208.................... T129 MD152622.................. T092 078109119D............... T218 1302820R00............... T078
D4FZ 6268 A............. T014 GTB1237.................... T142 MD154243.................. T204 081616 ....................... T018 1302845P00............... T251
D4ZE 6268 AE .......... T014 HM8268BA................. T013 MD160103.................. T090 081619 ....................... T069 1302851E00............... T137
D42E 6268 AB........... T014 JE2612205 ................. T183 MD161427.................. T195 081629 ....................... T189 1302851E10............... T137
D8EE 6268 AA .......... T014 JE2612205A............... T183 MD171748.................. T167 081632 ....................... T140 1302861A00............... T077
D9EE 6268 AA .......... T014 JE2612205B............... T183 MD171749.................. T168 081640 ....................... T188 1302885E00............... T104
ECP244...................... T129 JE26122050 ............... T183 MD176387.................. T201 088AG19 .................... T070 13029AA010 .............. T299
E1EE 6268 DA .......... T067 JF0112205 ................. T146 MD182195.................. T168 10068553 ................... T163 13029AA011 .............. T299
E1FZ 6268 D............. T067 JF0112205A............... T146 MD182201.................. T165 101R24....................... T099 13029AA040 .............. T151
E2CE 6268 AA .......... T194 JF0112205D............... T146 MD182291.................. T167 10162006 ................... T192 13029AA070 .............. T299
E2EE 6268 AA .......... T067 J0856351 ................... T140 MD182292.................. T256 102500 ....................... T078 13029AA080 .............. T299
E3EE 6268 AA .......... T067 KJ0112205 ................. T267 MD182293.................. T232 108R24....................... T094 13029AA11 ................ T299
E3FZ 6268 A ............. T067 KL0112205................. T214 MD182294.................. T230 1125360160 ............... T075 1320811M00 .............. T077
E43Z 6268 B ............. T103 K0AA352700 .............. T248 MD182295.................. T168 113R190..................... T065 1326288 ..................... T174
E43Z 6268 C ............. T102 K0BA352700 .............. T248 MD183005.................. T195 11311272384 ............. T106 13405PAAA01............ T186
E5FZ 6268 A ............. T067 MBP0112205B........... T185 MD183006.................. T253 11311286168 ............. T106 13405PAAA02............ T186
E5RE 6268 AA .......... T014 MB6S712205C........... T179 MD189522.................. T229 11311711082 ............. T131 13405PTO004............ T186
E5RE 8286 AA .......... T142 MD008960.................. T013 MD191982.................. T288 11311713361 ............. T131 13405PT0004............. T186
E5TZ 6268 A ............. T092 MD008961.................. T062 MD193874.................. T195 119RH250 .................. T083 13440P5A004 ............ T280
E5TZ 6268 B ............. T091 MD008968.................. T013 MD193875.................. T253 1191303105 ............... T120 1351415010 ............... T070
E5ZZ 6268 A ............. T014 MD008969.................. T062 MD199418.................. T165 119130310500 ........... T120 1351487711 ............... T178
E7GZ 6268 A............. T141 MD009277.................. T064 MD307487.................. T259 1257223 ..................... T083 135148771100 ........... T178
E7GZ 6268 B............. T141 MD009352.................. T013 MD322641.................. T287 1257237 ..................... T082 1351487711000 ......... T178
E7GZ 6268 C ............ T141 MD009651.................. T062 MD326059.................. T167 12612650044 ............. T129 1356422021 ............... T126
E80112205................. T077 MD009666.................. T064 MD336149.................. T232 1272382 ..................... T106 135680A010............... T257
E9DZ 6268 A............. T248 MD009667.................. T064 MD340625.................. T289 1272384 ..................... T106 1356803010 ............... T138
E9JY 6268 A ............. T179 MD013805.................. T093 MO4667611 ............... T246 12723842 ................... T106 1356803020 ............... T199
FC01201202 .............. T020 MD015310.................. T093 OK97212205.............. T264 1276150G00 .............. T194 1356803021 ............... T199
FC01201203 .............. T020 MD015311.................. T159 RF0312205 ................ T103 1276153B00............... T171 1356809040 ............... T199
FDU1464.................... T142 MD015701.................. T089 RF03122050 .............. T103 1276153B01............... T171 1356809041 ............... T199
FEO1122050.............. T088 MD030599.................. T073 RF0312206A .............. T102 1276160A00............... T164 1356809050 ............... T257
FEY812205 ................ T113 MD030600.................. T073 RF4312205 ................ T103 1276160B10............... T166 1356811030 ............... T136
FEY8122050 .............. T113 MD030610.................. T073 RF7112205 ................ T103 1276160E00............... T241 1356811031 ............... T233
FEY912205 ................ T113 MD040756.................. T062 RF7912205 ................ T103 1276163B00............... T095 1356811032 ............... T233
FE0112205................. T088 MD040797.................. T062 R1463635109............. T140 1276163E00............... T243 1356811033 ............... T233
FE01122050............... T088 MD041390.................. T158 T0718752 ................... T119 1276170C00............... T194 1356811100 ............... T208
FE0212205................. T088 MD041407.................. T159 T0718836 ................... T140 1276171C00............... T212 1356811101 ............... T208
FE0312205................. T113 MD050119.................. T092 T0729581 ................... T140 1276172F00 ............... T272 1356811111 ............... T208
FE03122050............... T113 MD050130.................. T091 XHM460 ..................... T129 1276173000 ............... T028 1356815010 ............... T070
FE0412205................. T113 MD050175.................. T092 ZZM112205................ T210 1276173001 ............... T028 1356815011 ............... T070
FE04122050............... T113 MD060461.................. T091 ZZM312205................ T276 1276178400 ............... T070 1356815020 ............... T070
FE0612205................. T117 MD068173.................. T124 Z50112205 ................. T266 1276180C00............... T243 1356815030 ............... T070
FE0812205................. T117 MD095866.................. T093 Z50212205 ................. T308 1276182000 ............... T095 1356815040 ............... T036
FE08122050............... T113 MD098491.................. T089 0B59712205............... T179 1286168 ..................... T106 1356815041 ............... T036
FE0912205................. T117 MD098492.................. T124 0K24712205............... T302 12861684 ................... T106 1356815042 ............... T239
FE09122050............... T113 MD098706.................. T073 0K95412205............... T281 130RG25.................... T084 1356815050 ............... T036
FE7912205................. T113 MD099706.................. T073 0K97212205............... T264 13028AA010 .............. T300 1356816010 ............... T112
FE7915205................. T113 MD099707.................. T091 0060562106 ............... T120 13028AA040 .............. T150 1356816020 ............... T176
FSY112205 ................ T228 MD099708.................. T090 027109119A............... T292 13028AA072 .............. T277 1356816040 ............... T236
FS0112205A .............. T228 MD100103.................. T090 027109119C............... T292 13028AA101 .............. T172 1356816041 ............... T236
Manufacturers Part Numbers
Mfr. Gates Mfr. Gates Mfr. Gates Mfr. Gates Mfr. Gates
Part No. No. Part No. No. Part No. No. Part No. No. Part No. No.
1356816050 ............... T236 1356887104 ............... T182 1711082 ..................... T131 4387534 ..................... T132 8970417840 ............... T122
1356816051 ............... T236 1356887104000 ......... T182 1713361 ..................... T131 4387549 ..................... T153 8970422680 ............... T147
1356816060 ............... T235 1356887708 ............... T178 2335632010 ............... T159 4401261 ..................... T069 8971363210 ............... T303
1356816061 ............... T235 1356888360 ............... T125 2335632020 ............... T159 4401269 ..................... T069 90122429 ................... T081
1356816070 ............... T235 1356888361 ............... T125 2335632030 ............... T159 4406634 ..................... T032 90231883 ................... T148
1356816071 ............... T235 1356888380 ............... T125 2335633110 ............... T168 4420507 ..................... T018 90234902 ................... T081
1356819045 ............... T236 1356888381 ............... T125 2335633120 ............... T168 4484494 ..................... T206 90324698 ................... T148
1356819046 ............... T236 1356888382 ............... T125 2335633130 ............... T168 4504163 ..................... T285 90324699 ................... T148
1356819055 ............... T235 139AG25 .................... T087 2335633140 ............... T168 4573944 ..................... T219 90325576 ................... T081
1356819056 ............... T235 14001168 ................... T061 2335633150 ............... T168 460165 ....................... T039 90325578 ................... T081
1356819085 ............... T233 14400PAAA01............ T244 2335633160 ............... T168 4621348 ..................... T285 90353179 ................... T203
1356819086 ............... T233 14400PAAA02............ T244 2413232010 ............... T089 4621844 ..................... T265 90353211 ................... T081
1356819115 ............... T208 14400PC6004 ............ T160 2431221040 ............... T073 46337 ......................... T032 90354783 ................... T148
1356819116 ............... T208 14400PC60040 .......... T094 2431222010 ............... T191 463377 ....................... T032 90409900 ................... T081
1356819125 ............... T070 14400PC60042 .......... T160 2431223001 ............... T278 4633772 ..................... T032 90410014 ................... T081
1356819135 ............... T239 14400PD2004 ............ T160 2431223201 ............... T284 4663598 ..................... T255 90410768 ................... T285
1356819145 ............... T112 14400PD6004 ............ T160 2431224000 ............... T128 4667530 ..................... T206 90410771 ................... T285
1356820010 ............... T257 14400PE0004 ............ T099 2431224010 ............... T128 4667606 ..................... T245 90500360 ................... T285
1356820020 ............... T257 14400PE00040 .......... T099 2431224050 ............... T128 4667611 ..................... T246 90530599 ................... T285
1356829015 ............... T257 14400PE3004 ............ T099 2431226000 ............... T282 4667625 ..................... T265
1356829025 ............... T257 14400PE30040 .......... T161 2431232610 ............... T124 4770491 ..................... T285 91112009 ................... T070
1356842010 ............... T126 14400PG6004............ T130 2431232620 ............... T124 4792353 ..................... T295 91171175 ................... T272
1356842011 ............... T237 14400PG60040 .......... T130 2431232820 ............... T089 484981001 ................. T028 91172367 ................... T194
1356842012 ............... T126 14400PG6014............ T130 2431233010 ............... T165 512430160 ................. T075 91173157 ................... T194
1356842020 ............... T126 14400PG6040............ T130 2431233020 ............... T165 512536016 ................. T075 9128500 ..................... T285
1356842021 ............... T237 14400PH7004 ............ T129 2431233030 ............... T165 5125360160 ............... T075 9135031 ..................... T252
1356843010 ............... T074 14400PH70040 .......... T129 2431233040 ............... T165 5203401 ..................... T071 9135032 ..................... T269
1356843020 ............... T074 14400PH7014 ............ T129 2431233050 ............... T165 52267904 ................... T163 9135450 ..................... T173
1356843030 ............... T101 14400PH70140 .......... T129 2431233060 ............... T165 52289664 ................... T163 9135733 ..................... T252
1356843040 ............... T101 14400PK1004 ............ T144 2431233110 ............... T167 524034 ....................... T017 9151772280 ............... T189
1356846020 ............... T215 14400PK10040 .......... T144 2431233120 ............... T167 5240346 ..................... T017 91540557 ................... T188
1356849015 ............... T237 14400PK2004 ............ T142 2431233130 ............... T167 5862021480 ............... T186 9154055780 ............... T188
1356849035 ............... T215 14400PK20040 .......... T142 2431233140 ............... T167 5862021620 ............... T187 91541318 ................... T188
1356849036 ............... T215 14400PK3004 ............ T142 2431233150 ............... T167 5862059260 ............... T186 9180954 ..................... T252
1356849046 ............... T074 14400PLM004............ T312 2431233160 ............... T167 5862059340 ............... T244 92029834 ................... T075
1356849055 ............... T101 14400PMMA01 .......... T312 2431235000 ............... T139 5985163 ..................... T087 92810515710 ............. T196
1356850010 ............... T190 14400PM3004............ T143 2431235010 ............... T139 60507464 ................... T120 92810515730 ............. T196
1356850020 ............... T298 14400PM30040.......... T143 2431235040 ............... T139 60562106 ................... T120 92810515740 ............. T196
1356854010 ............... T079 14400PM6004............ T145 24502982 ................... T192 636350 ....................... T081 92810515750 ............. T196
1356854020 ............... T079 14400PM70040.......... T142 24503363 ................... T273 636359 ....................... T081 94029834 ................... T075
1356854030 ............... T079 14400PR3004 ............ T227 271327 ....................... T252 636363 ....................... T081 94109626 ................... T118
1356854031 ............... T079 14400PR4A01............ T184 271705 ....................... T217 636365 ....................... T148 94158327 ................... T121
1356854038 ............... T079 14400PR4A01M1....... T184 2717056 ..................... T217 636368 ....................... T148 94160656 ................... T122
1356854050 ............... T084 14400PT0004............. T187 271714 ....................... T198 636370 ....................... T081 94215254 ................... T121
1356854051 ............... T084 14400PV1004 ............ T211 2717148 ..................... T198 636560 ....................... T081 94220922 ................... T076
1356859015 ............... T079 14400PY3A010 .......... T193 271720 ....................... T173 636562 ....................... T148 94337708 ................... T177
1356859016 ............... T079 14400PY3004 ............ T193 271747 ....................... T234 636565 ....................... T081 94386497 ................... T220
1356859017 ............... T079 14400P0A004 ............ T244 2717478 ..................... T234 6842469 ..................... T198 9440383 ..................... T311
1356859025 ............... T084 14400P0GA01............ T263 271834 ....................... T252 70HM 6268 AB .......... T013 94410221902 ............. T293
1356859026 ............... T084 14400P0GA010M1..... T263 2718344 ..................... T252 70HM 6268 BA .......... T013 94410221904 ............. T293
1356859027 ............... T084 14400P08004............. T223 271835 ....................... T269 7533266 ..................... T013 94410513703 ............. T107
1356859045 ............... T190 14400P13004............. T226 2718351 ..................... T269 7533267 ..................... T013 94410515703 ............. T107
1356859095 ............... T298 14400P14004............. T216 271856 ....................... T252 7700618657 ............... T018 94410515704 ............. T107
1356862020 ............... T157 14400P2E004 ............ T224 2718567 ..................... T252 7700663550 ............... T018 94410515706 ............. T152
1356862030 ............... T200 14400P2FA01 ............ T224 2718765 ..................... T270 7700666593 ............... T069 94410532300 ............. T152
1356862030A............. T200 14400P28004............. T224 271952 ....................... T217 7700717284 ............... T140
1356862040 ............... T157 14400P5A004 ............ T279 2719524 ..................... T217 7700718725 ............... T140 94410532301 ............. T152
1356862050 ............... T271 14400P7J004............. T184 272327 ....................... T252 7700718726 ............... T140 94410532302 ............. T152
1356863010 ............... T087 14400P72004............. T247 272329 ....................... T311 7700718752 ............... T119 94429486 ................... T169
1356863020 ............... T087 14400P72014............. T247 2723294 ..................... T311 7700718836 ............... T140 94452094 ................... T118
1356863022 ............... T087 14400P8AA01............ T286 272386 ....................... T270 7700729581 ............... T140 94479523 ................... T162
1356864010 ............... T098 14400P8AA02............ T286 3250141 ..................... T017 7700853660 ............... T140 94840054 ................... T070
1356864011 ............... T098 14400TG6004 ............ T130 3342103 ..................... T119 7701348801 ............... T018 94844702 ................... T112
1356865010 ............... T154 14400634003 ............. T028 3507227 ..................... T083 8091287220 ............... T305 94846144 ................... T036
1356865010A............. T154 14400634004 ............. T028 3507651 ..................... T217 82317934 ................... T065 94848472 ................... T176
1356865020 ............... T240 14400634005 ............. T028 3507704 ..................... T234 85867058 ................... T096 94849175 ................... T036
1356869025 ............... T200 144006340050 ........... T028 3514323 ..................... T173 8920639440 ............... T305 94849597 ................... T036
1356869035 ............... T157 144006340051 ........... T028 3531358 ..................... T198 894109626 ................. T162 94854403 ................... T236
1356869045 ............... T087 14400634014 ............. T028 3547459 ..................... T174 8941096260 ............... T118 94854404 ................... T235
1356869065 ............... T098 144006340141 ........... T028 35474592 ................... T174 8941583270 ............... T121 94856081 ................... T236
1356869066 ............... T098 14400657004 ............. T036 360525 ....................... T037 8941606560 ............... T122 94856082 ................... T235
1356869075 ............... T240 144006570040 ........... T036 376388 ....................... T037 8941743060 ............... T147 95ZA19....................... T100
1356869095 ............... T271 144006570042 ........... T041 376401 ....................... T037 894200372A............... T122 95951646 ................... T095
1356874010 ............... T138 14400657014 ............. T036 40028 ......................... T028 8942152540 ............... T121 96051646 ................... T095
1356874011 ............... T138 144006570140 ........... T036 414701001 ................. T028 8942187820 ............... T088 96057945 ................... T164
1356874012 ............... T199 14400657024 ............. T041 414705601 ................. T079 894220372A............... T122 96060050 ................... T166
1356874012B............. T199 144006570240 ........... T041 4164869 ..................... T020 8942209220 ............... T076 96067809 ................... T095
1356874013 ............... T199 144006570241 ........... T041 4176840 ..................... T018 8942220922 ............... T076 96068423 ................... T241
1356874020 ............... T138 144006570242 ........... T041 4182426 ..................... T020 8942353620 ............... T088 96068424 ................... T243
1356874021 ............... T199 1440065704 ............... T036 4201379 ..................... T068 8942372420 ............... T121 96068591 ................... T212
1356879025 ............... T199 14400673004 ............. T073 4201738 ..................... T068 894337708 ................. T177 96144976 ................... T148
1356879045 ............... T125 144006730040 ........... T073 4201739 ..................... T068 8943377080 ............... T177 96414718702 ............. T222
1356879095 ............... T199 144006730041 ........... T073 4242396 ..................... T069 8943864970 ............... T220 97016326 ................... T221
1356887101 ............... T181 144006730042 ........... T073 4300516 ..................... T122 8944161450 ............... T088 97027062 ................... T205
1356887101000 ......... T181 146R190..................... T020 4302971 ..................... T122 8944294860 ............... T169 97041784 ................... T122
1356887102 ............... T181 1649170 ..................... T067 4304099 ..................... T075 8944520940 ............... T162 97042268 ................... T147
1356887102000 ......... T181 1649171 ..................... T067 4343824 ..................... T114 8944795230 ............... T162 978M 6268 AA........... T294
1356887103 ............... T182 1680616A00............... T097 4343946 ..................... T071 8970163260 ............... T221 99314718701 ............. T290
1356887103000 ......... T182 1680616A10............... T097 43439469 ................... T071 8970270620 ............... T205 99919213150 ............. T213
Timing Belt Troubleshooting Guide
Synchronous belts have been used on automotive Symptom Probable Cause Corrective Action
camshaft drives for more than 20 years. Our belts will
give OEM equivalent service if the following points are
1. Excessive shock load. 1. Redesign drive for increased capacity.
observed. 2. Subminimal diameter. 2. Redesign drive using larger diameters.
Tensile Failure 3.Improper belt handling and storage prior to installation. 3. Follow proper storage and handling procedures.
4. Debris or foreign object in drive. 4. Remove objects and check guard.
Storage 5. Extreme sprocket run-out. 5. Replace sprocket.
Belts should be kept in their original packaging until

needed. Store in an environment which avoids: 1. Excessive shock load. 1. Redesign drive for increased capacity.
2. Extreme sprocket run-out. 2. Replace sprocket.
Temperature extremes
3. Worn spacer. 3. Replace sprocket.
Direct sunlight Tooth Shear
4. Backside idler. 4. Use inside idler.
5. Misaligned drive. 5. Realign.
High humidity
6. Belt undertensioned. 6. Adjust tension to recommended value.
Contamination by oil, water, chemicals, etc.
1. Too low or high belt tension. 1. Adjust tension to recommended value.
Handling Tooth Wear
2. Belt running partly off unflanged sprocket.
3.Misaligned drive.
2. Correct alignment.
3. Correct alignment.
It is important that belts are not crimped during han- 4. Worn sprocket. 4. Replace sprocket.
dling since this could seriously damage the tensile 5. Rough sprocket teeth. 5. Replace sprocket.
members and lead to premature failure.
1. Subminimal diameter. 1. Redesign drive for increased capacity.
Installation Tips Belt Cracking

2. Backside idler.
3. Extreme low temperature at start-up.
2. Use inside idler or increase diameter of backside idler
3. Pre-heat drive environment.
Pulleys should be clean, free from wear or damage 4. Extended exposure to harsh chemicals. 4. Protect drive.
and their alignment must be correct. 5. Cocked bushing/sprocket assembly. 5. Install bushing per instructions.
Tensioners and idlers (when applicable) should be

free to rotate and move (when appropriate).
1. Excessive tension. 1. Adjust tension to recommended value.
Land Wear
Bearings should be in good condition. Belts should be 2. Rough pulley(s). 2. Replace pulley(s).
fitted in accordance with the engine manufacturers in-
structions to ensure that belt tension and engine tim-
ing is correct.
IMPORTANT: Avoid crimping the belt when installing

Oil Contamination 1. Oil leak. 1. Replace faulty oil seal(s).
it on pulleys no tools should be used on the belt.
Refit cover to prevent drive contamination by foreign
matter.
1. Damage due to handling. 1. Follow proper handling instructions.
2. Flange damage. 2. Repair flange or replace sprocket.
Replacement 3. Belt too wide. 3. Use proper width sprocket.
Edge Wear 4. Belt tension too low. 4. Adjust tension to recommended value.
Follow vehicle manufacturers instructions regarding 5. Rough flange surface finish. 5. Replace or repair flange to eliminate abrasive surface.
belt replacement intervals. If the belt is removed, then 6. Improper tracking. 6. Correct alignment.
a new belt should be installed (except where an auto- 7. Belt hitting drive guard or bracketry. 7. Remove obstruction or use inside idler.
matic tensioner is used). If engine is being repaired 1. High tension. 1. Adjust tension to recommended value.
and belt is near OEM recommended replacement in- Unusual Noise
2. Low tension. 2. Adjust tension to recommended value.
terval, its a good time to replace the belt. 3. Misalignment. 3. Realign pulleys.
4. Damaged Flange. 4. Replace pulleys.
Overhead Valve
Engine Identification
The engine illustrations below are all overhead valve type engines. These
diagrams are provided for your reference and convenience. This page is also for
customers that may not know the engine type they have, but may be able to
identify it through these illustrations.
Overhead Valve (OHV) Double Overhead Cam

Push Rod Assembly (DOHC)
(No Timing Belt Required)
Single
Overhead
Cam
(SOHC)
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.
NOTE: For your convenience, interference engines have been footnoted with a star in the
application listings of this publication. This lets you easily identify them, and pass that
information on to your customers.
Since timing belts are inside the engine they tend to be an out-of-sight, out-of-mind item and are
seldom thought of as a part of routine maintenance. Here are some questions to ask customers
that will help sell belts and protect the customer from expensive repairs:
1. Did you buy the car new? If yes, theyll know if the belt has ever been replaced.
2. Did you buy the car used? If so, they wont know if the belt has been replaced. This is a
flag for the customer to get the belt checked, replaced or at least be aware that he has a
timing belt.
3. How many miles are on the vehicle? Generally belts should be replaced at around 60,000
miles or less. Our Timing Belt Replacement Recommendations Booklet is an excellent
tool for determining replacement intervals.
4. Have you ever replaced the timing belt? If the answer is yes or no (and the customer
knows the mileage) you can determine where the vehicle is in the replacement cycle.
Heres a helpful hint for customers with vehicles within a few thousand miles of the recommended
replacement interval. If they are having any engine repair done, have the timing belt checked. If it
needs replacing, do it along with the other repairs and save time and money.
Gates980-984 7/18/01 1:27 PM Page 1
BELT TENSIONING
V- Belt Tension Ranges for Manual Tensioners
Always use a belt tension gauge that indicates static tension, such as the Gates Krikit Tension Gauge, to deter-
mine proper tension from the Installation Chart. Tension ranges below are for drives requiring single belts. If
multiple belts are needed for a drive, divide tension by number of belts to give per belt tension to be measured.
Position belt and set tension to the prescribed Installation Tension.
Run belt for five minutes.
If belt tension drops below Suggested Tension range, retighten belt to Installation Tension. This will allow the
belt to seat-in and run at Suggested Tension after it has operated under normal driving conditions.
Suggested Installation Installation Suggested Installation Installation

Belt Top Tension (lbs.) Tension (lbs.) Tension (lbs.) Belt Top Tension (lbs.) Tension (lbs.) Tension (lbs.)
Width Ranges Used Belts New Belts Width Ranges Used Belts New Belts
1/4" 45-65 60.0 80.0 13/16" 175-240 190.0 255.0
5/16" 60-85 75.0 100.0 7/8" 190-255 205.0 270.0
3/8" 85-115 100.0 130.0 1" 215-295 230.0 310.0
1/2" 105-145 120.0 160.0 1-1/16" 225-310 240.0 325.0
5/8" 135-185 150.0 200.0 1-1/8" 245-330 260.0 345.0
11/16" 155-200 170.0 215.0 1-5/16" 285-385 300.0 400.0
3/4" 160-220 175.0 235.0
NOTE: A belt is considered "used" once it has been "run-in".
Micro-V Belt Tension Ranges for Manual Tensioners
Always use a belt tension gauge that indicates static tension, such as the Gates Krikit Tension Gauge, to
determine proper tension from the Installation Chart. Many Micro-V belts are automatically tensioned by a
spring-loaded automatic tensioner, which does not require tension to be set.
The tension ranges below are used for applications requiring manual tensioning.
For drives with manual take-up on locked-center drives, position the belt and set tension to the prescribed
Installation Tension.
Run belt for five minutes.
If belt tension drops below Suggested Tension range, retighten belt to the Installation Tension. This will allow
the belt to seat-in and run at Suggested Tension after it has operated under normal driving conditions.
Suggested Installation Installation Suggested Installation Installation

Number Tension (lbs.) Tension (lbs.) Tension (lbs.) Number Tension (lbs.) Tension (lbs.) Tension (lbs.)
of Ribs Ranges Used Belts New Belts of Ribs Ranges Used Belts New Belts
3 45-60 67.5 90.0 9 135-180 202.5 270.0
4 60-80 90.0 120.0 10 150-200 225.0 300.0
5 75-100 112.5 150.0 11 165-220 247.5 333.0
6 90-125 135.0 187.5 12 180-240 270.0 360.0
7 105-145 157.5 217.5 14 210-280 292.5 420.0
8 120-160 180.0 240.0
NOTE: A belt is considered "used" once it has been "run-in".
980
ACURA 1
*1.6L 4-Cylinder EL
TIMING BELT APPLICATION TIMING BELT
Application Labor Time Belt Part No. Removal:
1.6L 4-Cyl. SOHC Disconnect battery negative cable. Remove engine lower
splash shield. Remove power steering, alternator, and A/C
EL (Canadian) compressor drive belts. Rotate crankshaft counterclock-
1997-00 ................ 1 2.0 Hours .................... T224 wise to TDC of compression stroke. See Fig. 3.
1
- With Air Cond. add .4 hours. Remove engine oil dipstick. Remove power steering pump
With Cruise Control add .3 hours. and set aside with hoses attached. Remove timing belt
upper cover and A/C drive belt idler pulley bracket.
MANUFACTURERS SUGGESTED Use jack to support engine. Working from front of engine,
remove engine mount bracket nuts. Remove crankshaft
SCHEDULED MAINTENANCE pulley. Remove lower cover and dipstick tube.
For 1997-00 vehicles, normal replacement interval is at Remove Crankshaft Speed Fluctuation (CKF) sensor from
105,000 miles or 84 months. Replace at 60,000 miles if car is oil pump. Loosen the timing belt tension adjusting bolt 180
regularly driven in extreme temperatures (over 110 degrees F, degrees. Push tensioner to release belt tension. Retighten
or under -20 degrees F). tension adjusting bolt. Mark rotation direction of timing belt
if it is to be reused. Remove timing belt from pulleys. See
*NOTE: This application is an interference engine. Fig. 1.
See page A-59 for interference engine cautions. Installation:
Ensure No. 1 cylinder is at TDC of compression stroke.
Timing belt drive pulley TDC mark must align with pointer
REMOVAL & INSTALLATION on oil pump housing. See Fig. 2.
Set camshaft pulley to TDC. TDC marks should align with
NOTE: If the radio has a coded theft protection circuit, be sure top surface of cylinder head. See Fig. 3.
to get the customers code before disconnecting battery.
Courtesy of American Honda Motor Co. , Inc.

Fig. 1: Exploded View Of Timing Belt Components
2 ACURA
*1.6L 4-Cylinder EL (Cont.)
To adjust timing belt tension, set No. 1 piston at TDC (White
TDC mark on crankshaft pulley aligned with pointer on
cover). Loosen adjusting bolt 180 degrees. See Fig. 5. Ro-
tate crankshaft counterclockwise 3 teeth on camshaft pul-
ley. Tighten adjusting bolt. If necessary, retoque crankshaft
pulley bolt.
Ensure crankshaft and camshaft pulleys are still aligned at
TDC. If not, timing belt will need to be removed and reposi-
tioned. To complete installation,reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICA-
TIONS. Adjust drive belts to proper tension. See page A-60
for belt tension ranges.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Drive Belt Idler Pulley Bracket Bolt ........................ 17 (24)
Alternator Adjusting Bolt .................................................. 17 (24)
Courtesy of American Honda Motor Co. , Inc. Alternator Mount Bolt ................................................... 33 (45)
Fig. 2: Aligning Crankshaft TDC Mark & Oil Pump Mark Camshaft Pulley Center Bolt .......................................... 27 (37)
Crankshaft Pulley Bolt 1
Install timing belt in this sequence: timing belt drive pulley, Step 1 ....................................................................... 14 (20)
tension adjusting pulley, water pump pulley, and camshaft Step 2 ...................................... Plus 90 Degrees Clockwise
pulley. See Fig. 4. DO NOT bend or twist belt excessively. Engine Mount Bracket Nuts ............................................ 54 (74)
Ensure arrow on used belt points in original rotation direc- Power Steering Pump Bracket Bolt ............................ 17 (24)
tion. Ensure crankshaft and camshaft pulley timing mark Power Steering Pump Lock Bolt ................................ 17 (24)
are aligned with TDC marks. Timing Belt Tensioner Adjusting Bolt ........................... 33 (45)
Loosen and retighten adjusting bolt to tension timing belt. INCH Lbs. (N.m)
Install lower cover. Install crankshaft pulley. Tighten pulley CKF Sensor Bolt ....................................................... 106 (12)
bolt to specification. See TORQUE SPECIFICATIONS table. Engine Lower Splash Shield .......................................... 89 (10)
Rotate crankshaft pulley 5-6 turns counterclockwise so tim- Timing Belt Cover Bolt ................................................ 89 (10)
ing belt positions on pulley. Water Pump Bolt ...................................................... 106 (12)
1
- Lubricate bolt threads and bolt head shoulder.
CAUTION: Always adjust timing belt tension with engine cold.

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

4 ACURA
*1.6L 4-Cylinder Integra
TIMING BELT APPLICATION
Application Labor Time1 Belt Part No.
1.6L 4-Cyl.
Integra
1986-89 ................. 2.8 Hours ..................... T130
1
- With Air Cond. add .2 hours.
MANUFACTURERS SUGGESTED
SCHEDULED MAINTENANCE
Although the manufacturer does not recommend a specific
scheduled maintenance interval, belt manufacturers suggest
the belt be replaced every 60,000 miles.
* NOTE: This application is an interference engine.

See page A-59 for interference engine cautions.
REMOVAL & INSTALLATION

TIMING BELT
Removal:
Disconnect negative battery cable. Turn crankshaft coun-
terclockwise to bring piston in cylinder No. 1 to TDC of its
compression stroke. Remove all drive belts. Remove A/C
compressor and power steering pump and position out of
way without disconnecting hoses. Remove crankshaft pul- 96D14681 Courtesy of American Honda Motor Co., Inc.
ley. Fig. 1: Exploded View of Timing Belt & Components

Remove engine valve cover and upper timing belt cover.
Remove lower timing belt cover from engine block. Loosen
timing belt tensioner to relieve tension on timing belt.
Slide belt off sprockets. Remove bolts, washers, camshaft
sprockets, and Woodruff key (if necessary).
Installation:
Ensure No. 1 piston is still on TDC. Install Woodruff keys,
camshaft sprockets, washer, and retaining bolts (if re-
moved). Position UP mark on sprockets at top. Align
grooves on sprockets. See Fig. 2.
Install timing belt on sprockets. Use care not to excessively
bend or twist belt.
Rotate crankshaft counterclockwise 3 teeth on camshaft
sprockets to create tension on belt. Tighten tensioner ad-
justment bolt. Reverse removal procedure to complete in-
stallation. Adjust the drive belts to proper tension. See
page A-60 for belt tension ranges.
96E14682 Courtesy of American Honda Motor Co., Inc.
A/C Compressor/Bracket Bolts .................................. 33 (45)
Alternator Belt Adjustment Bolt .................................... 17 (23) Fig. 2: Camshaft Timing Marks
Alternator Mount Bolt ................................................... 33 (45)
Camshaft Pulley Bolt .................................................. 27 (37)
Crankshaft Pulley Bolt .............................................. 83 (112)
Power Steering Pump Mounting Bolts .............. 29-33 (38-45)
Timing Belt Adjustment Bolt ....................................... 33 (45)
Wheel Lug Nuts ....................................................... 80 (110)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .............................................. 86 (10)
Valve Cover Nuts ........................................................ 86 (10)
ACURA 5
*1.7L 4-Cylinder
TIMING BELT APPLICATION TORQUE SPECIFICATIONS
Application Labor Time 1
Belt Part No. Application Ft. Lbs. (N.m)
1.7L 4-Cyl.
Camshaft Sprocket Bolts ............................................ 27 (37)
Integra Crankshaft Pulley Bolt
1992-93 ................. 2.8 Hours ..................... T227 1992 ....................................................................... 87 (118)
1
- With Air Cond. add .2 Hours. 1993 .................................................................. 1 133 (180)
Power Steering Mount Bolt .......................................... 17 (23)
Timing Belt Tension Adjuster Bolt ............................... 40 (54)
SCHEDULED MAINTENANCE Wheel Lug Nuts ....................................................... 80 (110)
INCH Lbs. (N.m)
The manufacturer recommends the belt be replaced every Timing Belt Cover Bolts ............................................ 108 (12)
90,000 miles or 72 months. Valve Cover Nuts ......................................................... 84 (10)
* NOTE: This application is an interference engine. 1
- Tighten to 147 ft. Lbs. (200 N.m), loosen & retorque to 133 ft.
See page A-59 for interference engine cautions. lbs. (180 N.m).

TIMING BELT
Removal:
Disconnect negative battery cable. Raise and support ve-
hicle. Remove left front wheel. Remove left front wheelwell
splash shield. Remove drive belts. Remove power steer-
ing pump with hoses attached, and set it aside.
Remove valve cover and middle timing belt cover. See Fig.
1. Rotate crankshaft counterclockwise to bring No. 1 piston
to TDC of its compression stroke. Position UP mark on
sprockets at top. See Fig. 2. Align grooves on sprockets.
Remove crankshaft pulley.
Remove left engine mount. Remove cylinder head cover.
Remove crankshaft pulley. Loosen timing belt tension ad-
juster bolt 180 degrees. Push tensioner to relieve tension
on timing belt. Retighten adjuster bolt. Remove timing belt.
Installation:
Ensure No. 1 piston is at TDC of compression stroke. In-
stall timing belt onto sprockets. DO NOT bend or twist belt
excessively. Adjust timing belt tension.
To complete installation, reverse removal procedure. Lu-
bricate threads only of crankshaft pulley bolt, leaving un-
derside of bolt head dry. On 1993 models, tighten crank-
shaft pulley bolt to 147 ft. Ibs. (200 N.m), loosen, then re-
tighten to 133 ft. Ibs. (180 N.m). Adjust drive belts to proper
tension. See page A-60 for belt tension ranges.

6 ACURA
*1.7L 4-Cylinder (Cont.)
Fig. 2: Aligning Timing Marks

ACURA 7
*1.8L 4-Cylinder
Belt Part No. Application Ft. Lbs. (N.m)
1.8L 4-Cyl. (EXC. VTEC) A/C Compressor/Bracket Bolts .................................. 17 (23)
Alternator Belt Adjustment Bolt .................................... 17 (23)
Integra Alternator Mount Bolt ................................................... 33 (45)
1990-01 .................. 2.8 Hours .................... T184 Camshaft Sprocket Bolts ............................................ 27 (37)
1.8L 4-Cyl. (VTEC) Crankshaft Pulley Bolt
Integra 1990-92 ................................................................. 87 (118)
1994-01 .................. 2.8 Hours .................... T247 1993-01 ............................................................. 1 133 (180)
Engine Mount Bolts .............................................................. 2
1
- With Air Cond. add .2 hours. Engine Block-To Transaxle Bolt .................................. 47 (64)
Power Steering Bolt .................................................... 17 (23)
MANUFACTURERS SUGGESTED Timing Belt Tension Adjuster Bolt ............................... 40 (54)
INCH Lbs. (N.m)
SCHEDULED MAINTENANCE Timing Belt Cover Bolts ............................................ 106 (12)
For 1990-94 models, manufacturer recommends the belt be Valve Cover Nuts ........................................................ 88 (10)
replaced every 90,000 miles. For 1995-96 models, the manu- Water Pump Bolt ...................................................... 106 (12)
facturer recommends the belt be replace every 90,000 miles 1
- Tighten crankshaft pulley bolt to 147 ft. Lbs. (200 N.m),
for normal service and 60,000 miles for severe service. loosen then retorque to 133 ft. lbs. (180 N.m).
For 1997-01 models, normal replacement interval is at 105,000 2
- See Fig. 3.
miles or 84 months. For 1997-01 models, replace belt at
60,000 miles if vehicle is regularly driven in extreme tempera-
tures (over 110 degrees F, or under -20 degrees C).
NOTE: Some vehicles may be equipped with radio/cassette or

radio/CD players that contain anti-theft protection circuit. When
battery is disconnected, radio will go into anti-theft mode. When
battery is reconnected, radio will display CODE and will be inoperative
until proper code is entered by vehicle owner.


TIMING BELT
Removal:
hicle. Remove left front wheel. Remove left front wheelwell
splash shield. Remove all drive belts. Remove power steer-
ing pump with hoses attached. Set power steering pump
aside.
Remove valve cover and upper timing belt cover. See Fig. 1.
Turn crankshaft counterclockwise to bring No. 1 piston to
TDC of its compression stroke. Position UP mark on sprock-
ets at top. See Fig. 2. Align grooves on sprockets. Remove
crankshaft pulley.
Remove left engine mount bolts and nut. Remove engine
mount. See Fig. 3. Remove lower timing belt cover. Loosen
timing belt tension adjuster bolt. Push tensioner to relieve
tension on timing belt. Retighten adjuster bolt. Remove
timing belt.
Installation:
Ensure No. 1 piston is at TDC. Install timing belt onto sprock-
ets. DO NOT bend or twist belt excessively. Adjust timing
belt tension. To complete installation, reverse removal pro-
cedure. On 1993-96 models, tighten crankshaft pulley bolt
to 147 ft. Ibs. (200 N.m), loosen, then retorque to 133 ft. Ibs. Fig. 1: Exploded View Of Timing Belt Components
(180 N.m).
Adjust drive belts to proper tension. See page A-60 for belt
tension ranges.
8 ACURA
Fig. 4: Positioning Camshaft
Fig. 3: Engine/Transaxle Mount Location & Tightening

Sequence
ACURA 9
*2.2L & 2.3L 4-Cylinder

TIMING BELT APPLICATION Remove crankshaft pulley and lower cover. Ensure crank-
shaft is still at TDC. Lock timing belt adjuster arm in place
Belt Part No. by installing a 6x1.0 mm bolt. See Fig. 4. Loosen timing
2.2L 4-Cyl. belt adjusting nut about 1 turn and make sure balance
2.2CL shaft belt adjuster moves freely.
1997 Push tensioner to remove tension from balance shaft belt
Balance Shaft ............................................. T186 adjuster, then retighten nut.
Camshaft ............. 2.9 Hours ..................... T244 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
2.3L 4-Cyl. balance shaft, insert bolt through hole and into balance
2.3CL shaft.
1998-99 Align groove on balance shaft pulley with pointer on oil
Balance Shaft ............................................. T186 pump housing. See Fig. 6. Install balance shaft belt. Loosen
Camshaft ............. 2.9 Hours ..................... T244 adjuster nut about 1 turn to tension balance shaft belt.
Remove 6x100 mm bolt from balance shaft. Install sealing
1
- Balance shaft belt included in labor time. bolt in side of engine block. Install crankshaft pulley and
bolt. Rotate crankshaft about 1 turn counterclockwise, then
MANUFACTURERS SUGGESTED tighten adjuster nut. Remove 6x1.0 mm bolt from timing
belt adjuster arm.
SCHEDULED MAINTENANCE Remove crankshaft pulley. Install lower cover. Install rub-
For the 2.2CL, normal replacement interval is 90,000 miles ber seal around adjuster nut. DO NOT loosen adjuster nut.
for normal service or 60,000 miles for severe service. For the Install crankshaft pulley. To complete installation, reverse
2.3CL, normal replacement interval is at 105,000 miles or 84 removal procedure. Adjust drive belts to proper tension.
months. Replace at 60,000 miles if car is regularly driven in See page A-60 for belt tension ranges.
extreme temperatures (over 110 degrees F, or under -20 de-
grees F).


NOTE: If the radio has a coded theft protection circuit, be sure
TIMING BELT
Removal:
Disconnect negative battery cable. Rotate crankshaft coun-
terclockwise until cylinder No. 1 is at TDC of compression
stroke. While rotating crankshaft, check water pump for
signs of seal leakage. Remove accessory drive belts. Re-
move alternator terminal and connector. Raise and sup-
port vehicle. Remove wheelwell splash shield. Use a jack,
Courtesy of American Honda Motor Co., Inc.
with cushion between oil pan and jack, to support engine.
Remove side engine mount. Fig. 1: Identifying TDC Mark on Crankshaft Drive Pulley
Remove oil dipstick and pipe. Remove valve cover. Re-
move crankshaft pulley. Remove upper and lower timing
belt covers. Loosen timing belt tension adjuster bolt about
1/2 turn. Push tensioner to release belt tension from timing
belt and balancer belt. Retighten tension adjuster bolt.
Remove balance shaft drive pulley. Remove balance shaft
belt and timing belt from pulleys.
Installation:
Ensure No. 1 piston is at TDC of compression stroke. See
Fig. 1. Align camshaft pulley with mating marks on back
cover upper surface. Ensure UP mark is at 12 oclock
position. See Fig. 2.
Install timing belt in sequence shown. See Fig. 3. Loosen
and retighten the timing belt adjusting nut about 1 turn.
Install balance shaft drive pulley and lower cover. Install
crankshaft pulley and center bolt.
Rotate crankshaft about 5-6 times counterclockwise. Set Courtesy of American Honda Motor Co., Inc.
No. 1 piston at TDC. Loosen timing belt adjusting nut about Fig. 2: Aligning Camshaft Sprocket Timing Marks
1 turn. Rotate crankshaft counterclockwise 3 teeth on cam-
shaft pulley. Tighten timing belt adjusting nut. Make sure
crankshaft and camshaft pulleys are at TDC.
10 ACURA
*2.2L & 2.3L 4-Cylinder (Cont.)
Fig. 5: Aligning & Locking Balance Shaft
Fig. 4: Timing Belt Adjuster Nut

Alternator Bracket-to-Engine Bolt ................................. 33 (45)
Camshaft Sprocket Bolt ................................................. 27 (37)
Crankshaft Pulley Bolt ................................................ 181 (245)
Power Steering Pump Mount Bolt ............................... 16 (22)
Timing Belt Tension Adjuster Nut ............................... 33 (44)
Wheel Lug Nuts ....................................................... 80 (110)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ...................................... 86-104 (7.2-8.7)
Valve Cover Bolt ............................................................. 86 (9.8)
Fig. 6: Aligning Balance Shaft Pulley

ACURA 11
*2.5L 5-Cylinder
Application Labor Time Belt Part No.
2.5L 5-Cyl.
Vigor
1992-94 ................. 3.1 Hours .................... T211
2.5TL
1995-98 ................. 3.1 Hours ..................... T211
For Vigor models, normal replacement interval is 90,000 miles.
For 1995-96 2.5TL models, replacement interval is 90,000
miles for normal service and 60,000 for severe service. For
1997-98 2.5TL models, normal replacement interval is at
105,000 miles or 84 months. Replace at 60,000 miles if car is
regularly driven in extreme temperatures (over 110 degrees F,
or under -20 degrees F).
*NOTE: This application is an interference engine.

NOTE: Before disconnecting negative battery cable, obtain radid

anti-theft code from vehicle owner.

TIMING BELT
Removal: Courtesy of American Honda Motor Co. , Inc.
Disconnect battery negative cable. Remove accessory drive Fig. 1: Exploded View of Timing Belt Components
belts. Remove cylinder head cover and upper timing belt
covers. See Fig. 1. Rotate crankshaft counterclockwise to
bring No. 1 piston to TDC of compression stroke. Remove
crankshaft pulley. Remove lower timing belt cover.
Loosen timing belt tension adjuster bolt 180 degrees. See
Fig. 5. Push tensioner to relieve tension on timing belt.
Retighten adjuster bolt. If reusing timing belt, mark direc-
tion of belt rotation before removing. Remove timing belt.
Installation:
Ensure No. 1 piston is at TDC. See Fig. 2. Position timing
marks on camshaft pulley. See Figs. 3 and 6. Install timing
belt, in sequence, onto crankshaft pulley, tension adjuster
pulley, water pump pulley and camshaft pulley. See Fig. 4.
DO NOT bend or twist belt excessively. Ensure arrow on
used belt points in original rotation direction.
Loosen and retighten adjusting bolt to tension timing belt.
Install upper and lower covers. Install crankshaft pulley and
tighten to specification. Rotate crankshaft counterclockwise
about 5-6 turns.
Set No. 1 piston at TDC. Loosen the adjusting bolt 180
degrees. Rotate crankshaft counterclockwise 3 teeth on
camshaft pulley. Tighten adjusting bolt. Ensure camshaft Courtesy of American Honda Motor Co. , Inc.
and crankshaft pulleys are at TDC. If pulleys are not posi- Fig. 2: Aligning Crankshaft Timing Marks
tioned at TDC, remove and reposition timing belt.
To complete installation, reverse removal procedure.
for drive belt tension ranges.
12 ACURA

Fig. 3: Aligning Camshaft Timing Marks

A/C Belt Idler Pulley Bolt ............................................. 32 (44)
A/C Compressor Mount Bolts ..................................... 16 (22)
A/C Compressor Bracket Bolts .................................. 36 (49)
Alternator Mounting Bolts ............................................ 33 (45)
Camshaft Pulley Bolts ................................................ 52 (70)
Crankshaft Pulley Bolt ............................................ 181 (245)
Power Steering Pump Mount ...................................... 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover Bolts ............................................ 106 (12)
Cylinder Head Cover Nuts ........................................ 106 (12)
Water Pump Bolts .................................................... 106 (12)
ACURA 13
*2.5L & 2.7L V6

TIMING BELT APPLICATION NOTE: After timing belt installation, rotate engine clockwise
Application Labor Time Belt Part No. several times to ensure valves DO NOT contact pistons.
2.5L V6 TORQUE SPECIFICATIONS
Legend
1986-87 ................ 4.0 Hours ................... T129 Application Ft. Lbs. (N.m)
A/C Compressor Bolts ............................................... 16 (22)
2.7L V6 A/C Compressor Bracket Bolts .................................. 33 (45)
Legend Alternator Bracket Bolts .............................................. 33 (45)
1987-90 ................ 4.0 Hours ................... T129 Alternator Mount Bolts ................................................ 16 (22)
MANUFACTURERS SUGGESTED Crankshaft Pulley Bolt ............................................. 123(170)
Engine Mount Bolts .................................................... 40 (54)
SCHEDULED MAINTENANCE Power Steering Pump Mount Bolt ............................... 33 (45)
For 1986-89 models, although the manufacturer does not rec- Timing Belt Tensioner Bolt ......................................... 33 (45)
ommend a specific scheduled maintenance interval, belt INCH lbs (N.m)
manufacturers suggest the belt be replaced every 60,000 Timing Belt Cover Bolts .............................................. 86 (10)
miles. For 1990 models, the manufacturer recommends the Valve Cover Bolts ...................................................... 106 (12)
belt be replaced every 90,000 miles or 72 months. Water Pump Bolts .................................................... 106 (12)


TIMING BELT
Removal:
Remove negative battery cable. Turn crankshaft clockwise to
bring No. 1 piston to TDC of compression stroke. Remove
pulley cover from upper timing belt cover. Remove engine
wiring harness clamp from right side of engine compartment.
Support front of engine. On right side of engine compart-
ment, remove engine-to-body mount (on front of engine).
Remove lower engine splash shield. Remove A/C, power
steering, and all other drive belts.
Remove alternator. Leaving hoses connected, remove
power steering pump and secure out of way. Remove up-
per timing belt pulley covers. Remove crankshaft pulley.
Remove timing belt lower cover.
Loosen timing belt tensioner to relieve tension on timing
belt. Check belt for damage, missing teeth or cracks.
Installation:
Remove spark plugs. Turn crankshaft clockwise to bring
No. 1 piston to TDC of compression stroke. Advance crank-
shaft an additional 15 degrees from TDC position.
Rotate camshaft pulleys to compression stroke (TDC po-
sition) of No. 1 cylinder. See Fig. 1. Return crankshaft pulley
15 degrees to TDC position.
Push timing belt tensioner to full release position and snug
adjuster bolt. Install timing belt over crankshaft pulley, front
camshaft pulley, water pump pulley, tensioner and rear
camshaft pulley. See Fig. 1.
Note position of timing belt pulley guides on both sides of
crankshaft. Install pulley guides so guides form a V groove
for belt to ride in. Loosen timing belt tensioner bolt.
NOTE: Always adjust timing belt tension with engine cold.

Fig 1: Adjusting Timing Belt
Timing Belt Tension Adjustment:
Set No. 1 piston to TDC on compression stroke. Rotate
crankshaft clockwise 9 teeth on rear camshaft pulley. Blue
mark on crankshaft pulley should match pointer on lower
cover. Loosen timing belt tensioner bolt. See Fig. 1.
Ensure timing belt is seated properly on pulleys. Tighten
adjuster bolt. Reverse removal procedure to complete in-
stallation. Adjust drive belts to proper tension. See page A-
60 for belt tension ranges.
14 ACURA
*2.5L & 2.7L V6 (Cont.)
93H00122 Courtesy Of American Honda Motor Co., Inc.
Fig. 2: Exploded View of Timing Belt Components Fig. 3: Positioning Camshaft

ACURA 15
*3.0L, 3.2L & 3.5L V6

TIMING BELT APPLICATION *NOTE: These applications are interference en-
Application Labor Time Belt Part No. gines. See page A-59 for interference engine cautions.
3.0L V6 (J30A1)
3.0CL REMOVAL & INSTALLATION
1997-99 ................. 4.0 Hours ..................... T286
3.2L V6 (J32A1/A2) TIMING BELT
3.2CL Removal:
2001 ...................... 4.0 Hours ..................... T286 Disconnect negative battery cable. Turn crankshaft pulley
so that No. 1 piston is at TDC on compression stroke.
3.2TL White mark on crankshaft pulley should align with pointer
1999-01 ................. 4.0 Hours .................... T286 on front cover. Remove rubber plugs from front and rear
3.5L V6 (J35A3) upper timing belt covers. Ensure camshaft sprocket timing
MDX marks are aligned with tabs on bottom of access holes.
2001 ...................... 4.0 Hours ..................... T286 Remove lower engine splash shield. Remove the genera-
tor and power steering pump drive belts.
MANUFACTURERS SUGGESTED Remove dipstick tube from front of engine. Support engine
with a jack, and remove engine side mount from front of
SCHEDULED MAINTENANCE engine. Remove crankshaft pulley center bolt and pulley.
Normal replacement interval is at 105,000 miles or 84 months. Remove upper and lower timing belt covers. See Figs. 1
Replace at 60,000 miles if car is regularly driven in extreme and 2. If reusing timing belt, mark direction of belt rotation
temperatures (over 110 degrees F, or under -20 degrees F). for installation reference.

Fig. 1: Exploded View Of Timing Belt Components (1997-99)
16 ACURA
*3.0L, 3.2L & 3.5L V6 (Cont.)


Fig. 3: Installing Battery Clamp Bolt On Auto-Tensioner
ACURA 17
*3.0L, 3.2L & 3.5L V6 (Cont.)

Remove one of the battery clamp bolts from battery tray. TORQUE SPECIFICATIONS
Grind threaded end of bolt to a partial point (about 45 de-
gree chamfer). Thread battery bolt into rear cover to hold
Camshaft Sprocket Center Bolt ...................................... 67 (90)
timing belt adjuster in installed position. Hand tighten ONLY.
See Fig. 3.
Engine Side Mount-to-Engine Bolts ............................... 33 (44)
Remove side engine mount bracket from front of engine Engine Side Mount Bracket-to-Mount Through Bolt
(above water pump pulley). Loosen timing belt idler pulley
3.0CL ............................................................................. 47 (64)
bolt 5-6 turns. Remove timing belt.
Except 3.0CL ................................................................. 40 (54)
Installation
Idler Pulley Bolt .............................................................. 33 (44)
Ensure that engine is at TDC. Align dimple on timing belt Power Steering Pump Mount Bolt ................................... 17 (24)
drive pulley with pointer on oil pump. See Fig. 4. Align cam-
Power Steering Pump Locknut ....................................... 17 (24)
shaft pulleys with pointers on back covers.
INCH Lbs. (N.m)
CAUTION: Handle auto-tension carefully so oil does not spill Auto-Tensioner Mount Bolts ......................................... 106 (12)
or leak out. Replace any oil that may leak out. Auto-Tensioner Maintenance Bolt ..................................... 71 (8)
Lower Engine Splash Shield Bolts ............................... 106 (12)
Remove battery clamp bolt from back cover. Remove the Timing Belt Cover Bolts ............................................ 106 (12)
timing belt auto-tensioner. Water Pump Bolts .................................................... 106 (12)
For 1997-98 auto-tensioner with removable bolt, hold auto-
tensioner with maintenance bolt pointing up. Remove main-
tenance bolt. See Fig. 4. Clamp auto-tensioner in soft-jawed
vise. DO NOT grip auto-tensioner housing. Insert flat blade
screwdriver into maintenance hole. Place stopper on auto-
tensioner while turning screwdriver clockwise to compress
tensioner to bottom.
Replace any oil that may have spilled out of auto-tensioner.
Reinstall maintenance bolt with NEW gasket. Ensure no
oil is leaking around maintenance bolt, then reinstall auto-
tensioner onto engine with stopper in place.
CAUTION: Do NOT exceed 2200 lbs. of pressure when compressing

auto-tensioner.
On 2000-01 models with sealed auto-tensioner, place
tensioner in press. SLOWLY compress tensioner until pin
can be inserted through tensioner body and tensioner ap-
ply pin. See Fig. 5. Install auto-tensioner onto engine.
On all models, install timing belt in following sequence:
Crankshaft pulley, idler pulley, front camshaft pulley, water
pump pulley, rear camshaft pulley and tension adjust pul-
ley. See Fig. 6. Ensure crankshaft and camshaft pulleys
remained aligned with marks on back cover. Tighten idler
pulley bolt.
Remove stopper or pin from auto-tensioner. Install engine
side mount bracket to the front of engine (above water pump
pulley). Install upper and lower covers. Install crankshaft
pulley. Lubricate crankshaft pulley bolt threads and install
bolt. Tighten crankshaft pulley bolt to specification. See
TORQUE SPECIFICATIONS table.
Rotate crankshaft about 5-6 turns clockwise to position
timing belt on pulleys. Ensure crankshaft and camshaft
pulleys are aligned at TDC. Crankshaft pulley White mark
should be aligned with pointer on front cover. Remove rub-
ber plugs from upper covers to check camshaft pulley posi-
tions.
If either camshaft is not at TDC, remove timing belt and
readjust position. To complete installation, reverse removal
procedure. Tighten all fasteners to specification. See
TORQUE SPECIFICATIONS. Adjust drive belt to correct ten-
sion. See page A-60 for belt tension ranges.
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks

18 ACURA
*3.0L, 3.2L & 3.5L V6 (Cont.)

Fig. 5: Compressing Auto-Tensioner (1997-99 Models)
Fig. 7: Installing Timing Belt

Fig. 6: Compressing Auto-Tensioner (2000-01 Models)
ACURA 19
*3.2L V6 Legend & 1996-98 3.2 TL

TIMING BELT APPLICATION *NOTE: This application is an interference engine.
Application Labor Time Belt Part No. See page A-59 for interference engine cautions.
3.2L V6
Legend (C32A1) NOTE: Some vehicles may be equipped with radio/cassette or
1991-95 ................. 5.6 Hours ..................... T193 radio/CD players that contain anti-theft protection circuit. Obtain
3.2TL (C32A6) radio anti-theft code from vehicle owner before disconnecting
1996-98 ................. 4.0 Hours ..................... T193 negative battery cable.

MANUFACTURERS SUGGESTED TIMING BELT
SCHEDULED MAINTENANCE Removal (1991-93)
For 1991-94 model years, manufacturer recommends belt be Disconnect negative battery cable. Remove injector har-
replaced every 90,000 miles or 72 months. ness covers. See Fig. 2. Remove engine wiring harness
For 1995-96 model years, replacement interval is 90,000 miles from front of engine. Disconnect breather pipe. Remove
for normal service and 60,000 miles for severe service. For vacuum pipe bracket. Remove accessory drive belts.
1997-98 model years, normal replacement interval is at Remove timing belt upper covers. See Fig. 1. Rotate crank-
105,000 miles or 84 months. Replace at 60,000 miles if car is shaft clockwise until No. 1 piston is at TDC of compression
regularly driven in extreme temperatures (over 110 degrees F, stroke. Ensure timing marks are aligned. Remove A/C belt
or under -20 degrees F). tensioner pulley. Remove crankshaft pulley. Remove en-
gine oil dipstick tube.

Fig. 1: Exploded View Of Timing Belt & Components
20 ACURA
*3.2L V6 Legend & 1996-98 3.2 TL (Cont.)
Remove timing belt lower cover. If timing belt is to be re-
used, mark belt with arrow indicating direction of rotation.
Loosen timing belt adjusting bolt turn. Push tensioner to
release belt tension, then retighten adjusting bolt. Remove
timing belt.
Removal (1994-98)
Disconnect negative battery cable. Use jack to support en-
gine. Remove center bracket and mount from front, lower
part of engine. Remove the generator, A/C compressor, and
power steering belts.
If equipped, remove Traction Control System (TCS) valve
assembly brackets. Disconnect TCS throttle sensor and
actuator connectors. See Fig. 3. Remove TCS control valve
assembly, leaving breather pipe by-pass hose connected.
Remove engine front wiring harness cover with oil pres-
sure switch and engine ground cable connectors. Remove
idler pulley bracket, dipstick, and dipstick pipe. Remove
crankshaft pulley.
Remove timing belt upper and lower covers. See Fig. 1.
Rotate crankshaft clockwise until No. 1 piston is at TDC of
compression stroke. Align timing marks. See Fig. 4. Loosen
timing belt adjusting bolt 180 degrees to remove tension
from belt. Retighten adjusting bolt.
If timing belt is to be reused, mark direction of belt rotation
before removing. Remove timing belt.
CAUTION: DO NOT turn crankshaft or camshaft with timing belt

removed, because pistons may hit valves, causing damage. Do
NOT rotate crankshaft when tension adjusting bolt is loose.
Installation (1991-93)
Remove spark plugs. When installing timing belt, turn crank-
shaft clockwise 15 degrees past No. 1 cylinder TDC. After
adjusting left and right camshaft pulleys to TDC, turn crank-
shaft pulley counterclockwise back to TDC.
Install timing belt in this sequence: Crankshaft pulley,
tensioner pulley, left camshaft, water pump pulley, right cam-
shaft. To ease installation, advance right camshaft pulley
about a half tooth from TDC position.
Loosen timing belt tension adjusting bolt, and retight it af-
ter tensioning the timing belt. Temporarily install lower tim-
ing belt cover and crankshaft pulley. Rotate crankshaft about
5-6 turns clockwise to seat timing belt. Place No. 1 piston
at TDC of compression stroke.
Rotate crankshaft clockwise 9 teeth on camshaft pulley.
Blue mark on crankshaft pulley will should line up with Fig. 2: Exploded View Of Intake Manifold (1991-93 Models)
pointer on lower cover. See Fig. 5. Install timing belt in this sequence: Crankshaft pulley, ten-
Loosen timing belt adjusting bolt 180 degrees. Tighten sion adjuster pulley, left camshaft pulley, water pump pul-
timing belt adjusting bolt to 31 ft. lbs. (42 N.m). Verify crank- ley, and right camshaft pulley. Loosen and tighten tensioner
shaft and camshaft timing marks are still aligned. If timing adjuster bolt to remove slack in belt.
marks are not aligned, repeat timing belt installation pro-
cedure. To complete installation, reverse removal proce-
Install upper and lower covers and crankshaft pulley. Tighten
pulley bolt to specification. Rotate crankshaft clockwise 5-
dure. Coat crankshaft pulley center bolt threads with oil 6 revolutions to seat timing belt.
before installation. Adjust accessory drive belt to proper
tension.
Adjust timing belt tension. Remove upper left camshaft
cover. Remove damper from center bracket. Rotate crank-
NOTE: After installing timing belt, slowly rotate engine clockwise shaft clockwise until No. 1 piston is at TDC of compression
several times to be sure valves do not contact pistons. stroke. Rotate crankshaft 9 teeth clockwise on camshaft
pulley. Align Blue mark on crankshaft pulley with pointer on
Installation (1994-98) lower cover. See Fig. 5. Loosen tensioner adjusting bolt 1/
Remove all spark plugs. Ensure No. 1 piston is at TDC of 2 turn , and then tighten bolt to 31 ft. lbs. (42 N.m).
compression stroke. Position crankshaft and camshaft pul- Rotate crankshaft clockwise until No. 1 piston is at TDC Of
leys as shown. See Fig. 4. compression stroke. Verify camshaft timing marks are
Adjust camshaft pulley(s) until TDC mark on pulley and aligned. If timing marks are not aligned, repeat timing belt
pointer on cover plate are aligned. If reusing timing belt, installation procedure. To complete installation, reverse
ensure arrow made in removal procedure points in direc- removal procedure. Coat crankshaft pulley center bolt
tion of original rotation. threads with oil before installation.
ACURA 21
*3.2L V6 Legend & 1996-98 3.2 TL (Cont.)

Fig. 3: Locating TCS Control Valve & Connectors

Fig. 5: Adjusting Timing Belt Tension
Fig. 4: Aligning Timing Marks (TDC)
NOTE: After Installing timing belt, rotate engine clockwise several

times to be sure valves do not contact pistons.
Center Bracket Bolts ................................................... 40 (54)
Power Steering Mount Locknut ....................................... 16 (22)
TCS Lower Bracket Bolts ............................................ 16 (22)
Timing Belt Adjusting Bolt .......................................... 31 (42)
INCH Lbs. (N.m)
Front Engine Wiring Harness Bolts .............................. 106 (12)
TCS Upper Bracket Bolts .......................................... 106 (12)
Timing Belt Cover Bolts ................................................ 106 (12)
22 ACURA
*3.5L V6 3.5RL
TIMING BELT APPLICATION If timing belt is to be reused, mark direction of rotation be-
fore removing. Loosen timing belt adjusting bolt 1/2 turn,
Application Labor Time Belt Part No. push tensioner to remove tension from timing belt, then
3.5L V6 (C35A1) retighten bolt. Remove timing belt.
3.5RL
1996-01 CAUTION: DO NOT rotate crankshaft pulley or camshaft pulley
with timing belt removed. Pistons may hit valves and cause damage.
Balancer ..................... 1 ............................ T280
Camshaft ............ 3.6 Hours ..................... T279
NOTE: Ensure water pump turns freely in clockwise direction
1 -
Balancer belt labor included in camshaft belt and there are no leaks.
labor time.
Installation
Remove spark plugs. Remove balancer belt drive pulley.
MANUFACTURERS SUGGESTED Noting installed position, remove timing belt guide plate
SCHEDULED MAINTENANCE from end of crankshaft. Ensure timing belt drive pulley is
set so that No. 1 piston is at TDC. Align TDC mark on timing
For 1996 model year, manufacturer recommends belt be re- belt drive pulley with pointer on oil pump. See Fig. 4.
placed at 90,000 miles for normal service and 60,000 miles Set camshaft pulleys so that No. 1 piston is at TDC. Align
on severe service. For 1997-01 model years, normal replace- TDC marks on camshaft pulleys to pointers on back cov-
ment interval is at 105,000 miles or 84 months. Replace at ers. See Fig. 5. Install timing belt, in sequence, on timing
60,000 miles if car is regularly driven in extreme temperatures belt drive pulley, adjusting pulley, left camshaft pulley, water
(over 110 degrees F, or under -20 degrees F). pump pulley, and right camshaft pulley. See Fig. 6. Ensure
camshaft and crankshaft pulleys remain at TDC. Loosen
*NOTE: This application is an interference engine. and retighten timing belt adjusting bolt. Install lower cover
See page A-59 for interference engine cautions. and crankshaft pulley.
To set timing belt tension, rotate crankshaft pulley about 5
NOTE: Some vehicles may be equipped with radio/cassette or or 6 turns clockwise. Set No. 1 piston at TDC of compres-
radio/CD players that contain anti-theft protection circuit. When sion stroke. White mark on crankshaft pulley must be
battery is disconnected, radio will go into anti-theft mode. When aligned with pointer on lower cover. See Fig. 3. Rotate
battery is reconnected, radio will display CODE and will be inoperative crankshaft clockwise 10 teeth on camshaft pulley. Blue
until proper code is entered by vehicle owner mark on crankshaft pulley should align with pointer on lower
cover. Loosen timing belt adjusting bolt 180 degrees.
Tighten adjusting bolt to specification.
REMOVAL & INSTALLATION Remove crankshaft pulley and lower cover. Install timing
TIMING BELT belt guide plate and balancer belt drive pulley on crank-
shaft. Ensure guide plate is installed in correction direc-
Removal tion. See Fig. 1.
Remove negative battery cable. Turn crankshaft until No. 1 Remove 12mm sealing bolt from side of engine block. See
piston is at TDC of compression stroke. Remove engine Fig. 7. Align maintenance hole and balancer shaft hole.
cover, intake air duct, and air cleaner assembly. Insert a 6mm bolt into sealing bolt hole. Ensure balancer
Loosen alternator mounting bolt, lock bolt and adjusting belt pulley pointer aligns with pointer on balancer gear case.
rod, then remove alternator belt. Loosen idler pulley center See Fig. 8.
nut and adjuster bolt. Remove A/C belt. Remove Traction Set timing belt drive pulley to TDC. Install balancer belt
Control System (TCS) control valve upper and lower brack- pulley. Install balancer belt. Loosen and retighten balancer
ets. See Fig. 2. Loosen adjusting bolt, locknut and mount- belt adjusting bolt to tension balancer belt. Remove 6 mm
ing bolt, then remove power steering pump belt. bolt. Install sealing bolt in maintenance hole, using new
Disconnect TCS throttle sensor connector, TCS throttle ac- washer.
tuator connector and throttle position sensor connector. Re- Install crankshaft pulley. Rotate crankshaft pulley about 5
move TCS control valve assembly. Disconnect vehicle or 6 turns clockwise to position balancer belt on pulleys.
speed sensor sub-harness connector, then remove wire Loosen balancer belt adjusting bolt 180 degrees. Tighten
harness holder. balancer belt adjusting bolt to specification.
Remove crankcase breather hose and vacuum hoses from Remove crankshaft pulley. Install upper and lower covers,
front of right upper cover. Remove ignition control module then install crankshaft pulley. Ensure crankshaft pulley and
bracket from right upper cover. Remove idler pulley bracket, camshaft pulley are at TDC. Remove inspection plugs in
dipstick, and dipstick tube. Remove crankshaft pulley. See upper camshaft covers to check pulley alignment.
Fig. 1. To complete installation, reverse removal procedure. Coat
Remove upper and lower covers, loosen balancer belt ad- threads of crankshaft pulley bolt with oil before installation.
justing bolt 1/2 turn and push tensioner to remove tension Tighten all fasteners to specification. See TORQUE SPECI-
from balancer belt, then retighten bolt. Remove balancer FICATIONS. Adjust drive belts to proper tension. See page
belt. A-60 for belt tension ranges.
ACURA 23
*3.5L V6 3.5RL (Cont.)

Balancer Belt Tension Adjusting Bolt .......................... 33 (44)
Dipstick Tube/Idler Pulley Bolt ........................................ 16 (22)
Engine Sealing Bolt (12mm) .......................................... 14 (20)
TCS Lower Bracket Bolts ............................................ 16 (22)
Water Pump Bolt (8 x 1.25 mm) ..................................... 16 (22)
INCH Lbs. (N.m)
Engine Cover Bolts/Nuts ............................................ 89 (10)
TCS Upper Bracket Bolts .......................................... 106 (12)
Water Pump Bolt (6 x 1.0 mm) .................................. 106 (12)
Fig. 2: Locating TCS Control Valve & Connectors
24 ACURA
*3.5L V6 3.5RL (Cont.)
Fig. 3: Aligning Timing Marks (TDC)
Fig. 5: Aligning Camshaft Pulleys

Fig. 4: Aligning Timing Belt Drive Pulley

ACURA 25
*3.5L V6 3.5RL (Cont.)
Courtesy of American Honda Motor Co., Inc. Courtesy of American Honda Motor Co., Inc.
Fig. 6: Timing Belt Installation Sequence Fig. 8: Aligning Balancer Shaft Marks
Fig. 7: Installing Balancer Shaft Lock Bolt

26 ACURA
3.5L V6 DOHC, SLX
3.5L V6 DOHC
SLX
1998-99 ................. 2.4 Hours ..................... T303
Normal replacement interval is at 75,000 miles for 1998-99
model years.
TIMING BELT Fig. 2: Aligning Crankshaft Timing Marks (All Models)
Removal:
Disconnect negative battery cable. Remove air cleaner as- NOTE: For correct timing belt installation, lettering on belt must
sembly. Remove upper fan shroud. Remove serpentine be able to be read as viewed from the front of the vehicle. Also,
note arrow on belt which indicates direction of rotation.
drive belt.
Remove cooling fan and drive pulley. Remove serpentine Installation:
drive belt idler pulley assembly. Remove serpentine drive Align grove on crankshaft sprocket with mark on oil pump.
belt tensioner assembly. See Fig. 2. Install timing belt on crankshaft pulley, aligning
Remove power steering pump with hoses attached, and White dotted line on belt with timing mark on crankshaft
set aside. Remove crankshaft pulley bolt. Using Puller (J- pulley. Secure belt to sprocket with spring clip.
8614-01) or equivalent, remove crankshaft pulley. Align timing mark on right hand (passenger side) cam-
Remove timing belt covers. Rotate crankshaft to align tim- shaft sprocket with alignment mark on valve cover. See Fig.
ing marks. See Figs. 1 and 2. When timing marks are 3. Install timing belt on right hand camshaft sprocket, align-
aligned, No. 2 piston will be at TDC. ing the White alignment mark on timing belt with camshaft
If reusing timing belt, mark belt with arrow to indicate origi- sprocket mark. If reusing old timing belt, align mating marks
nal rotation direction. Also place mating marks on timing on belt and camshaft sprocket that were made during re-
belt and camshaft sprockets for reassembly reference. Re- moval. Secure belt with spring clip.
move timing belt tensioner, and set aside with push rod Align timing mark on left hand (driver side) camshaft
facing up. Remove timing belt. sprocket with alignment mark on valve cover. See Fig. 4.
Route timing belt around water pump pulley and install on
CAUTION: To prevent air from entering timing belt tensioner, other left hand camshaft sprocket, aligning the White align-
tensioner rod must always face up. ment mark on timing belt with camshaft sprocket mark.
Install pinch clip to hold belt on sprocket. Ensure there is
no slack in belt between camshaft pulleys.
Install timing belt around idler pulley and tensioner pulley.
Temporarily install crankshaft pulley. Turn pulley clockwise
slightly to give some belt slack between the crankshaft
sprocket and right hand camshaft sprocket.
NOTE: It will take about 220 lbs. (100 kg) to compress timing belt
tensioner rod.
Holding tensioner upright, SLOWLY compress timing belt
tensioner rod until hole in top of rod and holes in housing
are aligned. Install a locking pin through the holes. See
Fig. 5.
Install tensioner on engine with locking pin in place. Tighten
bolts to specification. See TORQUE SPECIFICATIONS.
Remove locking pin from timing belt tensioner. Remove
clips from camshaft and crankshaft sprockets.
Courtesy of Isuzu Motor Co.
Rotate crankshaft 2 turns clockwise. Ensure timing marks
Fig. 1: Aligning Camshaft Timing Marks are still aligned.
Remove crankshaft pulley and install timing belt covers.
Ensure rubber sealing bushings are installed on timing
belt cover bolts. See Fig. 6.
ACURA 27
3.5L V6 DOHC, SLX (Cont.)
Courtesy of American Honda Motor Co.

Fig. 3: Installing Timing Belt on Right Hand Camshaft Courtesy of American Honda Motor Co.
Sprocket Fig. 5: Installing Locking Pin in Timing Belt Tensioner

Fig. 6: Installing Timing Belt Cover Bushings

Fig. 4: Installing Timing Belt on Right Hand Camshaft
Sprocket
Install crankshaft pulley. Tighten center bolt to specifica-

tion. Install cooling fan pulley. Install power steering pump.
Install cooling fan. Install serpentine drive belt idler pulley
and tensioner assemblies. Install radiator fan shroud. Con-
nect battery.
Camshaft Sprocket Bolt .............................................. 72 (98)
Cooling Fan Pulley Bolt .............................................. 16 (22)
Power Steering Pump Bolt
M8 Bolt ......................................................................... 16 (22)
M10 ............................................................................. 34 (46)
Timing Belt 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)
28 ACURA & HONDA
3.2L V6 SOHC
3.2L V6 SOHC
Passport
1994-97 ................ 1 2.8 Hours .................... T221
SLX
1996-97 ................ 1 2.8 Hours .................... T221
1
With Pwr. Strng. add .3 hours.
The manufacturer recommends the belt be replaced every Fig. 1: Aligning Camshaft Timing Marks
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove air cleaner as-
sembly. Remove upper fan shroud. Remove cooling fan
assembly. Remove all accessory drive belts.
Remove fan pulley assembly. Remove crankshaft pulley
bolt. Using Puller (J-8614-01) or equivalent, remove crank-
shaft pulley. Remove oil cooler hose from timing cover. Re-
move timing belt cover. Align all timing marks prior to belt
removal. See Figs. 1 and 2. Remove belt tensioner pusher
and timing belt.
Installation:
Ensuring all timing marks are aligned. Install belt over one Fig. 2: Aligning Crankshaft Timing Marks
pulley at a time starting at crankshaft sprocket working coun-
terclockwise. Belt should go over tensioner last. Secure
belt at each pulley during installation with pinch clips. See
Fig. 3.
CAUTION: To ensure correct timing belt installation, ensure

direction of rotation arrows are pointing in proper direction.
If timing belt is being reused, install belt in original direction
of rotation.
Compress timing belt tensioner pusher and insert pin to
retain pusher. Apply pressure to tensioner against belt and
install tensioner pusher. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.
Loosen tensioner pulley bolt. Apply pressure on belt by
rotating tensioner. Tighten tensioner pulley bolt to specifi-
cation. Remove pin from timing belt tensioner pusher.
Remove pinch clips from timing belt, (if used). Install crank-
shaft pulley, tightening center bolt finger tight. Rotate crank-
shaft 2 turns clockwise. Ensure timing belt tensioner pusher
rod protrudes proper amount. See Fig. 4.
If timing belt tensioner pusher rod protrusion is not within
specification, remove pusher, loosen tensioner pulley bolt Fig. 3: Installing Pinch Clip On Timing Belt
and readjust. Reset timing belt tensioner pusher rod and
repeat timing belt tensioning procedure. Remove crank-
shaft pulley and install timing belt cover. To complete in-
stallation, reverse removal procedure. Tighten nuts and
bolts to specification. See TORQUE SPECIFICATIONS. Ad-
just drive belts to proper tension. See page A-60 for belt
tension ranges.
ACURA & HONDA 29
3.2L V6 SOHC (Cont.)
Fig. 4: Adjusting Timing Belt Tensioner Pusher
Fan Pulley Bolt ............................................................ 16 (22)
Front Plate Bolt ........................................................... 14 (19)
Idler Arm Retaining Bolt .............................................. 33 (44)
Power Steering Pump Bolt .......................................... 34 (46)
Timing Belt Tensioner Pulley Bolt ............................... 32 (43)
Timing Belt Tensioner Pusher Bolt ............................. 14 (19)
Fig. 5: Exploded View Of Cylinder Head Components
Upper Intake Manifold Bolt .......................................... 18 (24)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt ........................................ 87 (10)
Cooling Fan Assembly Nut ........................................... 69 (8)
30 ALFA ROMEO
3.0L V6
TIMING BELT APPLICATION Turn crankshaft in normal direction of rotation 2-3 revolu-
tions to seat timing belt. Keep timing belt under tension
Application Labor Time Belt Part No. and push hydraulic tension pulley against timing belt.
3.0L V6 Tighten 2 tensioner retaining nuts. Slightly lift belt tensioner
164 arm, then release tensioner arm, by removing tool holding
1991-93 .............. 4.8 Hours .................... T120 arm in position.
Position No. 1 cylinder at TDC compression stroke. En-
MANUFACTURERS SUGGESTED sure crankshaft and camshaft timing marks are aligned. If
SCHEDULED MAINTENANCE timing marks are not aligned, timing belt must be removed
and repositioned. Install spark plugs. Install timing belt
The manufacturer recommends the belt be replaced every covers.
50,000 miles. On models with heat exchanger, connect oil cooler tubes.
On all models, connect coolant hose to thermostat unit,
REMOVAL & INSTALLATION and return hose to water pump. Plug in coolant switch and
sensor electrical connectors. Install left side valve cover
TIMING BELT and gasket.
Removal: Connect spark plug wires for cylinders No. 4, No. 5, and
Disconnect negative battery cable. Raise and support ve- No. 6. Install right side valve cover and gasket. Install in-
hicle. Remove right front wheel. Remove right front inner take ducts and gaskets. Connect spark plug wires for cylin-
fenders. Disconnect throttle opening switch electrical con- ders No. 1, No. 2, and No. 3. Install air intake box. Connect
nector. Remove throttle body cover. ground strap to air intake box. Connect fuel pressure regu-
Remove water pump, air conditioning, and power steering lator and power brake unit vacuum hoses. Connect fuel
drive belts. Remove hydraulic belt tensioner. Disconnect vapor and cruise control hoses.
crankshaft position sensor connector, and remove sensor. On S models, connect engine throttle sensor electrical con-
Disconnect constant idle speed actuator electrical connec- nector. Connect accelerator cable. On models with auto-
tor. Disconnect oil vapor separator hoses. matic transmission, connect kickdown cable. Install throttle
Disconnect accelerator cable. On model equipped with au- body cover. Connect throttle body switch electrical connec-
tomatic transmission, disconnect kickdown cable. On S tor.
models, disconnect engine throttle sensor electrical con- Connect oil vapor separator hoses. Connect constant idle
nector. On all models, disconnect fuel vapor and cruise speed actuator electrical connector. Install crankshaft po-
control hoses. sition sensor and electrical connector. Install hydraulic drive
Disconnect fuel pressure regulator and power brake unit belt tensioner. Install power steering pump, A/C compres-
vacuum hoses. Disconnect ground strap from air intake sor, and water pump drive belts.
box. Remove air intake box attaching screws and clamps, Install front right inner fenders. Install right front wheel and
and remove air intake box. tire assembly, then lower vehicle. Connect negative cable.
Disconnect spark plug wires for cylinders No. 1, No. 2, and Adjujst accessory drive belt tension. See page A-60 for belt
No. 3. Remove intake ducts and gaskets. Remove right tension ranges.
valve cover and gasket. Disconnect spark plug wires for
No. 4, No. 5, and No. 6. Remove left side valve cover and
gasket.
Partially drain cooling system. Disconnect coolant hose
from thermostat unit. Disconnect return hose from water
pump. Disconnect coolant temperature switch and sensor
electrical connectors. If equipped, disconnect oil cooling
tubes from heat exchanger.
Remove timing belt covers. Remove spark plugs Rotate
crankshaft so No. 1 cylinder is at TDC of compression
stroke. Flywheel and transmission housing timing marks
should align. See Fig. 1. Camshaft sprocket timing marks
should align with bearing cap marks. See Fig. 2.
Lift belt tensioner arm from timing belt. Insert Holding Tool
(1.820.053.00) or equivalent into hole on arm to lock in
position. Loosen hydraulic belt tensioner retaining nuts.
Push tensioner downward to limit of travel, and tighten up-
per retaining nut. Remove timing belt.
Installation:
Position Adapter (1.825.007.000) or equivalent, and a dial
indicator into No. 1 cylinder spark plug hole. See Fig. 2.
Ensure camshaft and crankshaft timing marks align.
Install timing belt over crankshaft sprocket, left camshaft
sprocket, right camshaft sprocket, and oil pump sprocket
hydraulic belt tensioner pulley. See Fig. 3. Maintain tension
on timing belt during installation. Loosen timing belt hy-
draulic tensioner upper retaining nut. Fig. 1: Identifying Flywheel Timing Marks
ALFA ROMEO 31
3.0L V6 (Cont.)
Fig. 2: Identifying Camshaft Timing Marks

32 AMERICAN MOTORS
2.0L 4-Cylinder
Belt
Labor Component Part
Application Time 1 Kit No. No.
2.0L 4-Cyl.
Concord & Gremlin
1977-78 .......... 1.5 Hrs. ...... TCK017 .......... T017
Concord & Spirit
1979 ............... 1.5 Hrs. ...... TCK017 ......... T017
1
- With Air Cond. add .2 hours
NOTE: A timing belt component kit is available for

this application. See page I for information on component
kits.
MANUFACTURERS SUGGESTED Fig. 1: Aligning Timing Marks


TIMING BELT
Removal:
Disconnect negative battery cable. Rotate engine until tim-
ing mark (notch) on crankshaft is pointing to zero. Cam-
shaft sprocket timing mark should now be adjacent to
pointer on cylinder head cover. See Fig. 1.
NOTE: Rotate engine by turning crankshaft. Do not turn engine

by camshaft.
Loosen front pulley retaining screws. Remove alternator
and power steering drive belts. Remove cam drive belt
shield.
Mark rotation of belt rotation before removal. Loosen
tensioner retaining screw and remove camshaft drive belt.
See Fig. 2.
Installation:
Mount belt onto crankshaft sprocket. Position belt in
tensioning pulley groove and install belt to camshaft
sprocket. See Fig. 2.
NOTE: Use hands to install belt. DO NOT pry with tool.

Turn offset adjusting nut on tensioning pulley clockwise to
tighten belt tension. When belt can be twisted 90 with thumb
and forefinger, belt is properly tensioned.
Fig. 2: Timing Belt & Components
CAUTION: Excessive tension may cause pulley to fail.
Reverse removal procedure to complete installation. Ad-
just drive belts to proper tension. See page A-60 for belt Application Ft. Lbs. (N.m)
tension ranges. Camshaft Belt Tensioning Idler Screw ....................... 29 (39)
Camshaft Sprocket Screw .......................................... 58 (78)
Crankshaft Sprocket Screw .................................... 181 (123)
Water Pump Screw (Large) ....................................... 16 (21)
INCH Lbs. (N.m)
Camshaft Rear Bearing Cap Screw ........................... 84 (10)
Water Pump Screw (Small) ....................................... 84 (10)
AUDI 33
1.6L 4-Cylinder Diesel

Application Labor Time Belt Part No. Application Ft. Lbs. (N.m)
1.6L 4-Cyl. Camshaft Sprocket Bolt .............................................. 33 (45)
Crankshaft Pulley/Damper
4000 Standard ............................................................... 108 (150)
Diesel Turbo .................................................................... 145 (200)
1982-83 .............. 2.3 Hours .................... T043 Injection Pump Sprocket ............................................. 33 (45)
Intermediate Shaft Pulley ............................................ 33 (45)
MANUFACTURERS SUGGESTED Timing Belt Tensioner ................................................ 33 (45)
the belt be replaced at 60,000 mile intervals.

TIMING BELT & SPROCKET
Removal:
Disconnect negative battery cable. Remove accessory drive
belts. Remove timing belt cover and camshaft cover. Turn
crankshaft to place No. 1 piston on TDC at end of compres-
sion stroke. Lobes of camshaft on No. 1 cylinder must point
upward.
Secure camshaft in place by installing Setting Bar (2065)
at rear of camshaft. Tool must be properly installed to pre-
vent camshaft from moving. See Fig. 1.
Insert pin tool (2064) through small cutout in injection pump Fig. 1: Camshaft Locking Tool Installation
sprocket to lock sprocket in place. Injection pump sprocket
must not be allowed to move.
Check that timing marks on injection pump sprocket, pump
body and mounting plate are aligned. Check that TDC mark
on flywheel is aligned with reference mark on bell housing.
Loosen timing belt tensioner to relieve tension on timing
belt. Remove crankshaft pulley. Do not allow crankshaft to
turn. Remove timing belt.
Installation:
Check that TDC mark on flywheel is still aligned with refer-
ence mark. Loosen camshaft sprocket bolt 1/2 turn. Loosen
sprocket from camshaft by tapping with a rubber mallet.
Install timing belt. Tighten camshaft sprocket bolt. Remove
pin tool from injection pump sprocket. Apply tension to belt
by turning timing belt tensioner to right.
Using Tension Gauge (210), check timing belt tension mid-
way between camshaft and injection pump sprockets. Ten-
sion is correct if gauge reads 12-13. See Fig. 2.
Turn crankshaft clockwise 2 turns. Strike timing belt with a
rubber mallet midway between camshaft sprocket and in-
jection pump sprocket. Using Tension Gauge (210), re-
check timing belt tension. Fig. 2: Timing Belt Tension Tool Installation
If necessary, readjust timing belt tension. Check injection
pump timing. Install remaining components in reverse or
der of removal. Adjust drive belts to proper tension. See
34 AUDI
1.6L & 1.7L 4-Cylinder
Belt
Application Time Kit No. No.
1.6L 4-Cyl.
Fox
1973-79 .......... 1.1 Hrs. ...... TCK017 .......... T017
1.7L 4-Cyl.
4000
1980-83 .......... 1.1 Hrs. ...... TCK017 .......... T017

kits.
Fig. 2: Aligning Timing Marks (1.6L)

TIMING BELT
Removal:
Disconnect negative battery cable. Ensure No. 1 piston is
at TDC on compression stroke and that crankshaft pulley
notch is aligned with sprocket mark at TDC pointer. See
Fig. 2. Remove radiator grille. Remove accessory drive belts.
Remove water pump pulley. Remove camshaft belt guard.
Loosen mounting nut of camshaft belt tensioner arm and
remove tension from belt. Slide belt forward off camshaft
sprocket.
Installation:
Install new belt and adjust tensioner arm until belt can be
turned 90 with thumb and index finger at a point midway
between camshaft sprocket and intermediate sprocket.
Check valve timing. To complete installation, reverse re-
moval procedure. Adjust drive belts to proper tension. See
page A-60 for belt tension rannges
Fig. 3: Exploded View Of Timing Belt & Components (1.7L)
Fig. 4: Aligning Camshaft Sprocket With Upper Edge Of

Fig. 1: Adjusting Timing Belt Tension (1.7L) Gasket (1.7L)
AUDI 35
1.6L & 1.7L 4-Cylinder (Cont.)

Camshaft Sprocket ..................................................... 58 (80)
Crankshaft Drive Belt Sprocket ................................... 58 (80)
Crankshaft V Belt Pulley ........................................... 14 (20)
Drive Belt Tension Nut ................................................ 33 (45)
Intermediate Shaft Sprocket ....................................... 58 (80)
36 AUDI
*1.8L 4-Cylinder 1984-87
Belt Application Ft. Lbs. (N.m)
Labor Component Part Camshaft Sprocket Bolt
Application Time Kit No. 8-Valve ...................................................................... 58 (80)
16-Valve .................................................................... 48 (65)
1.8L 4-Cyl. Crankshaft Pulley Nut ................................................. 14 (20)
4000S Crankshaft Sprocket Bolt ........................................ 148 (200)
1984-87 ........ 1.1 Hrs. ...... TCK017 .......... T017 Intermediate Shaft Sprocket Bolt
8-Valve ...................................................................... 58 (80)
NOTE: A timing belt component kit is available for 16-Valve .................................................................... 48 (65)
Timing Belt Tensioner Nut .......................................... 33 (45)
kits.
MANFACTURERS SUGGESTED
Although the manufacturer does not recommend a specified
scheduled maintenance, belt manufacturers suggest the belt
be replaced at 60,000 mile intervals.

See page ,,,, for interference engine cautions.

TIMING BELT
CAUTION: Never use camshaft sprocket attaching bolt to turn
engine as timing belt could be stretched.
Removal:
Disconnect negative battery cable. Loosen alternator ad-
justing bolts. Remove all drive belts. Remove water pump
pulley, crankshaft pulley, and vibration damper. Remove Fig. 1: 16-Valve Timing Belt Cover & Timing Belt Assembly
upper and lower timing belt outer covers. On 16-valve en-
gine, remove upper half of intake manifold.
On all models, remove camshaft cover from cylinder head.
Turn crankshaft to position No. 1 piston at TDC of com-
pression stroke. Make sure distributor housing and flywheel
timing marks are correctly aligned.
Loosen timing belt tensioner to relieve tension on timing belt.
See Fig. 1. Slide timing belt off intermediate shaft sprockets.
Installation:
Set crankshaft at point just before TDC compression for
No. 1 cylinder. Place timing belt on crankshaft and interme-
diate shaft sprockets. Install crankshaft pulley and tighten
all 4 bolts. Align mark on crankshaft pulley with mark on
intermediate shaft sprocket at TDC. See Fig. 2.
Position camshaft so mark on back of sprocket is in line
with upper edge of timing belt rear cover. See Fig. 3. Both
lobes for No. 1 cylinder should point upward at 45 degrees
from camshaft follower so both valves are closed. Install Fig. 2: Aligning Intermediate Shaft & Crankshaft
timing belt on camshaft sprocket.
Adjust timing belt tension by turning tensioner adjusting
hex clockwise against belt. Make sure shaft timing marks
have not moved. Tighten tensioner lock nut and check ten-
sion of timing belt at point midway between camshaft
sprocket and intermediate sprocket. See Fig. 4.
Belt has correct tension when it can be twisted 90 degrees
with thumb and finger pressure. Rotate engine by hand
through 2 revolutions in clockwise direction. Check all tim-
ing marks. To complete installation, reverse removal proce
dure. Adjust drive belts to proper tension. See page A-60 for
belt tension ranges.
AUDI 37
*1.8L 4-Cylinder 1984-87 (Cont.)
Fig. 3: Setting Camshaft Timing Marks Fig. 4: Adjusting Timing Belt Tension
38 AUDI
*1.8L 4-Cylinder Turbo A4 & A4 Quattro
1.8L 4-Cylinder Turbo
A4 & A4 Quattro
1997-99 ............... 3.5 Hours ..................... T291
The manufacturer suggests the belt be replaced at 90,000
mile intervals.


TIMING BELT Courtesy of Audi of America, Inc.
Removal Fig. 1: Aligning Timing Marks

Remove complete front bumper assembly. Remove en-
gine undercover. Remove air intake duct from air filter hous-
ing. Disconnect all necessary electrical connectors from
front of vehicle.
Install Lock Carrier Support Tool (3369) through lock car-
rier to chassis. See Figs. 4 and 5. Remove lock carrier
support bolts securing lock carrier to vehicle. Slide lock
carrier forward onto support tool. This will allow servicing
of front engine components.
Remove serpentine drive belts. Remove serpentine drive
belt tensioner. Remove viscous fan clutch and pulley as-
sembly. Viscous fan pulley is secured by one Allen-head
bolt. Allen-head bolt is removed from rear of pulley, through
access hole in accessory mount bracket.
CAUTION: Crankshaft center bolt is torque-to-yield type. Manufacturer

recommends replacing bolt if it is loosened or removed.
Courtesy of Audi of America, Inc.
Remove upper timing belt cover. Rotate crankshaft by hand Fig. 2: Identifying Tensioner Pistons
to Top Dead Center (TDC). See Fig. 1. Remove crankshaft
vibration damper pulley. It is NOT necessary to remove
crankshaft center bolt. Remove lower timing belt cover.
Mark timing belt running direction. Using Torx T45 bit, loosen
timing belt tensioner. Push timing belt tensioner down and
remove timing belt.
CAUTION: To prevent pistons from hitting valves, make sure crankshaft

is NOT at TDC for any piston before turning camshaft.
Installation
Align mark on camshaft sprocket with mark on cylinder
head cover and/or timing belt guard. See Fig. 1. Install tim-
ing belt on crankshaft sprocket. Install lower timing belt
cover. Install vibration damper pulley and tighten bolts to
specification. See TORQUE SPECIFICATIONS.
Ensure crankshaft vibration damper is correctly aligned to
lower timing belt cover. See Fig. 1.
Install timing belt on the tensioner and camshaft sprocket.
To tension timing belt, use spanner wrench to rotate
tensioner pulley clockwise until tensioner piston No. 1 is Courtesy of Audi of America, Inc.
fully extended, and piston No. 2 lifts about .040 (1 mm). Fig. 3: Identifying Tensioner Dimensions
See Fig. 2.
Tighten tensioner pulley bolt to specification. See TORQUE
SPECIFICATIONS. Rotate crankshaft 2 revolutions in nor-
mal direction of rotation. Make sure camshaft and crank-
shaft timing marks are aligned.
AUDI 39
*1.8L 4-Cylinder Turbo A4 & A4 Quattro (Cont.)

Fig. 6: Positioning Lock Carrier Assembly Torx Bolts
Belt tension is correct if edge of tensioner lever aligns with

piston upper edge (Area A), or piston No. 1 is extended
0.98-1.14 (25-29 mm) (dimension D). See Fig. 3. Check
for wear in Areas B and C.
Install upper timing belt cover. Install serpentine drive belt
tensioner and belt. To complete installation, reverse re-
moval procedure. Ensure lock carrier Torx bolts are in-
stalled in correct position. See Fig. 6.
Fig. 4: Exploded View Of A4 Lock Carrier Assembly
Crankshaft Sprocket Center Bolt 1
Step 1 ....................................................................... 66 (90)
Step 2 ..................................................... Additional 1/4 Turn
Lock Carrier-To-Body Bolts ............................................ 33 (45)
Lower Timing Belt Cover-To-Engine
M6 .............................................................................. 7 (10)
M8 ............................................................................ 15 (20)
Serpentine Belt Tensioner Bolt ....................................... 18 (25)
Timing Belt Idler Pulley Bolt ............................................ 18 (25)
Vibration Damper Pulley Bolts 2 .................................................................. 30 (40)
Viscous Cooling Fan Pulley Bolt .................................... 33 (45)
INCH Lbs. (N.m)
Lock Carrier-To-Body Torx bolts ...................................... 89 (10)
Timing Belt Tensioner Bottom Bolt ................................. 89 (10)
Water Pump Bolt ............................................................ 89 (10)
1
REPLACE torque-to-yield bolt if loosened or removed.
2
Bolt strength grade is 10.9.
Fig. 5: Positioning Lock Carrier Support Tool (3369)
40 AUDI
*1.8L 4-Cylinder Turbo TT
1.8L 4-Cylinder Turbo (AMU, ATC & AWP)
TT Coupe & Roadster
2000 ...................... 3.5 Hours ..................... T306
NOTE: Engine code is located on machined pad on bellhousing

flange, where engine connects to transaxle.
mile intervals.


TIMING BELT
Removal
Disconnect charge air cooler duct at bottom of right-hand
crossmember (if equipped). See Fig. 2. Remove center
and right-hand noise insulation panels from under vehicle. Courtesy of Audi of America, Inc.
See Fig. 3. Fig. 1: Exploded View Of Timing Belt Components

Remove serpentine drive belt and tensioner. See Fig. 4.
Rotate tensioner clockwise (as viewed from front of en-
gine) to relieve belt tension.
Remove cooling system expansion tank and power steer-
ing reservoir bolts. Keeping hoses attached, secure ex-
pansion tank and reservoir out of way.
Rotate crankshaft by hand to Top Dead Center (TDC). See
Fig. 1. Remove crankshaft vibration damper pulley. Remove
lower timing belt cover. Remove vacuum hose connecting
fuel evaporative canister to throttle body.
Unplug electrical connectors on coolant expansion tank
and fuel evaporative canister. Remove upper timing belt
cover.
Remove weight of engine from engine mounts by installing
Support Bracket (10-222) or equivalent. Engine may be sup-
ported from below using floor jack.
Turn crankshaft sprocket center bolt in normal direction of
rotation to align the crankshaft vibration damper at TDC of
No. 1 cylinder. Ensure camshaft sprocket timing mark is
aligned with mark on rear timing belt cover. See Fig. 5. Courtesy of Audi of America, Inc.
Fig. 2: Identifying Air Duct (ATC & AWP Engines)
NOTE: Crankshaft sprocket center bolt is a torque-to-yield type.
If removed, manufacturer recommends replacing the bolt. Remove bolts for engine support, but do not remove en-
Remove 4 bolts around center bolt on vibration damper. gine support. See Fig. 7. If reusing old timing belt, mark
Remove vibration damper. It is NOT necessary to remove belt with arrow to indicate original direction of rotation.
crankshaft center bolt. Do NOT move crankshaft. Screw a M5 x 55 stud into the timing belt tensioner bracket.
See Fig. 8. Install hex nut and washer onto stud.
NOTE: Engine console and right-hand engine support bolts are SLOWLY turn hex nut on stud to compress timing belt
torque-to-yield type. Manufacturer recommends replacing the tensioner. Compress tensioner just enough so that a lock-
bolts if they are removed. ing pin or drill bit can be inserted through the tensioner
body, locking the tensioner in place. Remove timing belt.
Remove center and bottom timing belt covers. Remove
bolts from engine console and right-hand engine support CAUTION: To prevent engine damage, do NOT turn camshaft
arm. See Fig. 6. Remove engine console and right-hand while the crankshaft is a TDC.
engine support arm.
AUDI 41
*1.8L 4-Cylinder Turbo TT (Cont.)
Fig. 3: Identifying Noise Insulation Panels

Fig. 6: Identifying Right-Hand Engine Support Arm
Fig. 4: Identifying Serpentine Belt & Tensioner

Fig. 7: Identifying Right-Hand Engine Support
42 AUDI
*1.8L 4-Cylinder Turbo TT (Cont.)
Installation Remove engine Support Bracket (10-222) or floor jack from
Install timing belt onto crankshaft sprocket. Install lower under vehicle. Install center and upper timing belt covers.
timing belt cover. Install vibration damper pulley, making Install serpentine belt tensioner and serpentine belt.
sure notch in center hole of vibration damper is aligned Install coolant expansion tank and power steering reser-
with projection on crankshaft sprocket. Tighten bolts to voir. Install vacuum line between fuel evaporative canister
specification. See TORQUE SPECIFICATIONS table. and throttle body. To install remaining components, reverse
Ensure camshaft and crankshaft timing marks are still removal procedure.
aligned. See Fig. 5. Install timing belt on water pump, TORQUE SPECIFICATIONS
tensioner pulley and camshaft sprocket.
Remove locking pin or drill bit from timing belt tensioner. Application Ft. Lbs. (N.m)
Remove M5 x 55 stud from tensioner bracket. Turn crank- Camshaft Sprocket Bolt ................................................ 48 (65)
shaft 2 complete revolutions in normal direction of rotation. Crankshaft Sprocket Center Bolt 1
Align camshaft and crankshaft timing marks. Step 1 ....................................................................... 66 (90)
Install engine right-hand engine support arm and console Step 2 ..................................................... Additional 1/4 Turn
using NEW bolts. Adjust engine console and right-hand Engine Console-To-Body 1
engine support arm so clearance is about .50 (13 mm). Step 1 ....................................................................... 30 (40)
See Fig. 6. 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
Torque-to-yield type bolt. Manufacturer recommends
replacing bolt if it is removed.
Fig. 8: Compressing Timing Belt Tensioner

AUDI 43
2.0L 4-Cylinder
TIMING BELT APPLICATION REMOVAL & INSTALLATION
Belt TIMING BELT
Removal:
Application Time Kit No. No. Disconnect negative battery cable. Use exploded view to
2.0L 4-Cyl. locate components. See Fig. 1. Match mark all components
80 for reassembly reference. Place crankshaft at TDC with
1988-90 ......... 1.8 Hrs. ...... TCK017 .......... T017 No. 1 cylinder on compression stroke. Remove alternator
90 belt. Remove A/C and power steering belts (if equipped).
1988 ............... 1.8 Hrs. ...... TCK017 .......... T017 Remove upper timing belt cover. Remove water pump and
crankshaft pulleys. Remove lower timing belt cover. Re-
move timing belt.
NOTE: A timing belt component kit is available for Installation:
this application. See page I for information on component Align flywheel/flex plate 0 mark with pointer. Remove dis-
kits. tributor cap and check position of ignition rotor. Rotate in-
termediate shaft and position rotor at No. 1 cylinder mark
on housing. See Fig. 2. Install timing belt on crankshaft
MANUFACTURERS SUGGESTED and intermediate shaft gears.
SCHEDULED MAINTENANCE With intermediate shaft/ignition rotor positioned, rotate crank-
shaft and align mark on crankshaft pulley with mark on
Although the manufacturer does not recommend a specific sched-
intermediate shaft sprocket. Position camshaft sprocket
uled maintenance interval, belt manufacturers suggest the belt
mark even with base of valve cover. See Fig. 3. Install timing
belt on camshaft sprocket.
Rotate tensioner clockwise to tighten belt and install lock
nut. Proper tension is achieved when belt can be twisted
90 degrees. See Fig. 4. Rotate crankshaft 2 revolutions
and check timing mark alignment. To complete installa-
tion, reverse removal procedure. Adjust drive belts to proper
Crankshaft Pulley Nut ................................................... 5 (20)
Crankshaft Sprocket Bolt ........................................ 133 (180)
Timing Belt Tensioner Pulley Nut ............................... 33 (45)
Water Pump Pulley ..................................................... 15 (20)
INCH Lbs. (N.m)
Fig. 2: Aligning Distributor Rotor

44 AUDI
2.0L 4-Cylinder (Cont.)
Fig. 4: Checking Proper Belt Tension

AUDI 45
*2.0L 5-Cylinder Diesel & Turbo Diesel

TIMING BELT APPLICATION Using tension tester (VW210), check timing belt tension
midway between camshaft and water pump sprockets. Ten-
Application Labor Time Belt Part No. sion is correct when tester reads 12-13.
2.0L 5-Cyl. Diesel Check that crankshaft and injection pump timing marks
5000 are still aligned. Tighten camshaft sprocket bolt and re-
1979-83 move camshaft holding tool.
Camshaft ............ 2.6 Hours ..................... T083 Install injection pump sprocket, drive belt and inner pulley
half. Tighten injection pump drive sprocket retaining bolt
Inject. Pump ....... 1.1 Hours ..................... T082 until it is just possible to turn sprocket on camshaft by hand.
2.0L 5-Cyl. Turbo Diesel Adjust fuel injection pump drive belt tension by loosening
5000 mounting bolts and reposition mounting plate and support
1979-83 on engine. Using tension tester (VW 210), check belt ten-
Camshaft ............ 2.6 Hours ..................... T083 sion midway between fuel injection pump and drive sprock-
Inject. Pump ........ 1.1 Hours ..................... T082 ets.
Tighten fuel injection pump drive sprocket bolt and remove
pin tool (2064) from injection pump sprocket. Install re-
MANUFACTURERS SUGGESTED maining components in reverse order of removal. Ensure
SCHEDULED MAINTENANCE valve timing and injection pump timing are correct. Adjust
Although the manufacturer does not recommend a specific drive belts to proper tension. See page A-60 for belt tension
scheduled maintenance interval, belt manufacturers suggest ranges.
the belt be replaced at 60,000 mile intervals. TORQUE SPECIFICATIONS
* NOTE: This application is an interference engine. Application Ft. Lbs. (N.m)

Camshaft Sprocket
See page A-59 for interference engine cautions. Front ......................................................................... 33 (45)
Rear ....................................................................... 72 (100)
REMOVAL & INSTALLATION Crankshaft Damper/Pulley (Locktite) ...................... 258 (350)
Water Pump Bolts ...................................................... 14 (20)
TIMING BELT & INJECTION PUMP BELT
Removal:
belts. Remove outer half of vacuum pump pulley. Remove
power steering pump with hoses connected, and position
aside. Remove attaching bolts and remove upper and lower
timing belt covers. Remove injection pump covers. Note
position and number of spacer washers on pulley.
Remove cam cover. Rotate crankshaft to position No. 1
cylinder at TDC. Timing marks on flywheel and clutch hous-
ing must be aligned. Also, timing marks on fuel injection
pump sprocket and pump mounting plate must be aligned.
Lock injection pump sprocket with pin tool (2064). Hold
inner half of vacuum pump pulley and injection pump drive
sprocket with tool (3036). Remove sprocket center retain-
ing bolt. Remove inner pulley half, pump sprocket and in-
jection pump drive belt.
Secure crankshaft from moving with support tool (2084).
Loosen crankshaft damper/pulley center bolt. Install cam-
shaft holding tool (2065A) at rear of camshaft.
With camshaft locked in place, loosen water pump bolts to
relieve tension on timing belt. Remove crankshaft pulley
with timing belt sprocket and timing belt.
Installation:
Ensure crankshaft and injection pump timing marks are Fig. 1: Camshaft Timing Belt Replacement
aligned. Install crankshaft damper/pulley with sprocket and
timing belt. Using tool (2084) to hold crankshaft, install and
tighten center bolt.
With camshaft still locked in place, loosen camshaft sprocket
bolt 1 full turn. Using a brass drift inserted through hole in rear
timing belt cover, tap camshaft sprocket loose from camshaft
taper.
Attach timing belt to camshaft sprocket. To adjust timing
belt tension, turn water pump until pump sprocket provides
tension against timing belt.
46 AUDI
*2.0L 5-Cylinder Diesel & Turbo Diesel (Cont.)
Fig. 2: Injection Pump Drive Belt Replacement

AUDI 47
2.3L 5-Cylinder Coupe Quattro

2.3L 5-Cyl.
Coupe Quattro
1990-91 ................. 1.8 Hours ..................... T197

TIMING BELT & COVER
Removal:
Disconnect negative battery cable. Remove upper radiator
cover. Remove drive belts. Remove power steering pump
with pressure hoses connected. Set pump aside. Remove
valve cover and outer timing belt covers.
Using crankshaft bolt, turn crankshaft clockwise to TDC of
No. 1 cylinder compression stroke. Align timing mark on
back of camshaft sprocket with upper edge of gasket. See
Fig. 2.
Loosen water pump adjusting bolts to relieve tension on
timing belt. Remove timing belt. Remove water pump to
check O ring. DO NOT allow crankshaft or camshaft to
move.
92A00398 Courtesy of Audi of America, Inc.

48 AUDI
2.3L 5-Cylinder Coupe Quattro (Cont.)
Installation:
Ensure both camshaft lobes on No. 1 cylinder point up-
ward. Mark (notch or dot) on back of camshaft sprocket
must be aligned with top of valve cover gasket or rear tim-
ing belt cover. Crankshaft must be at TDC for No. 1 cylinder.
Flywheel TDC mark must be aligned with index point on
transmission housing.
Install water pump with new sealing O ring. Install timing
belt. Turn water pump body counterclockwise to increase
belt tension. Tension is correct when belt can be twisted 90
degrees using finger pressure at point midway between
camshaft sprocket and water pump sprocket.
Recheck valve timing. Complete installation in reverse or-
der of removal. Adjust drive belts to proper tension. See
Timing Belt Idler Pulley Bolt ........................................ 15 (20)
Vibration Damper Bolt ............................................ 258 (350)
Water Pump Bolt ........................................................ 15 (20)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 84 (10)
Fig. 4: Checking Proper Belt Tension
Fig. 3: Aligning Ignition Rotor

AUDI 49
2.2L 5-Cylinder Turbo, 1992-95

TIMING BELT APPLICATION Turn crankshaft to TDC of No. 1 cylinder. See Fig. 3. Cam-
shaft sprocket mark must align with mark on cylinder cover.
Application Labor Time Belt Part No. See Fig. 4. Remove vibration damper. Remove lower tim-
2.2L 5-Cyl. Turbo ing belt cover. Remove timing belt with vibration damper.
S4 Installation:
1992-94 ................. 1.8 Hours ..................... T225 Ensure crankshaft and camshaft are at TDC of cylinder No.
S6 & S6 Quattro 1. TDC marking must be positioned below edge in inspec-
1995 ....................... 1.8 Hours ..................... T225 tion hole. See Fig. 3. Markings on camshaft sprocket and
cylinder head cover must align. See Fig. 4. Place new belt
on crankshaft pulley. Install vibration damper and at same
MANUFACTURERS SUGGESTED time, fit lower timing belt cover. Fit belt onto idler pulley,
SCHEDULED MAINTENANCE water pump and camshaft sprocket. Tension belt by turn-
ing tensioner toward right with bolts loosened. See Fig. 1.
Ensure that belt can just be twisted 90 degrees with thumb
and forefinger between camshaft sprocket and water pump.
Tighten tensioner. To complete installation, reverse removal
REMOVAL & INSTALLATION procedure. Adjust drive belts to proper tension. See page
A-60 for belt tension ranges.
TIMING BELT TORQUE SPECIFICATIONS
Removal: Application Ft. Lbs. (N.m)
Disconnect negative battery cable. Raise and support ve- Camshaft Sprocket Bolt .............................................. 59 (80)
hicle. Remove underpanel. Remove front bumper. Remove Timing Belt Idler Pulley Bolt .......................................... 15 (20)
upper radiator support with attached parts. Remove bracket Timing Belt Tensioner (1992-95) ................................ 15 (20)
for trim panel from right side of vehicle. Remove radiator Vibration Damper Bolt ............................................ 258 (350)
bolts, radiator air guide and upper air duct from radiator. Water Pump Bolt ........................................................ 15 (20)
Attach special radiator support tool (3251) to right bumper INCH Lbs. (N.m)
mount bracket and swing radiator forward. Remove vis- Radiator Mounting Bolts ............................................. 89 (10)
cous fan and unclip wiring from fan frame. Relieve tension Timing Belt Cover ....................................................... 89 (10)
from accessory drive belt by swinging tensioner in direc- Valve Cover Nuts/Bolts ............................................... 89 (10)
tion shown. See Fig. 2. Insert Pin (3204) into holes. Re-
move belt. Remove tensioner. Remove upper timing belt
guard.
NOTE: Turn engine by hand using hex flange on hydraulic pump.

Loosen tensioner bolts.
96F14642 Courtesy of Audi of America, Inc.

Fig. 2: Relieving Tension On Accessory Drive Belt
96H14644 Courtesy of Audi of America, Inc.

50 AUDI
2.2L 5-Cylinder Turbo, 1992-95 (Cont.)
96G14643 Courtesy of Audi of America, Inc.
Fig. 3: Locating No. 1 Cylinder TDC Inspection Hole

Fig. 4: Aligning Camshaft Sprocket Timing Marking
AUDI 51
2.3L 5-Cylinder Exc. Coupe Quattro

TIMING BELT APPLICATION Loosen water pump adjusting bolts to relieve tension on
timing belt. Remove timing belt. Remove water pump to
Application Labor Time Belt Part No. check O ring. DO NOT allow crankshaft or camshaft to
2.3L 5-Cyl. move.
80 Installation (1986-90):
1991-92 .................. 1.8 Hours ..................... T170 Ensure both camshaft lobes on No. 1 cylinder point up-
80/90 Quattro ward. Mark (notch or dot) on back of camshaft sprocket
1988 ....................... 1.8 Hours ..................... T127 must be aligned with top of valve cover gasket or rear tim-
ing belt cover. Crankshaft must be at TDC for No. 1 cylinder.
1989 Flywheel TDC mark must be aligned with index point on
Thru Chassis No. transmission housing.
89 J 394 742 ......... 1.8 Hours ..................... T127 Install water pump with new sealing O ring. Install timing
From Chassis No. belt. Turn water pump body counterclockwise to increase
89 J 394 743 ........ 1.8 Hours ..................... T170 belt tension. Tension is correct when belt can be twisted 90
1990-92 ................. 1.8 Hours ..................... T170 degrees using finger pressure at point midway between
90 camshaft sprocket and water pump sprocket. Recheck valve
timing. Complete installation in reverse order of removal.
1988 ....................... 1.8 Hours ..................... T127 Adjust drive belts to proper tension.
1989 Removal (1991-92):
Thru Chassis No. Disconnect negative battery cable. Remove accessory drive
89 J 396 702 ........ 1.8 Hours ..................... T127 belts. Remove upper front and lower front timing belt cov-
From Chassis No. ers. Rotate crankshaft until timing marks are aligned. See
89 J 396 703 ........ 1.8 Hours ..................... T170 Fig. 2. Mark an arrow on timing belt (if reusing) to indicate
1990-91 .................. 1.8 Hours ..................... T170 direction of rotation.
Slightly loosen 3 water pump bolts. Pivot water pump to-
100/100 Quattro ward center of engine to relieve timing belt tension. Insert
1989-91 Holder (2084) into vibration damper to prevent crankshaft
Thru Chassis No. from turning. Using Extension (2079) and breaker bar, re-
063 969 ............... 1.8 Hours ..................... T127 move vibration damper bolt. Remove vibration damper/
From Chassis No. crankshaft sprocket. Remove timing belt.
063 970 ............... 1.8 Hours ..................... T170 Installation (1991-92):
1990-91 .................. 1.8 Hours ..................... T170 Ensure timing marks are aligned. See Fig. 3. With crank-
shaft sprocket attached to vibration damper, loop timing
5000S belt around crankshaft sprocket. Install vibration damper/
1987-88 .................. 2.2 Hours ..................... T127 crankshaft sprocket with belt onto crankshaft end, ensur-
5000S Quattro ing belt is not jammed between crankshaft sprocket and
1988 ....................... 2.2 Hours ..................... T127 front cover.
Slightly loosen 3 water pump bolts. Pivot water pump to-
ward center of engine to allow belt to be looped around
MANUFACTURERS SUGGESTED camshaft sprocket and idler pulley. Take up all slack in belt
SCHEDULED MAINTENANCE between camshaft and water pump, and between water
Although the manufacturer does not recommend a specific pump and crankshaft.
scheduled maintenance interval, belt manufacturers suggest Pivot water pump away from engine until belt is tight. To
the belt be replaced at 60,000 mile intervals. check belt tension, grasp belt with thumb and forefinger
between camshaft and water pump sprocket. Belt ten-
REMOVAL & INSTALLATION sion is correct if belt can be twisted 90 degrees. Tighten
water pump bolts to specification. Complete installation
TIMING BELT in reverse order of removal. Adjust drive belts to proper
Removal (1986-90): tension. See page A-60 for belt tension ranges.
Disconnect negative battery cable. Remove upper radiator TORQUE SPECIFICATIONS
cover. Remove drive belts. Remove power steering pump with
pressure hoses connected. Set pump aside. Remove valve Application Ft. Lbs. (N.m)
cover and outer timing belt covers. See Fig. 1. Camshaft Sprocket Bolt .............................................. 59 (80)
Using crankshaft bolt, turn crankshaft clockwise to TDC of Timing Belt Idler Pulley Bolt ........................................ 15 (20)
No. 1 cylinder compression stroke. Align timing mark on Vibration Damper Bolt ............................................ 258 (350)
back of camshaft sprocket with upper edge of gasket. See Water Pump Bolt ........................................................ 15 (20)
Fig. 2. INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 89 (10)
Timing Belt Cover ....................................................... 89 (10)
52 AUDI
2.3L 5-Cylinder Exc. Coupe Quattro (Cont.)
Fig. 1: Exploded View Of Timing Belt, Sprockets & Covers
96E14641 Courtesy of Audi of America, Inc.

Fig. 2: Aligning Camshaft Sprocket

AUDI 53
*2.7L V6 DOHC, S4 Quattro

2.7L V6
S4 Quattro
2000 ...................... 4.2 Hours ..................... T297
For 2000 model vehicles, manufacturer recommends belt be
replaced at 105,000 miles.


TIMING BELT
Courtesy Of Audi Of America, Inc.
CAUTION: Before removal, mark an arrow indicating direc-
Fig. 2: Removing Front Bumper (Up To VIN 8DXA200000;
tion of rotation on accessory drive belt or timing belt. Damage
Later Models Similar)
may result if belts are installed in opposite direction of rotation.
Removal:
Disconnect negative battery cable. Remove noise insula-
tor. See Fig. 1.

Fig. 3: Removing Inner End Of Air Inlet Grill
Fig. 1: Removing Noise Insulation
On VIN up to 8DXA200000, remove bumper by removing

Remove viscous fan using Pin Wrench (3212) to hold fan.
See Fig. 5.
Torx screws at wheel housing liner, and air inlet grill at
bumper by disengaging tabs at top and bottom using a NOTE: Viscous fan has left-hand threads.
screwdriver. see Fig. 2. Remove inner end of air inlet grill
first. See Fig 3. Remove combination bolts. Unclip bumper
from bracket and remove toward front. CAUTION: Mark the direction of rotation of the accessory drive
On VIN 8DXA200001 and forward, remove bumper by re- belt with chalk or felt pen before removing. A used belt can break
moving bolt with washer, impact absorber and hex bolts. if it rotates in the opposite direction when reinstalled.
Remove Torx screws at wheel housing liner, and air inlet Loosen accessory drive belt by using a 17 mm wrench to
grill at bumper by disengaging tabs at top and bottom us- turn to the right until two holes are aligned. Hold in position
ing a screwdriver. Remove inner end of air inlet grill first. with Mandrel (3204). Remove accessory drive belt. See
See Fig. 3. Remove bolt and washer assembly. Unclip Fig. 6.
bumper from bracket and remove toward front. Unscrew bolts and remove center engine cover panel. Re-
Move lock carrier to service position by removing 3 quick move pressure hoses between charge air coolers and pres-
release screws on front of noise insulation panel. See Fig. sure pipes on left and right sides. See Fig. 7. Remove
4. Unbolt air guide between lock carrier and air cleaner at pressure pipes, noting installed position of retaining strips.
lock carrier. If installed, remove retaining clamps for wiring Remove timing belt tensioner 1. Remove left and right
harness on left side of radiator frame. Remove bolt and timing belt guards 2 and center guard 3. See Fig. 8.
install Support Tool (3369) into left bore. Remove bolts. Rotate crankshaft by hand to TDC. Ensure notch A is
Remove bolts and pull lock carrier out to stop. To secure aligned with notch B. See Fig. 9. Check position of cam-
lock carrier, install appropriate M6 bolts into rear bored holes shafts. Ensure that the larger holes in the securing plates
of lock carrier and fender bore. on the camshaft sprockets must face one another on the
inside. See Fig. 15. If this is not the case rotate crankshaft
one revolution more.
54
AUDI
*2.7L V6 DOHC, S4 Quattro (Cont.)
Remove sealing plug from left side of cylinder block. The
NOTE: The center bolt does not have to be loosened to remove
TDC mark in crankshaft must be visible (or be able to be
the vibration damper.
felt) in line with sealing plug hole.
Remove idler wheel for accessory drive belt and timing belt
WARNING: DO NOT turn engine while feeling for TDC mark. Injury guard behind vibration damper. See Fig. 12.
could result. Using a hex key, turn timing belt tensioner clockwise 8 mm
Screw Crankshaft Holding Tool (Audi 3242) into sealing in direction of arrow. See Fig. 13. Turn until tensioning lever
plug and tighten. See Fig 10. Remove crankshaft vibration compresses the oil-damped tensioner element enough to
damper. See Fig. 11. enable Pin (T40011) to be fitted through holes in tensioner
housing and plunger. This will secure tensioner plunger in
place. Remove timing belt.
Installation:
Insert Camshaft Locator Bar (3391) into securing plates of
the two camshafts. See Fig. 15. Loosen both camshaft
bolts and unscrew approximately 5 turns. Remove Cam-
shaft Locator Bar (3391). Loosen, but do not remove, both
camshaft sprockets with Gear Puller (T40001). See Fig.
14. Reinstall both camshaft sprockets with securing plates
and tighten hand tight.
NOTE: Camshaft sprockets should be just tight enough on the

camshaft tapers so that they can still be turned but do not move
axially (up and down).
Fig. 4: Moving Lock Carrier To Service Position

Fig. 6: Loosening Accessory Drive Belt

Fig. 5: Removing Viscous Fan

Fig. 7: Removing Pressure Hoses
AUDI 55

Position timing belt over camshaft sprockets. See Fig. 16.
With large holes in camshaft securing plates facing in-
board, install Camshaft Locator Bar (3391) on camshafts.
Using hex key, turn timing belt tensioner clockwise 8 mm
until pin can be removed. See Fig. 13. Use a torque wrench
to pre-tension timing belt by turning clockwise with a torque
of 11 ft. lbs. (15 N.m). Tighten bolts on camshaft sprockets
to specification. See TORQUE SPECIFICATIONS.
Remove crankshaft holding tool from side of engine block.
Install sealing plug. Remove camshaft locator bar. Install
the accessory drive belt idler wheel and timing belt guard
behind vibration damper. Install vibration damper. Note the
position of locating lugs on belt sprocket.
Install accessory drive drive belt. Install lock carrier to body.
Ensure lock carrier aligns correctly with fender and install
Torx bolts. See Fig. 18. Install bumper. To complete instal-
lation, reverse removal procedure. Tighten all nuts and bolts
Fig. 10: Using Crankshaft Holding Tool

Fig. 8: Removing Accessory Drive Belt Tensioner
Fig. 11: Removing Vibration Damper
Bumper Combination Bolts ............................................ 17 (23)
Crankshaft Damper Center Bolt ........................... 1 147 (200)
Idler Wheel Bolt ............................................................ 33 (45)
Impact Absorber Hex Bolts ............................................. 33 (45)
Lock Carrier-
To-Body Support (Hex) Bolts ........................................ 33 (45)
INCH Lbs. (N.m)
Bracket Combination Bolts ........................................... 14 (1.5)
Courtesy Of Audi Of America, Inc. Lock Carrier-
To-Fender Torx Bolts ................................................... 89 (10)
Fig. 9: Aligning Crankshaft Timing Marks
1-
Plus 190 degrees. Always use new bolt.
56 AUDI

Fig. 15: Installing Camshaft Locator Bar
Fig. 12: Removing Timing Belt Guard

Fig. 16: Installing Timing Belt On Sprockets
Fig. 13: Using Hex Key To Compress Timing Belt Tensioner

Fig. 17: Routing Accessory Drive Belt Properly
Fig. 14: Removing Camshaft Sprockets With Gear Puller

Fig. 18: Locating Lock Carrier To Body
AUDI 57
*2.7L V6 DOHC, A6 Quattro & Allroad

2.7L V6, Twin Turbo (APB)
A6 Quattro
2000 ...................... 5.3 Hours ..................... T297
Allroad
2000 ...................... 5.2 Hours ..................... T297
For 2000 model vehicles, manufacturer recommends belt be
replaced at 105,000 miles.


TIMING BELT
Fig. 2: Removing Front Bumper

Fig. 1: Removing Noise Insulator
Removal:
tor. See Fig. 1.
Remove front wheels. Loosen front half of wheelhousing
and unscrew flanged nuts on both sides. Remove screw/
washer assembly from wheelhouse liner. Remove socket-
head bolts and remove bumper cover (together with impact
absorber) toward front. See Fig. 2.
Move lock carrier to service position by removing intake air
duct between lock carrier and air cleaner housing at lock
carrier. On right side, remove bolt and install Support Tool
(3369) into right bore. See Fig. 3. On left side, install Sup-
port Tool (3369) into threaded hole. Remove bolts on left
and right. See Figs. 3 and 4.
Remove bolts and pull lock carrier forward until rear hole in Courtesy Of Audi Of America, Inc.
lock carrier aligns with front threaded hole in fender flange. Fig. 3: Moving Lock Carrier To Service Position
Secure lock carrier using bolts. See Fig. 5.
NOTE: Viscous fan has left-hand threads.

Remove viscous fan using spanner wrench or Pin Wrench
(3212) to hold fan. See Fig. 6.
58
AUDI
*2.7L V6 DOHC, A6 Quattro & Allroad (Cont.)
CAUTION: Mark the direction of rotation of the accessory drive
belt with chalk or felt pen before removing. A used belt can break
if it rotates in the opposite direction when reinstalled.
Loosen accessory drive belt by using a 17 mm wrench to
turn to the right until two holes are aligned. Hold in position
with Mandrel (3204). Remove accessory drive belt. See
Fig. 7.
Unscrew bolts and remove center engine cover panel. Re-
move pressure hoses between charge air coolers and pres-
sure pipes on left and right sides. See Fig. 8. Remove
turbocharger pressure pipes.
NOTE: Take note of the position of retaining strips.

Remove accessory drive belt tensioner 1. Remove left
Courtesy Of Audi Of America, Inc. and right timing belt guards 2 and center guard 3. See
Fig. 9.
Fig. 4: Inserting 3369 Support Tool
Rotate crankshaft by hand to TDC. Ensure notch A is
aligned with notch B. See Fig. 10. Check position of cam-
shafts. Ensure that the larger holes in the securing plates
on the camshaft sprockets must face one another on the
inside. If this is not the case rotate crankshaft one revolu-
tion more.
Fig. 5: Securing Lock Carrier

Fig. 7: Loosening Accessory Drive Belt

Fig. 6: Removing Viscous Fan

Fig. 8: Removing Pressure Hoses
AUDI 59

Remove sealing plug from left side of cylinder block. See
Fig 11. The TDC mark in crankshaft must be visible (or be
able to be felt) in line with sealing plug hole.
WARNING: DO NOT turn engine while feeling for TDC mark. Injury
could result.
Screw Crankshaft Holding Tool (Audi 3242) into sealing
plug and tighten. See Fig 11. Remove vibration damper.
See Fig. 12.
NOTE: The center bolt does NOT have to be loosened to remove

the vibration damper.
Remove idler wheel for accessory drive belt. Remove tim-
ing belt guard behind vibration damper. See Fig. 13.
Using a hex key, turn timing belt tensioner clockwise 8 mm
in direction of arrow. See Fig. 14. Turn until tensioning lever
compresses the oil-damped tensioner element enough to
enable Pin (T40011) to be fitted through the holes in the
tensioner body and the plunger. This will secure plunger in
position. Remove timing belt.
Installation: Fig. 11: Using Crankshaft Holding Tool
Insert Camshaft Locator Bar (3391) into securing plates of
the two camshafts. See Fig. 16. Loosen both camshaft
bolts and unscrew approximately 5 turns.

Fig. 12: Removing Vibration Damper

Fig. 9: Removing Accessory Drive Belt Tensioner

Fig. 13: Removing Accessory Drive Belt Idler Wheel

60 AUDI
*2.7L V6 DOHC, A6 Quatto & Allroad (Cont.)

Fig. 17: Installing Timing Belt On Sprockets

Fig. 14: Using Hex Key To Compress Timing Belt Tensioner

Fig. 18: Routing Accessory Drive Belt
Remove Camshaft Locator Bar (3391). Loosen, but do not

remove, both camshaft sprockets with Gear Puller (T40001).
See Fig. 15.
NOTE: Camshaft sprockets should be just tight enough on the

camshaft tapers so that they can still be rotated, but do not move
axially (up and down).
Reinstall both camshaft sprockets with securing plates and
tighten hand tight.
Courtesy Of Audi Of America, Inc. Position timing belt over camshaft sprockets. See Fig. 17.
Fig. 15: Removing Camshaft Sprockets With Gear Puller Install Camshaft Locator Bar (3391) on camshafts. Using
hex key, turn timing belt tensioner clockwise 8 mm until pin
can be removed from tensioner. See Fig. 14.
Pre-tension timing belt by turning tensioner pulley center
bolt clockwise with a torque of 11 ft. lbs. (15 N.m). Tighten
bolts on camshaft sprockets to specification. See TORQUE
SPECIFICATIONS.
Remove camshaft locator bar. Remove crankshaft holding
tool. Install plug in engine block. Install timing belt guards.
Install accessory drive belt idler wheel behind crankshaft
pulley. Install crankshaft pulley. Note position of locating
lugs on crankshaft pulley.
Install accessory drive belt. See Fig. 18. Install viscous fan.
Install lock carrier to body. Ensure lock carrier-to-fender
Torx bolts are installed correctly. See Fig. 5.
Install bumper. Install turbocharge pressure pipes and
hoses. Install engine cover. Install noise insulator.

AUDI 61

Bumper Combination Bolts ............................................ 17 (23)
Camshaft Pulley-To-Sprocket Bolt .............................. 40 (55)
Crankshaft Damper Center Bolt 1
Step 1 ....................................................................... 147 (200)
Step 2 ......................................................... Plus 180 Degrees
Crankshaft Pulley-To-Sprocket Bolt ............................ 15 (20)
Idler Wheel Bolt ............................................................ 33 (45)
Impact Absorber Hex Bolts ............................................. 33 (45)
Lock Carrier-To-Body Hex Bolt ....................................... 37 (50)
Viscous Fan ................................................................... 52 (70)
INCH Lbs. (N.m)
Lock Carrier-To-Fender Torx Bolt ................................... 89 (10)
Timing Belt Tensioner Bolt .......................................... 89 (10)
Water Pump Bolt ............................................................ 89 (10)
1
ALWAYS replace bolt if loosened or removed.
62 AUDI
*2.8L V6 12-Valve
TIMING BELT APPLICATION Installation:
Position timing belt over camshaft sprockets. See Fig. 2.
Application Labor Time Belt Part No. Install camshaft holder. Position timing belt over all sprock-
2.8L V6 ets, then position over tensioner. Lightly tighten tensioner
A4 bolt (ensure tensioner can be rotated by hand).
1996-97 ................. 2.5 Hours ..................... T218 Tighten belt by rotating tensioner on bolt. Tighten belt until
A4 Quattro it can be twisted 90 degrees by hand at midway point be-
tween right camshaft sprocket and water pump pulley.
1996-97 ................. 2.5 Hours ..................... T218 Tighten tensioner bolt to specification. See TORQUE SPECI-
A6 FICATIONS.
1995-97 ................. 2.5 Hours ..................... T218 Tighten camshaft sprocket bolts to specification. Remove
A6 Quattro Camshaft Holding Tool. Remove Crankshaft Holding Tool.
1995-97 ................. 2.5 Hours ..................... T218 Install Crankshaft Position (CKP) sensor. To install acces-
Cabriolet sory drive belt, install mandrel. Position accessory drive
1994-98 ................. 2.5 Hours ..................... T218 belt over drive sprockets and idler roller, then over tensioner
roller. Remove mandrel. To complete installation, reverse
90 & 90 Quattro removal procedure. Adjust drive belts to proper tension.
1993-95 ................. 2.5 Hours ..................... T218 See page A-60 for belt tension ranges.
100 & 100 Quattro
1992-94 ................. 2.5 Hours ..................... T218
For 1997-98 model vehicles, manufacturer recommends belt
be replaced at 90,00 miles. For 1996 and earlier model years,
the manufacturer does not recommend a specific scheduled
maintenance interval. However, belt manufacturers suggest
*NOTE: This is application is an interference engine.


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

camshaft, but not loose enough to tilt.
AUDI 63
*2.8L V6 12-Valve (Cont.)

Camshaft Bearing Cap Nut ........................................ 11 (15)
Crankshaft Damper Bolt ......................................... 295 (400)
INCH Lbs. (N.m)
Crankshaft Position Sensor (CKP) ............................. 96 (10)
Valve Cover Bolt .................................................. 53-89 (6-10)
Fig. 4: Using Camshaft Holding Tool
Fig. 3: Using Crankshaft Holding Tool

64 AUDI
*2.8L V6 30-Valve
2.8L V6, 30-Valve (AHA & ATQ Engines)
A4 & A4 Quattro
1998-99 ................. 4.2 Hours ..................... T297
A6 & A6 Quattro, Non-Turbo
1998-00 ................. 4.6 Hours ..................... T297
A6 & A6 Quattro, Turbo
1998-00 ................. 5.2 Hours ..................... T297
mile intervals for 1997-98 models, 75,000 mile intervals for
1999 models, and 105,000 miles on 2000 models.

REMOVAL & INSTALLATION Fig. 2: Exploded View Of A6 Bumper Assembly
TIMING BELT
NOTE: Obtain radio anti-theft code before disconnecting battery.
Removal
Disconnect negative battery cable. Remove engine top cover.
Remove noise insulation panel from under front of vehicle.
Remove front bumper. See Figs. 1 and 2. Remove air in-
take duct from air cleaner housing. On right side of lock
carrier, remove bolt and install Lock Carrier Support Tool
(3369). See Figs. 3, 4 and 5. Remove lock carrier-to-body
bolts. Carefully slide lock carrier forward on support tool.
Hold cooling fan pulley with spanner wrench. Unscrew and
remove viscous cooling fan clutch from pulley. Viscous cool-
ing fan is LEFT-HAND threaded.
Fig. 3: Exploded View Of A4 Lock Carrier Assembly
Use a 17 mm box wrench to turn serpentine belt tensioner

counterclockwise to relieve belt tension and remove ser-
pentine belt. If reusing belt, mark belt rotation direction with
arrow for reassembly reference.
Unclip timing belt guard on front of both camshafts and
remove. Turn crankshaft in normal direction of rotation until
TDC marks on crankshaft pulley and timing belt cover are
aligned. See Fig. 6.
Note securing plate on front end of each camshaft sprocket.
If large hole in each plate does not face inward, toward
center of engine, rotate crankshaft one revolution. See Fig.
7. Ensure crankshaft timing marks are still aligned.
Fig. 1: Exploded View Of A4 Bumper Assembly
Remove sealing plug from left side of engine block. TDC
mark on crankshaft must be visible or be felt through seal-
AUDI 65

Installation:
Install Camshaft Locator Bar (3391) into locking plates of
camshafts. See Fig. 10. Loosen camshaft sprocket bolts
about 5 turns. Remove locator bar. Leaving camshaft
sprocket bolts in place, use gear puller to loosen camshaft
sprockets on camshaft taper.
NOTE: Camshaft sprockets must be loose enough to rotate on

camshaft, but not loose enough to tilt.
Ensure all timing marks are still aligned. Install timing belt
on engine. Ensure belt routing is correct and there is no
slack in belt. See Fig. 11. Install Camshaft Locator Bar
(3391) into locking plates of camshafts.
Using an 8 mm hex wrench, SLOWLY compress timing
belt tensioner so that 2 mm pin can be removed from
tensioner.
Using 8 mm hex socket, place torque wrench on timing belt
tensioner pulley. Apply 11 ft. lbs. (15 N.m) to tensioner in
direction of tension (clockwise). This will preload belt ten-
sion.
Tighten camshaft sprocket bolts to specification. See
TORQUE SPECIFICATIONS. Remove camshaft locator bar.
Remove crankshaft holder. Install sealing plug. To com-
Fig. 4: Exploded View Of A6 Lock Carrier Assembly plete installation, reverse removal procedure. When install-
ing crankshaft pulley, ensure notches in pulley are aligned
with locating lugs in crankshaft. On A4, A6 and Quattro mod-
els, ensure lock carrier-to-body Torx bolts are correctly po-
sitioned. See Fig. 12.
Fig. 5: Positioning Lock Carrier Support Tool (3369)

ing plug hole. Install Crankshaft Holding Tool (Audi 3242)
into sealing plug hole. See Fig. 8.
Remove serpentine belt tensioner. Remove center and left
timing belt covers.
Using an 8 mm hex wrench, SLOWLY turn timing belt
tensioner pulley clockwise to compress timing belt
tensioner. See Fig. 9. Compress timing belt tensioner just
enough so that a 2 mm pin can be inserted through the
holes in top of tensioner body and push rod. This will hold
the tensioner in the compressed position.
CAUTION: If reusing old timing belt, mark an arrow indicating

direction of rotation on accessory drive belt or timing belt. Damage
Remove crankshaft vibration damper from crankshaft. It is
NOT necessary to remove center bolt. If center bolt is re-
moved, manufacturer recommends using NEW bolt on re-
assembly. Remove serpentine belt idler pulley.
Remove lower timing belt guard (if equipped). Remove tim- Fig. 6: Aligning Crankshaft Timing Marks
ing belt.
66 AUDI
Crankshaft Pulley-To-Crankshaft Hex Bolt ..................... 15 (20)
Crankshaft Pulley
Center Bolt ................................... 1 148 (200) + 180 Degrees
Lock Carrier-To-Body Bolts ........................................... 37 (50)
Timing Belt Idler Pulley Bolt ........................................... 33 (45)
Timing Belt Tensioner Center Bolt .............................. 15 (20)
INCH Lbs. (N.m)
Timing Belt Tensioner Bolt/Nut ................................... 89 (10)
Water Pump Bolt ........................................................ 89 (10)
1
If removed, manufacturer recommends using NEW bolt.

Fig. 7: Locating Camshaft Sprocket Holes

Fig. 8: Installing Crankshaft Holding Tool

Fig. 11: Timing Belt Routing

Fig. 12: Positioning Lock Carrier Torx Bolts
AUDI 67
3.6L & 4.2L V8 1990-94

TIMING BELT APPLICATION Removal:
Disconnect negative battery cable. Battery is under rear
Application Labor Time Belt Part No. seat. Remove noise insulation panel from under front of
3.6L V8 (PT Engine) vehicle. Remove coolant expansion tank cap. Drain cool-
V8 Quattro ant from radiator. Remove alternator cooling air duct. See
1990-91 ............... 4.3 Hours ..................... T207 Fig. 2. Loosen clip and disconnect coolant temperature
4.2L V8 (ABH Engine) sensor harness connector.
V8 Quattro Disconnect outer half of air duct at alternator. Remove
screws securing wiring harness at alternator. Using 13
1992-94 ............... 4.3 Hours ..................... T207 mm box wrench, turn serpentine belt tensioner clockwise
to relieve tension. See Figs. 1 and 3. Remove alternator
MANUFACTURERS SUGGESTED and set aside.
SCHEDULED MAINTENANCE Working from under vehicle, remove lower timing belt cover.
In engine compartment, remove bolt securing intake air
The manufacturer recommends belt be replaced at 60,000 ducts. Remove left and right side intake air ducts. Remove
miles on 3.6L engines, and 90,000 miles on 4.2L engines. upper part of air cleaner housing and air filter.
Replacement interval revision is from Audi technical service Remove bolts securing lower part of air cleaner housing.
bulletin 93-02, September 1, 1993. Lift out lower part of air cleaner housing. Remove upper
radiator hose. Remove electric cooling fan bolts. See Fig.
REMOVAL & INSTALLATION 4. Remove electric cooling fan. Remove serpentine belt.
TIMING BELT Remove lower radiator hose from thermostat housing. Move
lower radiator hose to right at rear. Remove viscous fan
shroud. Remove bolts securing viscous fan to pulley and
CAUTION: If serpentine or timing belt is being reused, mark belt
remove fan.
with an arrow indicating direction of rotation. Damage may
result if belts are installed in opposite direction of rotation.
Disconnect fan shrouds for viscous fan and electric fan.
Hold viscous cooling fan mount with a spanner wrench.
Loosen viscous cooling fan by turning clockwise. Viscous
cooling fan is LEFT-HAND threaded. See Fig. 5. Lift out fan
and shroud.

Fig. 1: Exploded View Of Serpentine Belt Assembly
68 AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
Remove front engine support mount. Note number and
position of shims for reassembly. Remove lower radiator
hose. Loosen center bolt of cranshaft pulley one turn while
using Crankshaft Pulley Holder (3197). See Fig. 6.
Remove flanged nuts and left side timing belt cover. See
Fig. 7. Remove lower radiator hose support from front of
engine.
Turn serpentine belt tensioner clockwise and insert Set-
ting Tool (3204) below mounting bolt. See Fig. 9. Remove 2
lower mounting bolts from right side timing belt cover. Do
not loosen upper mounting bolt yet. Remove Setting Tool
(3204). Remove top mounting bolt from right side timing
belt cover. Remove right side timing belt cover.
Noting positions for reassembly, disconnect ignition sec-
ondary wires at ignition coils. Remove both ignition dis-
tributor caps.
Rotate crankshaft to TDC of compression stroke. Ensure
TDC mark on crankshaft pulley aligns with mark on timing
belt cover. See Fig. 10.
Fig. 4: Removing Electric Cooling Fan
Fig. 2: Locating Coolant Temperature Sensor
Fig. 5: Removing Viscous Cooling Fan (Left-Hand Threads)
Fig. 6: Loosening Crankshaft Pulley Center Bolt

Fig. 3: Removing Serpentine Belt
AUDI 69
3.6L & 4.2L V8 1990-94 (Cont.)
Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.
Fig. 7: Removing Left Side Timing Belt Cover Fig. 9: Positioning Serpentine Belt Tension
Fig. 8: Exploded View Of Timing Belt Assembly

70 AUDI
3.6L & 4.2L V8 1990-94 (Cont.)
Fig. 10: Aligning Crankshaft Pulley Timing Marks

Fig. 13: Timing Belt Tensioner With Eccentric Center
Fig. 11: Aligning Distributor Rotor To Housing

Fig. 14: Positioning Camshafts With Locating Flange (3199)

Fig. 15: Positioning Adjusting Tool (3204) Into Stop Plate
Fig. 12: Timing Belt Routing (3.6L Engine)
Ensure distributor rotor points to mark on distributor hous- flange. See Fig. 14. Secure locating flange with distributor
ing. If not, turn crankshaft one more revolution. See Fig. 11. mounting bolts.
Remove both distributors. Using spanner wrench, hold camshaft sprocket. Loosen
For 3.6L engine, loosen stop plate at timing belt tensioner. camshaft sprocket bolts about 2 turns. DO NOT use Locat-
See Fig. 12. On 3.6L and 4.2L engines, loosen center bolt ing Flange (3199) to hold camshaft while loosening sprocket
on tensioner pulley with eccentric center (right side of en- bolt.
gine block). See Fig. 13. Remove timing belt damper top Using a plastic hammer, LIGHTLY tap edge of camshaft
bolt. Remove timing belt tensioner pulley with eccentric sprockets until camshaft sprockets are loose. Remove
center. camshaft sprocket Woodruff keys.
Fit Locating Flange (3199) at end of each camshaft. Locat-
ing pin on distributor flange should fit in slot in locating
AUDI 71
3.6L & 4.2L V8 1990-94 (Cont.)

Position timing belt in position over idler pulleys, water
pump pulley and camshaft sprockets. Install tensioner pul-
ley with eccentric center. Leave center nut loose so that
eccentric can be turned. Fully tighten 4 crankshaft pulley
On 3.6L engine, insert Adjusting Tool (3204) into tensioner
lever so that tool engages recess on back of stop plate.
See Fig. 15. Firmly press tensioner lever once by hand
clockwise. See Fig. 16.
On 3.6L and 4.2L engines, set basic timing belt tension by
turning tensioner pulley with eccentric center in clockwise
direction. Use spanner wrench to turn eccentric. Turn ec-
centric until damper length is at specified dimension. See
Fig. 17. Tighten tensioner pulley center nut to specification.
See TORQUE SPECIFICATIONS table.
Holding camshaft sprockets in place, tighten camshaft
sprocket center bolts to specification. Remove camshaft
Locating Flanges (3199). Turn crankshaft at least 2 turns.
Tighten crankshaft pulley center bolt to specification.
Fig. 16: Rotate Tensioner Lever In Direction Of Arrow Ensure timing belt damper length is still correct. Readjust,
if necessary. On 3.6L engine, tighten stop plate mounting
bolt to specifcation. See TORQUE SPECIFICATIONS table.
Remove Adjusting Tool (3204).
On 3.6L and 4.2L engines, complete installation reverse
removal procedure. When refilling cooling system, manu-
facturer recommends using Audi anti-freeze (Part No. G
001 1V8A). Use 50/50 mix of coolant and water.
To bleed air from cooling system, turn on ignition with en-
gine off. Set A/C controls to high. Open radiator expansion
tank. Fill with coolant while squeezing upper hoses to al-
low trapped air to escape. Install expansion tank cap.
Start and run engine between 2000-3000 RPM until warm.
With A/C still on high, raise engine RPM to 4000-5000 RPM
several times. Coolant temperature gauge must read just
under 212F (100C). Turn off ignition. After about 5-10
minutes, carefully open expansion tank cap. Top off cool-
ant level to MAX mark. Restart engine and repeat topping
off procedure. Adjust drive belts to proper tension. See page
Courtesy of Audi of America, Inc. A-60 for belt tension information.
Fig. 17: Setting Timing Belt Damper Length TORQUE SPECIFICATIONS
Remove 4 bolts fastening crankshaft pulley to crankshaft Application Ft. Lbs. (N.m)
sprocket. Remove crankshaft center bolt and remove crank- Alternator Bottom Mount Bolt .......................................... 18 (25)
shaft pulley. It is not necessary to remove sprocket from Alternator Top Mounting Bolt ........................................... 33 (45)
crankshaft. Remove timing belt. Camshaft Sprocket Bolt .............................................. 33 (45)
Inspection: Crankshaft Pulley Center Bolt ................................. 1 332 (450)
Inspect tensioner and idler pulley for ease of rotation and Crankshaft Pulley-To-Sprocket Bolts .............................. 18 (25)
rough bearings. Replace as necessary. Engine Front Support Mount Bolt .................................... 30 (40)
Installation: Serpentine Belt Idler Pulley Bolt ..................................... 18 (25)
Ensure crankshaft is still at TDC position. Place timing Timing Belt Adjustment Damper Bolts ........................... 18 (25)
belt over crankshaft sprocket. Install crankshaft pulley on Timing Belt Damper Mount Bolt ..................................... 18 (25)
crankshaft. Install 4 bolts that hold crankshaft pulley to Timing Belt Idler Pulley Bolt ............................................ 18 (25)
sprocket. Hand tighten temporarily. Timing Belt Tensioner Nut .......................................... 18 (25)
Apply locking sealant (AMV 188 0012), or equivalent, to crank- INCH Lbs. (N.m)
shaft center bolt threads. Install crankshaft pulley center Fan Shroud Bolts ........................................................... 89 (10)
bolt and hand tighten temporarily. Stop Plate Mounting Bolt (3.6L) ..................................... 89 (10)
Loosen camshaft sprocket center bolts by about 1 turn. Timing Belt Cover Flanged Nut ...................................... 89 (10)
Camshaft sprocket should still be loose on camshaft. In- Water Pump Bolts ...................................................... 89 (10)
stall Vibration Damper Locking Tool (3211). If there is no 1
- Installwith thread locking sealant AMV 18800102.
hole to accept Vibration Damper Locking Tool, ensure TDC
mark on vibration damper is aligned with pointer before
and after tightening camshaft sprockets.
72 AUDI
*3.7L & 4.2L V8 1997-99
Application Labor Time Belt Part No. tion panel from under front of vehicle. Remove air intake
3.7L V8 (AEW Engine) grille from front of bumper. Drain coolant from radiator.
A8 Using box wrench, turn serpentine belt tensioner clock-
1997-99 ............... 4.3 Hours ..................... T207 wise to relieve tension. Remove serpentine belt. See Fig.
4.2L V8 (ABZ Engine) 1. Remove engine top trim cover. Remove coolant hose
retaining clamp on right side upper timing belt cover.
A8 Quattro Remove air intake duct between air cleaner and throttle
1997-99 ................. 4.3 Hours ..................... T207 body. Disconnect fan shrouds for viscous fan and electric
fan.
MANUFACTURERS SUGGESTED Hold viscous cooling fan pulley with a spanner wrench.
SCHEDULED MAINTENANCE Remove viscous fan by turning clockwise. Viscous fan is
LEFT-HAND threaded. See Fig. 2.
For 1997 and 1998 model vehicles, manufacturer recom- Remove right front engine mount. See Fig. 3. Remove cool-
mends belt be replaced at 90,000 miles. For 1999 model ant hoses at front of engine. Rotate crankshaft to TDC of
year, the manufacturer recommends the belt be replaced at compression stroke. Ensure TDC mark on crankshaft pul-
75,000 miles. ley aligns with mark on timing belt cover. See Fig. 4.
*NOTE: This is an interference engine. See page CAUTION: Manufacturer recommends that crankshaft pulley
A-59 for interference engine cautions. center bolt be REPLACED whenever the bolt is loosened or removed.
Holding crankshaft pulley with Crankshaft Pulley Holder
REMOVAL & INSTALLATION (3197), loosen center bolt about 1 turn. See Fig. 5. Remove
camshaft position sensor at housing at rear of left cylinder
TIMING BELT head. See Fig. 6. If camshaft sensor is NOT positioned
behind sensor plate window, rotate crankshaft 1 full revolu-
CAUTION: If serpentine or timing belt are being reused, mark tion. Remove camshaft flange at rear of right side cylinder
belt with an arrow indicating direction of rotation. Damage head.

Fig. 1: Exploded View Of Serpentine Belt Assembly
AUDI 73
*3.7L & 4.2L V8 1997-99 (Cont.)

Disconnect harness connector from switch for intake mani-
fold change-over valve. Remove timing belt guard. Unclip
cap at guide pulley for serpentine belt at right side timing
belt guard. Remove top of air cleaner housing. Remove
right side timing belt guard mounting bolts. Carefully lift
right side timing belt guard up and out.
Holding camshaft sprocket with Sprocket Holder (3036),
loosen camshaft sprocket bolts. See Fig. 7. Remove cam-
shaft position sensor plate and housing. See Fig. 6. Install
Camshaft Locking Device (3341) at rear of each cylinder
head. If necessary, rotate camshaft to allow locking device
to engage. See Fig. 8. Camshafts can be rotated by remov-
ing the valve cover and using the hex machined into the
front end of the camshaft. Courtesy of Audi of America, Inc.
Fig. 4: Aligning Crankshaft Pulley TDC Marks
CAUTION: The Camshaft Locking Devices (3341) are NOT to be
used to hold camshafts in place when loosening or tightening
the camshaft sprocket bolts.
Using spanner wrench, hold timing belt tensioner pulley.
Loosen tensioner pulley center nut. See Figs. 9 and 10.
Turn tensioner pulley to relieve timing belt tension.
Remove timing belt from camshaft sprockets. LIGHTLY
strike edge of camshaft sprockets with plastic hammer to
loosen sprocket from tapered ends of camshafts.

Fig. 5: Loosening Crankshaft Pulley Center Bolt

Fig. 2: Removing Viscous Cooling Fan (Left-Hand Threads) Courtesy of Audi of America, Inc.
Fig. 6: Camshaft Position Sensor & Housing

Fig. 3: Removing Right Front Engine Mount Fig. 7: Loosening Camshaft Sprocket Bolts
74 AUDI
*3.7L & 4.2L V8 1997-99 (Cont.)
Fig. 8: Installing Camshaft Locking Device (3341) Fig. 10: Locating Timing Belt Tensioner Pulley
Fig. 9: Exploded View Of Timing Belt Assembly

AUDI 75
*3.7L & 4.2L V8 1997-99 (Cont.)

Remove 4 bolts fastening crankshaft pulley to crankshaft
sprocket. Remove crankshaft center bolt and remove crank-
shaft pulley. It is not necessary to remove sprocket from
crankshaft. Remove timing belt.
Installation:
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 pul-
ley center bolt be REPLACED whenever the bolt is loos-
ened or removed.
Lightly oil threads and contact surfaces of NEW center bolt.
Using locking compound AMV 00102, or equivalent, install
crankshaft pulley center bolt and hand tighten temporarily.
Loosen camshaft sprocket center bolts by about 1 turn.
Camshaft sprocket should still be loose on camshaft tapers.
Position timing belt in position over idler pulleys, water
pump pulley and camshaft sprockets. See Fig. 9.
Push timing belt over tensioner pulley. Tighten tensioner Fig. 11: Adjusting Timing Belt Damper Length
pulley center nut hand tight. Eccentric insert should still be
able to turn. Set A/C controls to LO position. Start engine and run at
Tighten 4 crankshaft pulley-to-crankshaft sprocket mount- about 2000 RPM for about 3 minutes. Check coolant level
ing nuts. See TORQUE SPECIFICATIONS. in radiator expansion tank. Refill to MAX level, if necessary.
To set basic timing belt tension, turn tensioner pulley ec- Turn off ignition. Reconnect coolant pump 2-pin connector.
centric insert clockwise. Use a spanner wrench inserted Set A/C controls to HI position, and blower motor to lowest
into the 2 holes in the eccentric insert. Adjust position of setting. Start and run engine at 2000-3000 RPM for about
timing belt tensioner until damper length is within speci- 10 minutes. Turn off ignition. Turn ignition on, with engine
fied range. See Fig. 11. off.
Tighten timing belt tensioner center nut to specification. With ignition on, and A/C controls set to HI, coolant pump
See TORQUE SPECIFICATIONS. Holding camshaft sprock- must NOT make any noise. Noise indicates that air is
ets in place, tighten camshaft sprocket center bolts to speci- trapped in system and bleed procedure needs to be re-
fication. peated. If there are no unusual noises from coolant pump,
Remove Camshaft Locking Device (3341) from rear of each turn off ignition. Refill radiator expansion tank.
camshaft. Install housing behind camshaft position sen- TORQUE SPECIFICATIONS
sor and tighten bolts to specification. Camshaft position Application Ft. Lbs. (N.m)
sensor plate MUST engage in camshaft with catch. Camshaft Position Sensor Housing Bolt ................... 15 (20)
Turn crankshaft at least 2 revolutions in normal direction of Camshaft Sprocket Bolt .............................................. 41 (55)
rotation. Tighten crankshaft center bolt to specification. Crankshaft Pulley Center Bolt ................................. 1 332 (450)
Check timing belt damper length. Readjust timing belt ten- Crankshaft Pulley-To-Sprocket Bolts .............................. 18 (25)
sion, if necessary. Serpentine Belt Idler Pulley Bolt ..................................... 18 (25)
To complete installation, reverse removal procedure. When Timing Belt Adjustment Damper Bolts ........................... 18 (25)
refilling cooling system, use Audi coolant additive G12-A8D Timing Belt Idler Pulley Bolt ............................................ 18 (25)
TL 774D (Red color). Use 50/50 mix of coolant and water. Timing Belt Tensioner Nut .......................................... 18 (25)
Before filling cooling system, open vent screws at heater INCH Lbs. (N.m)
core feed and return lines (rear of engine). Remove cap Timing Belt Cover Flanged Nut ...................................... 89 (10)
from radiator expansion tank. Add coolant until it flows from Water Pump Bolts ...................................................... 89 (10)
vent valves. Close vent valves. Install cap on radiator ex-
pansion tank.
1
- Use NEW bolt if loosened or removed. Oil threads. Install
Disconnect 2-pin electrical connector from coolant pump with thread locking compound AMV 00102, or equivalent.
unit. Coolant pump unit is located in left rear corner of en-
gine compartment, near power brake booster.
76 AUDI
*4.2L V8 2000
4.2L V8 (AKB, AUX & AYS Engines)
A8 Quattro
2000 .................... 4.3 Hours ..................... T297
The manufacturer recommends belt be replaced at 105,000
miles.

REMOVAL & INSTALLATION Fig. 2: Aligning Crankshaft Pulley TDC Marks
TIMING BELT
CAUTION: If serpentine or timing belt are being reused, mark
belt with an arrow indicating direction of rotation. Damage
Removal:
Remove trim cover at front of engine compartment. Re-
move air intake duct for air cleaner. Remove engine top
trim cover and cylinder head trim covers. Disengage spring
clips at timing belt covers. Remove timing belt covers. Re-
move noise insulation panel from under front of vehicle.
Using box wrench, turn serpentine belt tensioner clock-
wise to relieve tension. Remove serpentine belt.
Remove electric cooling fan. Remove viscous cooling fan
shroud. Hold viscous cooling fan pulley with a spanner
wrench. Remove viscous fan by turning clockwise. Vis- Courtesy of Audi of America, Inc.
cous fan is LEFT-HAND threaded. See Fig. 1. Fig. 3: Aligning Camshaft Sprocket Securing Plate Holes
Rotate crankshaft to TDC of compression stroke. Ensure
TDC mark on crankshaft pulley aligns with mark on engine.
See Fig. 2.
Check position of camshafts. Larger hole in camshaft
sprocket securing plates must face inboard and align with
each other. See Fig. 3.
Fig. 4: Locating Crankshaft Clamping Bolt (3242)
Remove sealing plug from lower left side of engine block.

TDC drilling in crankshaft MUST be behind sealing plug
hole. Screw Crankshaft Clamping Bolt (3242) into hole.
See Fig. 4.
Remove serpentine belt tensioner from front of engine block.
Remove crankshaft pulley retaining bolts. It is NOT neces-
sary to remove center bolt. Remove crankshaft pulley.
Fig. 1: Removing Viscous Cooling Fan (Left-Hand Threads)
AUDI 77
*4.2L V8 2000 (Cont.)

Fig. 7: Installing Camshaft Bar (T40005)
Fig. 5: Viscous Cooling Fan Mounting Bracket
Installation:
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.
Hand tighten camshaft sprocket bolts. Camshaft sprock-
ets must be tight enough on camshaft tapers to be turned,
but should not tilt back and forth.
Attach Camshaft Bar (T40005) to camshafts. Insert a 5 mm
drill bit between the tensioning lever and the tip of the hy-
draulic tensioner piston.
Set initial timing belt tension using Tensioning Key
(T40009), Socket Attachment (5122) and Torque Wrench
(1410). See Fig. 9. Set tension to 35 INCH lbs. (4 N.m).
While holding tensioner at this point, tighten center nut to
16 ft. lbs. (22 N.m). Remove 5 mm drill bit.
Using 8 mm hex wrench, rotate timing belt tensioning lever
counterclockwise until Spring Pin (T40011) can be removed
from hydraulic tensioner.
Rotate timing belt tensioner lever CLOCKWISE until a 7
mm drill bit can be inserted between the tip of the tensioning
Courtesy of Audi of America, Inc. lever and the top of the hydraulic tensioner body. Tighten
Fig. 6: Relieving Timing Belt Tension camshaft sprocket bolts to specification. See TORQUE
SPECIFICATIONS. Keep Camshaft Bar (T40005) in place
CAUTION: Manufacturer recommends REPLACING crankshaft to prevent camshafts from moving.
pulley center bolt if it has been loosened or removed.
Remove bracket for viscous cooling fan. See Fig. 5.
Using 8 mm hex wrench, SLOWLY compress hydraulic tim-
ing belt tensioner by turning tensioning lever counterclock-
wise. See Fig. 6. Insert Spring Pin (T40011) through top of
timing belt tensioner and through hole in top of tensioner
piston.
Install Camshaft Bar (T40005) onto securing plates of both
camshafts. See Fig. 7.
Loosen both camshaft sprocket securing bolts about 5
turns. Remove Camshaft Bar (T40005). Using 2-jaw gear
puller, loosen camshaft sprockets so that they are free to
rotate, but not tilt, on the end of the camshaft.
Loosen center bolt of timing belt tensioner pulley with ec-
centric center. Tensioner pulley is located above and to the
right of crankshaft sprocket. Remove timing belt along with
camshaft sprocket for cylinders No. 1 through No. 4 (pas-
senger side cylinder head).
Fig. 8: Measuring Tensioning Lever-To-Piston Clearance

78 AUDI
*4.2L V8 2000 (Cont.)

Fig. 10: Measuring Timing Belt-To-Guard Clearance
(Right-Side Cylinder Head)
Fig. 9: Setting Initial Timing Belt Tension
Remove Camshaft Bar (T40005) after camshaft sprocket

bolts are tightened. Remove 7 mm drill bit. Remove Crank-
shaft Clamping Bolt (3242) from side of engine block. In-
stall sealing plug in hole. Turn crankshaft 2 revolutions in
normal direction of rotation.
Measure distance between tensioning lever and top of hy-
draulic tensioner body. Dimension should be .197 (5 mm).
See Fig. 8. If dimension is not correct, readjust timing belt
tension until dimension is .197 (5 mm).
Measure clearance between bottom of right hand timing
belt guard and top of timing belt. See Fig. 10. If clearance is
not correct, turn crankshaft until all rear timing belt cover
bolts are exposed. Loosen bolts and adjust clearance to
.0393 (1 mm). Tighten rear timing belt cover bolts.
Measure clearance between bottom of left hand timing belt
guard and top of timing belt. See Fig. 11. If clearance is not
correct, turn crankshaft until all rear timing belt cover bolts
are exposed. Loosen bolts and adjust clearance to .0393
(1 mm). Tighten rear timing belt cover bolts. Fig. 11: Measuring Timing Belt-To-Guard Clearance
Install crankshaft pulley. Tighten all bolts to specification. (Left-Side Cylinder Head)
To complete installation reverse removal procedure.
Crankshaft Pulley Center Bolt
Step 1 ..................................................................... 1 148 (200)
Step 2 ................................................. Plus 180 Degrees Turn
Crankshaft Pulley-To-Sprocket Bolts .............................. 15 (20)
Timing Belt Tensioner Center Nut ................................ 16 (22)
Viscous Cooling Fan-To-Pulley ...................................... 52 (70)
Water Pump Bolts ...................................................... 10 (14)
INCH Lbs. (N.m)
Timing Belt Hydraulic Tensioner Bolts ........................... 89 (10)
Timing Belt Rear Cover Bolts ......................................... 89 (10)
Viscous Cooling Fan Bracket Mount Bolts ..................... 89 (10)
1
- Use NEW bolt if loosened or removed.
AUDI & VOLKSWAGEN 79
2.1L & 2.2L 5-Cylinder, 1978-91

TIMING BELT APPLICATION MANUFACTURERS SUGGESTED
Application Labor Time Belt Part No. SCHEDULED MAINTENANCE
2.1L 5-Cyl. Although the manufacturer does not recommend a specific
Quantum scheduled maintenance interval, belt manufacturers suggest
1984-85 the belt be replaced at 60,000 mile intervals.
.70 Belt T.W. ....... 1.8 Hours ..................... T127 REMOVAL & INSTALLATION
.75 Belt T.W. ....... 1.8 Hours ..................... T065
2.2L 5-Cyl. TIMING BELT
Coupe Removal:
1981-83 ................ 2.2 Hours ..................... T065 Disconnect negative battery cable. Remove upper radiator
1984-85 cover. Remove drive belts. Remove power steering pump
120 Tooth Belt .... 2.2 Hours ..................... T127 with pressure hoses connected. Set pump aside. Remove
valve cover and outer timing belt covers. See Fig. 1.
113 Tooth Belt ..... 2.2 Hours ..................... T065 Using crankshaft bolt, turn crankshaft clockwise to TDC of
1986-87 .................. 2.2 Hours ..................... T127 No. 1 cylinder compression stroke. Align timing mark on
Quantum back of camshaft sprocket with upper edge of gasket. See
1983-86 Fig. 2.
.70 Belt T.W. ....... 1.8 Hours ..................... T127 Loosen water pump adjusting bolts to relieve tension on
.75 Belt T.W. ....... 1.8 Hours ..................... T065 timing belt. Remove timing belt. Remove water pump to
1987-88 .................. 1.8 Hours ..................... T127 check O ring. DO NOT allow crankshaft or camshaft to
move.
Quattro Installation:
1983 ....................... 1.1 Hours ..................... T065 Ensure both camshaft lobes on No. 1 cylinder point up-
1984-85 ward. Mark (notch or dot) on back of camshaft sprocket
120 Tooth Belt .... 2.2 Hours ..................... T127 must be aligned with top of valve cover gasket or rear tim-
113 Tooth Belt ..... 2.2 Hours ..................... T065 ing belt cover. Crankshaft must be at TDC for No. 1 cylinder.
200 Flywheel TDC mark must be aligned with index point on
transmission housing.
1989
Install water pump with new sealing O ring. Install timing
(Thru Chassis No. belt. Turn water pump body counterclockwise to increase
44 K 400 000) ....... 2.5 Hours ..................... T127 belt tension. Tension is correct when belt can be twisted 90
(From Chassis No. degrees using finger pressure at point midway between
44 K 400 001) ....... 2.5 Hours ..................... T170 camshaft sprocket and water pump sprocket. Recheck valve
1990-91 ................ 2.5 Hours ..................... T170 timing. Reverse installation order of removal. Adjust drive
200 Quattro belts.See page A-60 for belt tension ranges.
1989 NOTE: Turn engine by hand using hex flange on hydraulic pump.
(Thru Chassis No. Loosen tensioner bolts.
44 K 004 457) ....... 2.5 Hours ..................... T127
(From Chassis No. TORQUE SPECIFICATIONS
44 K 004 458) ....... 2.5 Hours ..................... T170 Application Ft. Lbs. (N.m)
1990-91 .................. 2.5 Hours ..................... T170 Camshaft Sprocket Bolt .............................................. 59 (80)
4000 Timing Belt Idler Pulley Bolt .......................................... 15 (20)
1980-81 .................. 1.8 Hours ..................... T065 Timing Belt Tensioner (1992-95) ................................ 15 (20)
Vibration Damper Bolt ............................................ 258 (350)
4000CS Water Pump Bolt ........................................................ 15 (20)
1986-87 .................. 1.8 Hours ..................... T127 INCH Lbs. (N.m)
4000CS Quattro Radiator Mounting Bolts ............................................. 89 (10)
1987 ....................... 1.8 Hours ..................... T127 Timing Belt Cover ....................................................... 89 (10)
4000S Quattro Valve Cover Nuts/Bolts ............................................... 89 (10)
1984-85
120 Tooth Belt .... 1.8 Hours ..................... T127
113 Tooth Belt ..... 1.8 Hours ..................... T065
1986 ....................... 1.8 Hours ..................... T127
5000
1978-83 .................. 1.1 Hours ..................... T065
5000CS Quattro
1987-88 .................. 2.2 Hours ..................... T127
5000S
1984-85
120 Tooth Belt .... 1.8 Hours ..................... T127
113 Tooth Belt ..... 1.8 Hours ..................... T065
1986-87 ................. 1.8 Hours ..................... T127
80 AUDI & VOLKSWAGEN
2.1L & 2.2L 5-Cylinder, 1978-91 (Cont.)
96I14520 Courtesy of Audi of America, Inc.

Fig. 1: Exploded View Of Timing Belt, Sprockets & Covers
96E14641 Courtesy of Audi of America, Inc.
Fig. 2: Aligning Camshaft Sprocket
92A00398 Courtesy of Audi of America, Inc.

BMW 81
*2.5L & *2.7L 6-Cylinder

TIMING BELT APPLICATION Remove front cover. Loosen timing belt tensioner mount-
ing bolts and press in on tension roller. Tighten upper
Application Labor Time Belt Part No. mounting bolt to hold tensioner in place. Remove timing
2.5L 6-Cyl. belt.
325 Series Installation:
1987-88 Ensure arrow on camshaft sprocket is still aligned with
127 Tooth Belt ... 3.2 Hours ..................... T131 timing mark on cylinder head. Ensure timing mark on crank-
shaft sprocket is aligned with notch in cover (about one
128 Tooth Belt ... 3.2 Hours ..................... T106 oclock position). See Fig. 1.
1989-91 ................. 3.2 Hours ..................... T131 Install timing belt on sprockets. Loosen tensioner adjust-
525i ing bolt to allow spring tension on timing belt. Turn crank-
1989-95 ................. 3.2 Hours ..................... T131 shaft in direction of normal rotation until timing belt tight-
2.7L 6-Cyl. ens. Tighten tensioner bolt.
325 Series Clean gasket mating surfaces. Coat oil pan-to-cover gas-
1984-88 ket with gasket sealer. Install Centering Tool (11 2 211) on
crankshaft and on intermediate shaft to align front cover.
127 Tooth Belt ... 3.2 Hours ..................... T131 Using new gasket, install and tighten timing belt cover.
128 Tooth Belt ... 3.2 Hours ..................... T106 When installing crankshaft sprocket, lettering must face
528e forward. Install remaining components in reverse order of
1982-88 removal procedure. Adjust drive belts to proper tension.
127 Tooth Belt ... 3.2 Hours ..................... T131 See page A-60 for belt tension ranges.
128 Tooth Belt ... 3.2 Hours ..................... T106 TIGHTENING SPECIFICATIONS
Application Ft. Lb.s. (N.m)
NOTE: Use 127 tooth belt with retrofit tensioner pulley. Use 128 Camshaft Sprocket ........................................... 47-50 (65-70)
tooth belt with with OEM tensioner pulley. DO NOT use 128 tooth Intermediate Shaft Sprocket ............................. 40-47 (55-64)
belt on new style adjusting pulley. Vibration Damper Hub .............................. 283-311 (390-430)
The manufacturer recommends the belt be replaced every
60,000 miles or whenever tensioner roller has been released.


TIMING BELT COVER
Removal:
Disconnect negative battery cable. Remove lower splash
shield. Remove all drive belts. Remove cooling fan and
water pump pulley. Drain cooling system. Disconnect both
hoses and transmission cooling line. Disconnect electri-
cal connector from radiator switches. Remove radiator. Hold
crankshaft in place and remove center bolt from vibration
damper hub.
Using a puller, remove vibration damper hub from crank-
shaft. Remove distributor cap and rotor. Remove cover from
distributor housing. Ensure cylinder No. 1 is set to TDC on
compression stroke. See Fig. 1. Remove alternator ten-
sion bracket and move aside.
Fig. 1: Aligning Timing Sprockets
82 BMW
*2.5L & *2.7L 6-Cylinder (Cont.)
Fig. 2: Exploded View Of Camshaft Drive Assembly

CHRYSLER 83
*1.4L 4-Cylinder
TIMING BELT APPLICATION Slowly turn crankshaft one revolution clockwise and realign
crankshaft sprocket timing mark at TDC. Do not push or
Application 1
Labor Time Belt Part No. shake belt while turning or turn crankshaft in counterclock-
1.4L 4-Cyl. wise direction. Loosen tensioner spring bolt first then slot-
Colt ted adjustment hole bolt. Tighten tensioner bolts by tight-
1979-84 ................. 1.1 Hours ..................... T073 ening slotted adjustment hole bolt first and tensioner spring
Champ bolt last.
1979-82 ................. 1.1 Hours ..................... T073 Check belt tension by pushing tension side of timing belt in
horizontally using about 11 lbs. (5 kg) force. Timing belt
1
- With Air Cond. add .2 hours. tooth end should be approximately 1/4 of tensioner mount-
ing bolt head width (across flats) away from bolt head cen-
ter. See Fig. 3. Adjust drive belts to proper tension. See
MANUFACTURERS SUGGESTED page A-60 for belt tension ranges.
SCHEDULED MAINTENANCE TORQUE SPECIFICATIONS
The manufacturer recommends the belt be replaced every Application Ft. Lbs. (N.m)
60,000 miles. Camshaft Sprocket ........................................... 47-54 (64-73)
Crankshaft Sprocket Bolt .................................. 37-43 (50-58)
* NOTE: This application is an interference engine. Timing Chain Tensioner ................................... 15-18 (20-24)
See page A-59 for interference engine cautions. INCH Lbs. (N.m)
Crankshaft Pulley Bolt .................................... 90-102 (10-11)
REMOVAL & INSTALLATION Oil Pump Cover ................................................ 72-108 (8-10)
TIMING BELT
Removal:
Disconnect negative battery cable. On front wheel drive mod-
els, remove air cleaner assembly, then disconnect accel-
erator cable and oxygen sensor lead. On all models, mark
position of spark plug wires for installation, then remove
wires from spark plugs. On front wheel drive models, sup-
port engine using a suitable engine support bar.
Remove left engine mount bracket. Remove fan, spacer,
water pump pulley and drive belt. Remove rocker arm cover
and timing belt cover. Move timing belt tensioner upward
toward water pump and secure. Remove timing belt from
camshaft sprocket. Mark belt with an arrow indicating di-
rection of rotation for installation reference, and remove
timing belt.
Installation:
Align camshaft and crankshaft sprockets. Mount belt
tensioner, spring, spacer and temporarily tighten bolt. Po-
sition spring against tensioner first, then against case and
tighten bolt. See Fig. 2. Position and secure tensioner to-
ward water pump.
Install timing belt on crankshaft and camshaft sprockets.
Ensure tension side is tight and timing marks are aligned
when pressure is applied to turn camshaft in reverse di-
rection. Align dowel and install crankshaft pulley. Loosen
tensioner bolt. Ensure proper mesh of belt and sprocket.
With only spring tension applied to belt, tighten tensioner
spring bolt first and slotted adjustment hole bolt last.
Fig. 1: Removing/Installing Timing Belt

84 CHRYSLER
Fig. 3: Checking Timing Belt Tension
Fig. 2: Installing Timing Belt Tensioner

CHRYSLER 85
1.6L 4-Cylinder With Balance Shaft

1.6L 4-Cyl. SOHC
Arrow & Sapporo
1977-80 ................ 1 1.7 Hours ................. 2 T013
1977-80 ................ 1 1.7 Hours ................. 3 T062
Challenger
1978-79 ................ 1 1.7 Hours ................. 2 T013
1978-79 ................ 1 1.7 Hours ................. 3 T062
Champ
1979-80 ................ 1 1.7 Hours .................. 2 T013
1979-80 ................ 1 1.7 Hours .................. 3 T062
Colt
1977-80 ................ 1 1.7 Hours .................. 2 T013
1977-80 ................ 1 1.7 Hours .................. 3 T062
1
- Counterbalance shaft belt included in labor
time.
With Air Cond. add .2 hours.
2
Camshaft timing belt.
3
Counterbalance shaft belt.
Fig. 1: Counterbalance & Timing Belt Routing
60,000 miles.

TIMING BELT
Removal:
Disconnect negative battery cable. Rotate crankshaft so
that No. 1 cylinder is at TDC of compression stroke. Re-
move crankshaft pulley, upper and lower timing belt front
covers. Loosen timing belt tensioner mounting nut and bolt.
Move tensioner away from timing belt and temporarily tighten
nut. Remove timing belt. See Fig. 1. Fig. 2: Installing Screwdriver To Hold Counterbalance
Remove plug at bottom of left side of cylinder block. See (Silent) Shaft In Place
Fig. 2. Insert a screwdriver to keep left counterbalance
(silent) shaft in position. Screwdriver MUST insert at least
2.36 (59.9 mm). If not, turn oil pump sprocket (which drives
left counterbalance shaft) one full turn until timing mark is
aligned again. Keep screwdriver in place until timing belt is
installed.
Remove outer crankshaft sprocket and flange. Loosen cen-
ter bolt on counterbalance belt tensioner pulley. Remove
counterbalance shaft belt.
Installation:
Align counterbalance shaft and crankshaft sprocket timing
marks. See Fig. 3. Install counterbalance shaft belt so that
there is no slack on tension side of belt.
Position counterbalance shaft tensioner so that the eccen-
tric in the center of the pulley is located to the left and above
the bolt. See Fig. 4. Ensure pulley flange faces toward front
of engine. While keeping tension on counterbalance shaft
belt, tighten tensioner pulley bolt. DO NOT allow tensioner Fig. 3: Aligning Counterbalance Shaft Timing Marks
pulley to rotate while tightening center bolt.
If camshaft timing belt tensioner was removed, install
tensioner. Ensure tension spring is seated in correct posi-
tion on water pump body. See Fig. 5. Secure tensioner away
from timing belt.
86 CHRYSLER
1.6L 4-Cylinder With Balance Shaft (Cont.)
Fig. 6: Checking Camshaft Timing Belt Tension
Fig. 4: Positioning Counterbalance Pulley then bolt. If bolt is tightened first, the tensioner may also
turn more than necessary.
Ensure all camshaft timing marks are still aligned. Turn
crankshaft one revolution in normal direction of rotation
(clockwise). Do NOT turn crankshaft counterclockwise.
CAUTION: Do NOT push or twist camshaft timing belt during

final tension adjustment.
Loosen tensioner mounting bolt and nut. This will take any
slack out of timing belt. Final tighten tensioner mounting
nut to specified torque. See TORQUE SPECIFICATIONS.
Tighten tensioner mounting bolt.
To check timing belt tension, grasp camshaft timing belt
between thumb and forefinger. Clearance between back of
timing belt and edge of rear timing case seal line should
be .47 (12 mm). See Fig. 6. Readjust camshaft timing belt
tension, if necessary.
Remove crankshaft pulley. Install timing belt covers. Install
crankshaft pulley. Tighten crankshaft sprocket center bolt
and pulley bolts to specification. Install accessory drive
belts. Adjust drive belts to proper tension. See page A-60
Fig. 5: Positioning Camshaft Timing Belt Tensioner Spring TORQUE SPECIFICATIONS
Install outer crankshaft sprocket. Install camshaft timing Application Ft. Lbs. (N.m)
belt first on crankshaft sprocket, then around the oil pump Camshaft Sprocket Bolt ...................................... 44-57 (60-78)
sprocket and camshaft sprocket. Keep slack out of belt Crankshaft Sprocket Center Bolt ........................ 44-50 (60-68)
during installation. Ensure crankshaft, camshaft and oil Oil Pump Sprocket Bolt ....................................... 25-28 (34-39)
sprocket timing marks are still aligned. Timing Belt Tensioner Mounting Bolt ................ 16-21 (22-29)
Remove screwdriver inserted in left side of engine block. Timing Belt Tensioner Mounting Nut ................ 16-21 (22-29)
Install plug. Temporarily install crankshaft pulley to prevent INCH Lbs. (N.m)
timing belt movement when crankshaft is turned. Loosen Crankshaft Pulley Bolt ...................................... 90-102 (10-11)
camshaft timing belt tensioner nut and bolt.
Lightly push camshaft belt tensioner toward timing belt.
Ensure timing belt fully meshes with all teeth on sprockets.
Tighten camshaft timing belt tensioner mounting nut first,
CHRYSLER 87
1.6L 4-Cylinder Without Balance Shaft

TIMING BELT APPLICATION Ensure that all timing marks are still in alignment. See Fig.
1. If tensioner was removed, ensure spring is positioned
Application Labor Time Belt Part No. correctly under water pump body. See Fig. 2. Secure
1.6L 4-Cyl. SOHC, Without Balance Shaft tensioner out of way so that timing belt can be installed.
Arrow & Sapporo Install timing belt on crankshaft sprocket, on oil pump
1978-80 ................ 1 1.6 Hours .................. T064 sprocket and camshaft sprocket, in that order. Keep slack
Challenger & Colt (RWD) out of belt during installation.
1978-79 ................ 1 1.6 Hours .................... T064 Ensure all timing marks are still aligned. Temporarily in-
stall crankshaft pulley.
Champ Loosen tensioner mounting bolt so that spring-loaded
1979-82 ................. 2.8 Hours ..................... T064 tensioner applies pressure to the timing belt. Lightly push
Colt (FWD) tensioner up by hand to ensure timing belt completely
1979-82 ................ 1 2.8 Hours .................... T064 meshes with drive sprockets. Tighten tensioner mounting
1983-89 ................ 1 2.8 Hours .................... T093 nut, then tighten mounting bolt. See Fig. 3.
Vista (Canadian) Turn crankshaft one turn in normal direction of rotation. Do
NOT turn in opposite direction. Loosen the timing belt
1989 ..................... 1 2.8 Hours .................... T093 tensioner mounting bolt and nut. This will take out any slack
1
- With Air Cond. add .2 hours. in belt. Tighten mounting nut to specifed torque. See
With Pwr. Strng. add .2 hours. TORQUE SPECIFICATIONS. Tighten timing belt tensioner
bolt.
To check timing belt tension, grasp belt between thumb
MANUFACTURERS SUGGESTED and forefinger near timing belt tensioner. See Fig. 4. Ten-
SCHEDULED MAINTENANCE sion is correct when distance between back of belt and
The manufacturer recommends the belt be replaced every edge of rear timing case cover is .47" (12 mm) with finger
60,000 miles. pressure. Readjust tension, if necessary.

TIMING BELT
Removal:
Disconnect negative battery cable. On front wheel drive only,
support engine under oil pan with a floor jack. Remove
engine mount on timing belt end of engine.
On all models, remove accessory drive belts. Remove crank-
shaft pulley, upper and lower timing belt front covers. Turn
crankshaft clockwise to align camshaft and crankshaft tim-
ing marks. See Fig. 1.
Loosen belt tensioner mounting nut and bolt. Move
tensioner away from belt and temporarily tighten nut. Re-
move timing belt. See Fig. 1.
Installation:
Fig. 1: Timing Belt Routing & Alignment

88 CHRYSLER
1.6L 4-Cylinder Without Balance Shaft (Cont.)
Remove crankshaft pulley. Install timing belt covers. Install
crankshaft pulley and tighten bolts to specification. On front
wheel drive vehicles, install engine mount. Adjust drive
belts to proper tension. See page A-60 for belt tension
ranges.
Timing Belt Tensioner Nut/Bolt ......................... 16-21 (22-29)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt ...................................... 90-102 (10-11)

CHRYSLER 89
1.7L 4-Cylinder
TIMING BELT APPLICATION NOTE: Do not turn engine by turning camshaft pulley. This will
Belt cause belt to skip teeth.
Labor Component Part Turn engine clockwise from TDC 2 complete crankshaft
Application Time1 Kit No. No. revolutions to TDC. Tighten tensioner lock nut while hold-
1.7L 4-Cyl. ing belt tensioner wrench in position. Reverse removal pro-
Charger cedure to complete installation. Adjust drive belts to proper
1983 ............... 3.1 Hours ... TCK017 .......... T017
Horizon
1978-83 .......... 3.1 Hours ... TCK017 .......... T017
Omni
1978-83 .......... 3.1 Hours ... TCK017 .......... T017
TC3
1981-82 .......... 3.1 Hours ... TCK017 .......... T017
Turismo
1983 ............... 3.1 Hours ... TCK017 .......... T017
024
1981-82 .......... 3.1 Hours ... TCK017 .......... T017
1
With Air Pump add .2 hours.
With Pwr. Strng. add .2 hours

kits.
the belt be replaced at 60,000 mile intervals. Courtesy of DaimlerChrysler Corp.

TIMING BELT
Removal:
Disconnect negative battery cable. If equipped, remove A/C
compressor and power steering pump from mounting
brackets and position aside, leaving refrigerant lines and/
or hoses connected. Remove alternator from mounting
bracket and position aside.
Raise vehicle and remove inner fender splash shield. On
1981-83 Models, remove water pump. If equipped, remove
AIR pump belts. Remove idler pulley assembly. Remove
crankshaft pulley and power steering belt. Remove lower
plastic timing belt cover. See Fig. 1.
Lower vehicle and place jack under engine. Remove right
motor mount through bolt and raise engine slightly. Loosen
timing belt tensioner and remove timing belt.
Installation:
Align timing marks on crankshaft and intermediate sprock-
ets. See Fig. 2. Turn camshaft sprocket until timing mark
on sprocket is lined up with camshaft cover sealing sur-
face. See Fig. 3.
Install timing belt and Belt Tensioner Tool (L-4502 or equiva-
lent) horizontally on large hex of belt tensioner pulley and
loosen tensioner lock nut. See Fig. 4. If necessary, reset Fig. 2: Crankshaft & Intermediate Sprocket Timing Marks
belt tensioner tool to have axis within 15 of horizontal.
90 CHRYSLER
Fig. 3: Camshaft Timing Mark

Application Ft. Lbs (N.m)
Fig. 4: Tensioning Timing Belt
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)
CHRYSLER 91
1.8L 4-Cylinder VIN T

TIMING BELT APPLICATION Inspection:
Check belt teeth for cracks, damage or oil contamination.
Application Labor Time1 Belt Part No. Inspect all sprockets for damage. Check belt tensioner for
1.8L 4-Cyl. signs of grease leakage or roughness in tensioner rota-
Colt & Colt Wagon tion. Replace components if damaged.
1989-90 ................. 2.4 Hours .................... T093 Installation:
Rotate tensioner toward water pump and temporarily
1
- With Air Cond. add .2 hours. tighten retaining nut. See Fig. 2. Ensure camshaft and crank-
With Pwr. Strng. add .2 hours. shaft timing marks are aligned. See Fig. 1.
Apply pressure on tension side of belt and install timing belt
MANUFACTURERS SUGGESTED on oil pump sprocket and then on crankshaft sprocket. Apply
force on camshaft sprocket, in counterclockwise direction, to
SCHEDULED MAINTENANCE apply tension on tension side of belt. Ensure all timing marks
The manufacturer recommends the belt be replaced every are aligned.
60,000 miles. Loosen belt tensioner bolt, then loosen nut to place tension
on timing belt. Rotate camshaft sprocket clockwise until tim-
REMOVAL & INSTALLATION ing mark is offset by 2 teeth to apply tension on belt. Ensure all
timing marks are aligned. Tighten tensioner nut, then tighten
TIMING BELT bolt.
Check belt tension by applying slight thumb pressure to
CAUTION: To prevent engine damage, DO NOT rotate crankshaft timing belt in direction of timing belt lower rear cover. See
counterclockwise (as viewed from timing belt end of engine). Fig. 3. Ensure distance between back of timing belt (smooth
Removal: side) and timing belt lower rear cover is approximately .23"
Disconnect negative battery cable. Remove protective cover (6 mm). To complete installation, reverse removal proce-
below engine. Support engine and remove engine mount dure. Adjust accessory drive belts to proper tension. See
from timing belt end of engine. Remove spark plug wires page A-60 for belt tension ranges.
and rocker cover. Remove drive belts and water pump pul- TORQUE SPECIFICATIONS
ley. Remove A/C belt tensioner (if equipped). Application Ft. Lbs. (N.m)
Remove crankshaft pulley assembly. Remove upper front Camshaft Sprocket Bolt .................................... 58-72 (79-98)
and lower timing belt covers. Note bolt lengths and loca- Crankshaft Pulley Bolt ...................................... 11-13 (15-18)
tions. Rotate engine clockwise (as viewed from timing belt Crankshaft Sprocket Bolt ............................. 80-94 (109-127)
end of engine) to align timing mark on camshaft sprocket Damper Pulley Bolt ........................................... 11-13 (15-18)
with mark on upper rear cover. See Fig. 1. Engine Support Bracket Bolt ............................. 22-30 (30-41)
If reusing belt, mark timing belt position on camshaft Front Cover Bolt ................................................ 11-13 (15-18)
sprocket and indicate direction of belt rotation. Loosen tim- Tensioner Pulley Bracket Bolt ........................... 17-20 (23-27)
ing belt tensioner bolt and nut. Move timing belt tensioner Water Pump Bolt
toward water pump to release tension and tighten nut tem- 8 X 70 mm ...................................................... 15-19 (20-26)
porarily to maintain tensioner position. See Fig. 2. Remove All Others .................................................................. 10 (14)
timing belt. 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. 2: Positioning Timing Belt Tensioner

Fig. 1: Aligning Timing Mark & Arranging Belt
92 CHRYSLER
1.8L 4-Cylinder VIN T (Cont)
91G00816 Courtesy of Chrysler Corp.

CHRYSLER 93
*2.0L 4-Cylinder SOHC, VIN C

TIMING BELT APPLICATION NOTE: The following revised information regarding the tensioner
Application Labor Time Belt Part No. pulley pivot bolt is from Chrysler technical service bulletin 09-
06-96; March 29, 1996.
2.0L 4-Cyl. SOHC
Breeze Timing Belt Tensioner Bracket Precaution:
1996-00 ................ 1 2.4 Hours .................... T245 On models with hydraulic timig belt tensioner, do not loosen,
Cirrus tighten, or remove timing belt tensioner pivot bolt. Bolt is
installed at factory with special threadlocking compound
2000 ..................... 1 2.4 Hours .................... T245 that is not reusable. If tensioner pivot bolt is disturbed,
Neon entire bracket assembly must be replaced. The tensioner
1995-00 ................ 1 2.4 Hours .................... T245 pulley center bolt MAY be removed and installed.
Stratus
1995-00 ................ 1 2.4 Hours .................... T245
1
On Neon models, the manufacturer recommends the belt be
replaced at 105,000 mile intervals.
On Breeze, Cirrus and Stratus models, the manufacturer rec-
ommends the belt be replaced at 100,000 mile intervals on
vehicles with Federal emissions, and 105,000 mile intervals
with California emissions.
*NOTE: This application is an interference engine. Oil Pump Body

See page A-59 for interference engine cautions. 96F14485 Courtesy of DaimlerChrysler
TIMING BELT
Removal (Hydraulic Tensioner):
Remove No. 1 spark plug. Using dial indicator, set number
one cylinder to TDC of compression stroke. Remove ac-
cess plug from top of timing belt cover. See Fig. 1. Ensure
timing mark on camshaft aligns with mark on rear cover.
See Fig. 2.
belts. Raise vehicle and remove right inner splash shield.
See Fig. 7. Remove crankshaft damper bolt. Use gear puller
to remove crankshaft damper.
Lower vehicle and place a jack under engine to support
weight. Remove right engine mount. On Breeze and Stra-
tus, remove generator (with wiring attached) and bracket,
and secure out of way. On Neon, remove power steering
pump with hoses attached, and secure out of way. Remove
upper and lower engine torque struts (2001-00 Neon). On
all models, remove right engine mount bracket from en-
gine. See Fig. 3.
Remove front timing belt cover. See Fig. 1. Rotate crank-
shaft so that timing marks are aligned. See Fig. 2. Loosen
timing belt tensioner bolts. If reusing timing belt, mark ar-
row on belt to indicate direction of rotation. Remove timing
belt and tensioner. DO NOT loosen, tighten, or remove
tensioner pulley pivot bolt.
CAUTION: To prevent pistons from hitting valves, do not rotate

camshaft or crankshaft after removing the timing belt.
NOTE: When tensioner is removed from engine, it is necessary

to compress plunger into tensioner body. Index tensioner in vise Courtesy of DaimlerChrysler
the same way it is installed on engine to ensure proper pin orientation Fig. 2: Aligning Timing Marks & Adjusting Belt Tension
when tensioner is installed on engine. (Hydraulic Timing Belt Tensioner)
94 CHRYSLER
*2.0L 4-Cylinder SOHC, VIN C (Cont.)
Inspection:
Check belt teeth for damage or oil contamination. Inspect
belt for glossy, hardened or non-elastic surface. Ensure
the belt is not cracked, separated or showing canvas fiber.
Inspect all sprockets for damage. Check tensioner pulley
and idler pulley for signs of grease leakage or roughness
in rotation. Replace components if damaged.
Installation (Hydraulic Tensioner):
Place tensioner in soft-jawed vise and slowly compress
plunger. See Fig. 4. When plunger is compressed into
tensioner body, install a 5/16" (1.9 mm) hex wrench or lock-
ing pin through body and plunger to hold plunger in place
until tensioner is installed.
Set crankshaft sprocket to TDC by aligning sprocket with
arrow on oil pump housing, then back off to 3 notches be-
fore TDC.
Set camshaft to TDC by aligning mark on sprocket with
arrow on rear of timing belt cover. See Fig. 2. Move crank-
shaft to 1/2 notch mark before TDC for belt installation. See
96D14483 Courtesy of DaimlerChrysler Fig. 5. Install timing belt by starting at crankshaft, then around
water pump sprocket and then camshaft sprocket.
Fig. 3: Locating Right Engine Mount Bracket (Typical)
Move crankshaft sprocket to TDC to take up belt slack. In-
stall tensioner to block, but do not final tighten bolts. Using
a torque wrench on tensioner pulley, apply 21 ft. lbs. (28 N.
m) of torque in clockwise direction. With torque applied to
tensioner pulley, move the tensioner up against the
tensioner pulley bracket. Final tighten tensioner bolts. See
Fig. 1.
Pull tensioner plunger locking pin. Pretension is correct
when pin can be removed and installed. Rotate crankshaft
2 revolutions. Check alignment of the timing marks. Install
front timing belt cover. Install engine mount bracket. Install
generator and bracket (Breeze and Stratus) or power steer-
ing pump (Neon).
96I14488 Courtesy of DaimlerChrysler

Fig. 4: Compressing Hydraulic Timing Belt Tensioner
Courtesy of DaimlerChrysler
Courtesy of DaimlerChrysler Fig. 6: Aligning Timing Marks & Adjusting Belt Tension
Fig. 5: Aligning Crankshaft Sprocket Timing Marks (Mechanical Timing Belt Tensioner)
CHRYSLER 95
*2.0L 4-Cylinder SOHC, VIN C (Cont.)

Install right engine mount. Remove jack from under en- Installation (Mechanical Tensioner):
gine. Install crankshaft damper and tighten bolt to specifi- Set crankshaft sprocket to TDC by aligning sprocket with
cation. See TORQUE SPECIFICATIONS. arrow on oil pump housing, then back off to 3 notches be-
Raise vehicle on hoist. Install right inner splash shield. fore TDC.
Lower vehicle. Install accessory drive belts. Adjust drive Set camshaft to TDC by aligning mark on sprocket with
belts to proper tension. See page A-60 for belt tension arrow on rear of timing belt cover. See Fig. 6. Move crank-
ranges. shaft to 1/2 mark before TDC for belt installation. See Fig.
On Neon models, connect scan tool to Data Link Connec- 5. Install timing belt by starting at crankshaft, then around
tor (DLC) under lower left edge of instrument panel. Follow water pump sprocket and then camshaft sprocket. See Fig.
scan tool manufacturers instructions to access the cam/ 6. Move crankshaft sprocket to TDC to take up belt slack.
crank relearn procedure. Perform cam/crank relearn pro- Remove Allen wrench from timing belt tensioner pulley. Ro-
cedure. tate crankshaft clockwise 2 revolutions. Check alignment
of camshaft and crankshaft timing marks. If timing marks
NOTE: Chrysler recommends replacing worn mechanical tensioners do not align, remove timing belt and realign timing marks.
with updated hydraulic tensioner kits. Information is from Chrysler Install front timing belt cover. Install engine mount bracket
technical service bulletin 09-06-00; March 10, 2000. to engine. Continue installation in reverse of removal pro-
Removal (Mechanical Tensioner): cedure. Tighten all fasteners to specification. See TORQUE
Remove No. 1 spark plug. Using dial indicator, set number SPECIFICATIONS. Adjust accessory drive belts to proper
one cylinder to TDC of compression stroke. Remove ac- tension. See page A-60 for belt tension ranges.
cess plug from top of timing belt cover. See Fig. 1. Ensure On 1998-00 Neon models, connect scan tool to Data Link
timing mark on camshaft aligns with mark on rear cover. Connector under lower left edge of dash. Follow scan tool
See Fig. 6. manufacturers instructions to access the cam/crank re-
Disconnect negative battery cable. Remove accessory drive learn procedure. Perform cam/crank relearn procedure.
belts. Raise vehicle and remove right inner splash shield. TORQUE SPECIFICATIONS
See Fig. 7. Remove crankshaft damper bolt. Use gear puller
to remove crankshaft damper.
Camshaft Sprocket Bolt ............................................ 85 (115)
On Breeze and Stratus, lower vehicle and place a jack un- Crankshaft Damper Bolt ......................................... 105 (142)
der engine to support weight. Remove right engine mount
Engine Mount Bolt .......................................................... 45 (61)
from engine and body. Remove generator (with wiring at-
Engine Mount Bracket-to-Engine Bolts ....................... 45 (61)
tached) and bracket, and secure out of way. Remove en-
Engine Torque Strut Bolts (2001-00 Neon) .................. 87 (118)
gine mount bracket from engine. For 2000 Breeze and Stra-
Generator Mounting Bolts ............................................... 45 (61)
tus, remove accessory drive belt idler pulley from genera-
Power Steering Pump Mounting Bolts ............................ 40 (54)
tor bracket. Remove generator bracket-to-engine bolts.
Timing Belt Tensioner Bolt
Move bracket away from engine for clearance to remove
Hydraulic Tensioner ................................................... 23 (31)
timing belt cover.
Timing Belt Tensioner Bracket Bolt
On 2000 Neon, remove lower torque strut. On all Neon Mechanical Tensioner ................................................ 23 (31)
models, lower vehicle and place jack under engine to sup-
INCH Lbs. (N.m)
port weight. Remove power steering pump with hoses at-
Timing Belt Cover Bolts (M6) .................................... 106 (12)
tached, and secure out of way. Remove upper torque strut
Water Pump Mounting Bolts ..................................... 106 (12)
(if equipped). Remove right engine mount-to-engine mount
bracket through bolt. Remove engine mount bracket from
engine.
On all models, remove timing belt cover. Rotate the crank-
shaft so that timing marks are aligned. See Fig. 6.
Install an 8 mm Allen wrench into timing belt tensioner. See
Fig. 6. Insert long end of a 3 mm Allen wrench into pin hole
in the front of tensioner. Slowly rotate tensioner counter-
clockwise with 8 mm Allen wrench while pushing lightly on
the 3 mm Allen wrench, until it slides into the locking hole.
If reusing old timing belt, mark belt with arrow to indicate
direction of rotation. Remove timing belt.

NOTE: Mechanical timing belt tensioner is serviced as an assembly.

To prevent premature timing belt failure and engine damage,
do NOT separate tensioner pulley from tensioner bracket.
Inspection:
the belt is not cracked, separated or showing canvas fiber.
and idler pulley for signs of grease leakage or roughness Courtesy of DaimlerChrysler
in rotation. Replace components if damaged.
Fig. 7: Exploded View Of Splash Shield Components
96 CHRYSLER
2.2L 4-Cylinder DOHC, VIN A
TIMING BELT APPLICATION Install a belt tension gauge on the timing belt. Install ten-
sion on the belt run between the 2 camshafts. Tension
Application Labor Time Belt Part No. gauge must contact timing belt between the teeth to get an
2.2L 4-Cyl. DOHC, Turbo III accurate reading. Rotate timing belt tensioner clockwise to
Daytona (Includes Canadian) obtain a tension of 110 lbs. (445 N.) for a new belt, or 70
1992-93 .............. 1 2.6 Hours .................... T206 lbs. (311 N.) for a used belt. Tighten timing belt tensioner
Spirit center bolt to specification. See TORQUE SPECIFICA-
TIONS.
1991-92 ................ 1 4.1 Hours .................... T206
1
- With Air Cond. add .2 hours. CAUTION: Do NOT reverse rotate crankshaft or attempt to rotate
crankshaft using camshaft or intermediate shaft bolt.
Rotate crankshaft clockwise 2 revolutions. Check align-
MANUFACTURERS SUGGESTED ment of camshaft and crankshaft timing marks.
SCHEDULED MAINTENANCE Recheck timing belt tension. Readjust, if necessary. Tighten
rocker arm shafts in sequence. See Fig. 1. See TORQUE
Although the manufacturer does not recommend a specific SPECIFICATIONS.
scheduled maintenance interval, belt manufacturers suggest Install valve covers, spark plugs and ignition wire covers.
the belt be replaced every 60,000 miles. Install fresh air duct. To complete installation, reverse re-
REMOVAL & INSTALLATION page A-60 for belt tension ranges.
TIMING BELT
Removal:
Remove PCV hose. Remove upper timing belt cover. Re-
move accessory drive belts. Rotate crankshaft so that cyl-
inder No. 1 is at TDC of compression stroke.
Raise vehicle on hoist and remove right wheel and inner
splash shield. Remove water pump pulley. Remove crank-
shaft pulley bolts and remove pulley. It is NOT necessary to
remove center bolt from the crankshaft.
Remove lower accessory drive belt idler pulley and
tensioner pulley. Remove lower timing belt cover. Remove
accessory drive belt idler pulley bracket.
Lower vehicle. Place floor jack under vehicle to support
weight of engine and transaxle assembly. Remove right
engine mount (timing belt end of engine). Note position
and number of shims for reassembly reference.
Remove air cleaner fresh air duct. Remove ignition sec-
ondary wire cover from top of engine. Remove valve covers.
Loosen center bolt of timing belt tensioner pulley to relieve
timing belt tension. If reusing old timing belt, mark belt with
arrow to indicate original direction of rotation. Remove tim-
ing belt.
Inspection:
Inspect timing belt for damaged teeth, cracking and oil con-
tamination. Check timing belt tensioner for worn bearing.
Check camshaft, crankshaft and intermediate shaft seals
for leaks. Replace damaged components.
Installation:
Loosen rocker arm assembly bolts about 3 turns. See Fig.
1. Align and pin both camshafts with 3/32 drill bits or pins.
See Fig. 2. Accessory drive shaft does not have to be timed.
Remove spark plugs.
Install a dial indicator in No. 1 spark plug hole. Rotate crank-
shaft until No. 1 piston is at TDC. Mark engine block for
TDC reference.
Install timing belt and idler pulley in correct sequence. See
Fig. 2. Remove dial indicator from cylinder head. Remove
drill bits or pins from camshaft sprockets.
Fig. 1: Rocker Arm Loosening & Tightening Sequence

CHRYSLER 97
2.2L 4-Cylinder DOHC, VIN A (Cont.)

Camshaft Sprocket Bolt .................................................. 65 (89)
Crankshaft Pulley-To-Sprocket Bolt ............................... 27 (31)
Crankshaft Sprocket Center Bolt .................................. 85 (115)
Intermediate Shaft Bolt ................................................... 65 (88)
Right Engine Mount
To-Engine Bracket Through Bolt .............................. 100 (136)
To-Frame Rail Bolts .................................................... 50 (68)
Water Pump Pulley Bolt .................................................. 21 (28)
Wheel Lug Nut ............................................................. 95 (129)
INCH Lbs. (N.m)
Rocker Arm Shaft Bolts
Step 1 ........................................................................ 106 (12)
Step 2 ......................................................................... 210 (24)
98 CHRYSLER
2.2L 4-Cylinder DOHC, VIN R
TIMING BELT APPLICATION Remove the spark plugs. Remove the pin punches. Rotate
crankshaft to TDC. Place Tension Tool (C-4703) on large
Belt hex nut in center of timing belt tensioner pulley. See Fig. 4.
Labor Component Part Loosen tensioner pulley lock nut. Adjust tensioner tool in-
Application Time Kit No. No. dex, if necessary, to position the axis within 15 degrees of
2.2L 4-Cyl. DOHC, Turbo horizontal. See Fig. 4.
TC (Maserati) CAUTION: Do NOT rotate crankshaft counterclockwise or attempt
1990 ............... 2.9 Hrs. ...... TCK153 .......... T153 to rotate the engine using the camshaft or intermediate shaft
mounting bolt.
this application. See page I for information on component Rotate crankshaft clockwise from TDC 2 full revolutions
back to TDC. Tighten the locknut on the timing belt tensioner.
kits. To complete installation, reverse removal procedure. Ad-
MANUFACTURERS SUGGESTED tension ranges.
SCHEDULED MAINTENANCE TORQUE SPECIFICATIONS
Although the manufacturer does not recommend a specific Application Ft. Lbs. (N.m)
scheduled maintenance interval, belt manufacturers suggest Camshaft Sprocket Bolt .................................................. 60 (80)
the belt be replaced every 60,000 miles. Crankshaft Pulley-To-Sprocket Bolt ............................... 21 (28)
Crankshaft Sprocket Center Bolt ................................. 50 (68)
REMOVAL & INSTALLATION Generator Drive Belt Idle Pulley Bolt .............................. 40 (54)
Intermediate Shaft Bolt ................................................... 65 (88)
TIMING BELT Right Engine Mount
Removal: To-Engine Bracket Through Bolt ................................ 75 (102)
Rotate crankshaft so that cylinder No. 1 is at TDC of com- To-Frame Rail Bolts .................................................... 21 (28)
pression stroke. Raise vehicle on hoist and remove right Timing Belt Tensioner Bolt ......................................... 45 (61)
inner splash shield. Remove accessory drive belts. INCH Lbs. (N.m)
Remove water pump pulley. Remove crankshaft pulley bolts Water Pump Pulley Bolt ............................................... 106 (12)
and remove pulley. It is NOT necessary to remove center
bolt from the crankshaft. Lower vehicle. Remove upper and
lower timing belt covers.
Place floor jack under vehicle to support weight of engine
and transaxle assembly. Remove right engine mount (tim-
ing belt end of engine). Remove valve cover.
Loosen center bolt of timing belt tensioner pulley. If reusing
old timing belt, mark belt with arrow to indicate original
Inspection:
Check camshaft, crankshaft and intermediate shaft seals
for leaks. Replace damaged components. Courtesy of DaimlerChrysler
Installation:
Turn crankshaft and intermediate shaft until the alignment Fig. 1: Installing Pin Punches In Camshafts
marks on the sprockets are aligned. See Figs. 2 and 3. The
distributor rotor must be facing the No. 1 cylinder in the
distributor cap.
Position pin punches in intake and exhaust camshaft align-
ment holes. See Fig. 1. Position both camshafts so that the
2 alignment holes in the exhaust and intake camshaft
sprockets are below and adjacent to the centerline of the 2
sprockets. See Fig. 2. The 2 keyways not used must be
positioned at the top, outside of the vertical centerline of the
camshafts.
Turn crankshaft until the alignment mark on the sprocket is
in line with the crankshaft and intermediate shaft centerline.
Turn the intermediate shaft until the marking on the sprocket
(if there is one) is in line with the marking on the crankshaft
sprocket. If there is no marking on the intermediate shaft
sprocket, set timing hole on vertical line through center of
the axis, upper side, 2 degrees clockwise.
Position timing belt on the crankshaft sprocket first. Then,
install timing belt on intermediate shaft sprocket by turning Courtesy of DaimlerChrysler
it slightly, if necessary. Repeat this procedure for the cam- Fig. 2: Aligning Camshaft Timing Marks
shaft sprockets.
CHRYSLER 99
2.2L 4-Cylinder DOHC, VIN R (Cont.)
Fig. 3: Aligning Camshaft, Crankshaft & Intermediate Shafts

100 CHRYSLER
2.2L 4-Cylinder DOHC, VIN R (Cont.)
CHRYSLER 101

TIMING BELT APPLICATION TIMING BELT APPLICATION (Cont.)
Belt Belt
Labor Component Part Labor Component Part
Application Time1 Kit No. No. Application Time1 Kit No. No.
2.2L 4-Cyl. SOHC 2.2 L 4-Cyl. SOHC (Cont.)
Aries & Reliant 400
1981-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1982-83 .......... 2.2 Hrs. ...... TCK071 .......... T071
1989 ............... 2.2 Hrs. ...... TCK153 .......... T153 600
Caravan, Town & Country & Voyager 1983-88 .......... 2.2 Hrs. ...... TCK071 .......... T071
1982-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 2.5L 4-Cyl. SOHC
Caravelle, New Yorker & 600 Acclaim
1983-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1989-95 .......... 2.2 Hrs. ...... TCK153 .......... T153
Charger & Turismo Aries, Lancer & Reliant
1983-87 .......... 2.2 Hrs. ...... TCK071 .......... T071 1986-87 .......... 2.2 Hrs. ................................ T114
Dakota 1988 ............... 2.2 Hrs. ................................ T132
1987-88 .......... 2 1.1 Hrs. .... TCK071 .......... T071 1989 ............... 2.2 Hrs. ...... TCK153 .......... T153
Daytona Caravan, Town & Country & Voyager
1984-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1986-87 .......... 2.2 Hrs. ................................ T114
1989-93 .......... 2.2 Hrs. ...... TCK153 .......... T153 1988 ............... 2.2 Hrs. ................................ T132
E Class 1989-95 .......... 2.2 Hrs. ...... TCK153 .......... T153
1983-84 .......... 2.2 Hrs. ...... TCK071 .......... T071 Caravelle & 600
Executive Limo (Canadian) 1986-87 .......... 2.2 Hrs. ................................ T114
1986 ............... 2.2 Hrs. ...... TCK071 .......... T071 1988 ............... 2.2 Hrs. ................................ T132
Expo (Canadian) Dakota
1987-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1989-95 .......... 1.1 Hrs. ...... TCK153 .......... T153
1989 ............... 2.2 Hrs. ...... TCK153 .......... T153 Daytona
Horizon & Omni 1986-87 .......... 2.2 Hrs. ................................ T114
1981-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1988 ............... 2.2 Hrs. ................................ T132
1989-90 .......... 2.2 Hrs. ...... TCK153 .......... T153 1989-93 .......... 2.2 Hrs. ...... TCK153 .......... T153
Lancer Dynasty
1985-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1988 ............... 2.2 Hrs. ................................ T132
1989 ............... 2.2 Hrs. ...... TCK153 .......... T153 1989-93 .......... 2.2 Hrs. ...... TCK153 .......... T153
Laser Lancer
1984-86 .......... 2.2 Hrs. ...... TCK071 .......... T071 1986-87 .......... 2.2 Hrs. ................................ T114
LeBaron & LeBaron GTS 1988 ............... 2.2 Hrs. ................................ T132
1982-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1989 ............... 2.2 Hrs. ...... TCK153 .......... T153
1989-90 .......... 2.2 Hrs. ...... TCK153 .......... T153 Laser
Mini Ram Van 1986 ............... 2.2 Hrs. ................................ T114
1984-87 .......... 2.2 Hrs. ...... TCK071 .......... T071 LeBaron & LeBaron GTS
New Yorker 1986-87 .......... 2.2 Hrs. ................................ T114
1983-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1988 ............... 2.2 Hrs. ................................ T132
Rampage 1989-94 .......... 2.2 Hrs. ...... TCK153 .......... T153
1982-84 .......... 2.2 Hrs. ...... TCK071 .......... T071 Mini Ram Van
Scamp Pickup 1987 ............... 2.2 Hrs. ................................ T114
1983 ............... 2.2 Hrs. ...... TCK071 .......... T071 1988 ............... 2.2 Hrs. ................................ T132
Shadow & Sundance New Yorker
1987-88 .......... 2.2 Hrs. ...... TCK071 .......... T071 1986-87 .......... 2.2 Hrs. ................................ T114
1989-94 .......... 2.2 Hrs. ...... TCK153 .......... T153 1988 ............... 2.2 Hrs. ................................ T132
TC3 Shadow & Sundance
1981-82 .......... 2.2 Hrs. ...... TCK071 .......... T071 1988 ............... 2.2 Hrs. ................................ T132
Turismo 1989-94 .......... 2.2 Hrs. ...... TCK153 .......... T153
1983-87 .......... 2.2 Hrs. ...... TCK071 .......... T071 Spirit
024 1989-1995 ...... 2.2 Hrs. ...... TCK153 .......... T153
1981-82 .......... 2.2 Hrs. ...... TCK071 .......... T071 1
2
102 CHRYSLER
kits.

TIMING BELT
Removal:
Disconnect negative battery cable. Remove all accessory
drive belts. If necessary, remove alternator, mounting brack-
ets, and A/C compressor (if equipped). DO NOT discon-
nect refrigerant lines. Remove A/C belt idler pulley.
Raise and support vehicle. Remove right inner splash shield.
Remove water pump and crankshaft pulleys. Remove upper
and lower timing belt covers. See Fig. 1. Support engine using
a jack.
CAUTION: If timing belt is to be reused, mark direction of rotation

96I14660 Courtsey of Chrysler Corp.
for reassembly reference.
Fig. 1: Removing Timing Belt Covers
Remove right engine mount bolt, and raise engine slightly.
Loosen the timing belt tensioner and remove timing belt. See
Fig. 2.
Installation:
Remove spark plugs. Place cylinder No. 1 on TDC. Align tim-
ing marks on crankshaft and intermediate shaft sprockets.
See Fig 3. Rotate camshaft sprocket until 2 marked arrows on
sprocket hub align with camshaft bearing cap-to-cylinder head
parting line. Small hole in camshaft sprocket must be at 12
oclock relative to cylinder head line. See Fig. 3.
Install timing belt. Ensure timing belt is installed in original
direction of rotation. Install Timing Belt Tensioner (C-4703)
horizontally on large hex of belt tensioner pulley. Loosen
tensioner lock nut (if necessary) to reset belt tensioner to
within a 15-degree axis of horizontal position of tool. See
Fig. 2. Tighten lock nut.
CAUTION: DO NOT rotate crankshaft counterclockwise. DO NOT

rotate engine using camshaft or intermediate shaft sprocket bolts.
Rotate crankshaft clockwise 2 complete revolutions to TDC.
Tighten tensioner retaining bolt to specification while hold-
ing belt tensioner wrench in position. See TORQUE SPECI-
FICATIONS. Check all timing marks for proper alignment. Fig. 2: Adjusting Timing Belt Tension
To complete installation, reverse removal procedure. Ad-
just drive belts to proper tension. See page A-60 for belt TORQUE SPECIFICATIONS
tension ranges. Application Ft. Lbs. (N.m)
Bracket-To-Block Bolt ................................................. 70 (95)
Damper Weight ............................................... 21-23 (28-30)
INCH Lbs. (N.m)
Balance Shaft Chain Guide Nut ................................ 106 (12)
Balance Shaft Chain Pivot & Tensioner Bolt ............. 106 (12)
Balance Shaft Cover Bolt .......................................... 106 (12)
Intermediate Shaft Retainer Bolt ............................... 106 (12)
Timing Belt Cover Bolt .................................................. 44 (5)
Valve Cover Bolt ........................................................ 106 (12)
Water Pump Pulley Bolt ............................................ 106 (12)
CHRYSLER 103
Fig. 4: Aligning Crankshaft, Intermediate Shaft &

Camshaft Timing Marks

104 CHRYSLER
2.4L 4-Cylinder DOHC, VIN B
2.4L 4-Cyl. DOHC, VIN B
Caravan & Voyager
1996-00 .............. 1 3.6 Hours .................... T265
1
- With Pwr. Strng. add .2 hours.
120,000 miles.
TIMING BELT
Removal:
Raise vehicle on hoist and remove right front wheel. Re-
move right inner splash panel. Remove accessory drive
belts. Remove crankshaft vibration damper.
Remove generator drive belt idler pulley. Remove lower
timing belt cover. Lower vehicle and remove upper timing
belt cover.
Place floor jack under vehicle to support weight of engine
and transaxle assembly. Remove purge duty solenoid and Courtesy of DaimlerChrysler
wiring harness from right engine mount bracket (timing Fig. 1: Aligning Crankshaft & Camshaft Timing Marks
belt end of engine).
Remove 2 right engine mount vertical bolts from frame rail.
Remove the one horizontal fastener. DO NOT remove large
nut from center bolt of insulator rubber. Remove horizontal
and vertical fasteners from engine side of mount. Remove
right engine mount assembly. Rotate crankshaft to align
timing marks on camshafts and oil pump housing. See
Fig. 1.
CAUTION: Crankshaft sprocket mark must be located on trailing

edge of sprocket tooth. Failure to align trailing edge of sprocket
tooth with oil pump housing mark will cause camshaft marks
to be misaligned.
On 1996 models equipped with hydraulic tensioner, re-
move hydraulic tensioner bolts and remove tensioner. Place
hydraulic tensioner in vise and SLOWLY compress
tensioner plunger. Align holes in tensioner body and plunger
and insert a pin through body and plunger to lock plunger
in place. Skip next step.
On models with a mechanical timing belt tensioner, insert
a 6 mm Allen wrench into tensioner. Insert long end of 3
mm Allen wrench into pin hole on front of tensioner. While
rotating the tensioner counterclockwise, push in lightly on
the 3 mm Allen wrench until it can be pushed into locking Courtesy of DaimlerChrysler
hole. See Fig. 3.
On all models, if reusing old timing belt, mark belt with Fig. 2: Installing Timing Belt Tensioner Assembly
arrow to indicate original direction of rotation. Remove tim- Installation:
ing belt. Ensure camshaft and crankshaft timing marks are still
Inspection: aligned. See Fig. 1. Set camshafts timing marks together
Inspect timing belt for damaged teeth, cracking and oil con- by aligning notches on sprockets. Turn exhaust camshaft
tamination. Check timing belt tensioner for worn bearing. sprocket clockwise about 1/2 notch below intake camshaft
Replace damaged components. sprocket. See Fig. 4.
Install timing belt starting at crankshaft, around water pump
NOTE: If timing belt tensioner needs to be replaced, camshaft sprocket, idler pulley, camshafts sprockets and then around
sprockets and rear timing belt cover will need to be removed. tensioner pulley.
Move exhaust camshaft counterclockwise to take out belt
slack and align timing marks. See Fig. 1.
CHRYSLER 105
2.4L 4-Cylinder DOHC, VIN B (Cont.)

On 1996 models with hydraulic timing belt tensioner, in-
stall tensioner on engine block but do NOT final tighten
bolts. Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley
in a clockwise direction. See Fig. 5. With torque applied to
tensioner pulley, push timing belt tensioner against
tensioner pulley bracket and final tighten tensioner bolts.
See TORQUE SPECIFICATIONS. Remove holding pin from
tensioner. Timing belt tension is correct when pin can be
removed and installed freely. Skip next step.
On models with mechanical timing belt tensioners, pull
locking Allen wrench from timing belt tensioner.
On all models, rotate crankshaft 2 revolutions and check
alignment of timing marks. If timing marks are not correct,
reposition timing belt.
Install right engine mount support and support bracket.
Install upper and lower timing belt covers. Install generator
idler pulley. Install crankshaft vibration damper.
tension ranges. Courtesy of DaimlerChrysler
TORQUE SPECIFICATIONS Fig. 4: Moving Exhaust Camshaft To 1/2 Notch Position

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)
Fig. 5: Adjusting Timing Belt Tension (Hydraulic)
Fig. 3: Adjusting Timing Belt Tension (Mechanical)

106 CHRYSLER
2.4L 4-Cylinder DOHC, VIN X
TIMING BELT APPLICATION the 3 mm Allen wrench until it can be pushed into locking
hole. See Fig. 3.
Application Labor Time Belt Part No. On all models, if reusing old timing belt, mark belt with
2.4L 4-Cyl. DOHC, VIN X arrow to indicate original direction of rotation. Remove tim-
Breeze ing belt.
1996-00 ................ 1 3.6 Hours .................... T265 Inspection:
Cirrus Inspect timing belt for damaged teeth, cracking and oil con-
1995-00 ................ 1 3.6 Hours .................... T265 Replace damaged components.
Sebring Convertible
1996-99 ................ 1 3.6 Hours .................... T265
Stratus
1995-00 ................ 1 3.6 Hours .................... T265
1
Up to 1999 model year, the manufacturer recommends the
timing belt be replaced every 105,000 miles. For 2000 model
years, the manufacturer recommends the timing belt be re-
placed at 100,000 miles for Federal vehicles and at 105,000
miles for California vehicles.
TIMING BELT
Removal:
Raise vehicle on hoist and remove right front wheel. Re-
move right inner splash panel. Remove accessory drive
belts. Remove crankshaft vibration damper.
Remove generator drive belt idler pulley. Remove lower
timing belt cover.
Remove right engine support assembly vertical bolts from
bottom of frame rail (timing belt end of engine).
Lower vehicle. Remove upper timing belt cover. Place floor
jack under vehicle to support weight of engine and transaxle Courtesy of DaimlerChrysler
assembly. Remove 3 bolts attaching engine mount assem- Fig. 1: Aligning Crankshaft & Camshaft Timing Marks
bly to engine bracket.
Move A/C drier aside. Remove coolant reservoir tank. Re-
move right engine mount. Remove 3 bolts attaching en-
gine mount bracket to engine block.
CAUTION: Align timing marks by rotating crankshaft only. Do

not rotate camshaft after timing belt is removed or engine damage
may result.
Rotate crankshaft clockwise to align timing marks on cam-
shafts and oil pump housing. See Fig. 1.
CAUTION: Crankshaft sprocket mark must be located on trailing

edge of sprocket tooth. Failure to align trailing edge of sprocket
tooth with oil pump housing mark will cause camshaft marks
to be misaligned.
On models equipped with hydraulic tensioner, remove hy-
draulic tensioner bolts and remove tensioner. Place hy-
draulic tensioner in vise and SLOWLY compress tensioner
plunger. Align the holes in the tensioner body and plunger
and insert a pin through the body and plunger to lock the
plunger in place. Skip next step.
On models with a mechanical timing belt tensioner, insert
a 6 mm Allen wrench into tensioner. Insert long end of 3
mm Allen wrench into pin hole on front of tensioner. While Courtesy of DaimlerChrysler
rotating the tensioner counterclockwise, push in lightly on Fig. 2: Installing Timing Belt Tensioner Assembly
CHRYSLER 107
2.4L 4-Cylinder DOHC, VIN X (Cont.)
Fig. 3: Adjusting Timing Belt Tension (Mechanical)
Fig. 5: Adjusting Timing Belt Tension (Hydraulic)

tensioner. Timing belt tension is correct when pin can be
removed and installed freely. Skip next step.
On models with mechanical timing belt tensioners, pull
locking Allen wrench from timing belt tensioner.
On all models, rotate crankshaft 2 revolutions and check
alignment of timing marks. If timing marks are not correct,
reposition timing belt.
Install right engine mount and support bracket. Install up-
per and lower timing belt covers. Install generator idler pul-
ley. Install crankshaft vibration damper.
tension ranges.
Fig. 4: Moving Exhaust Camshaft To 1/2 Notch Position
Crankshaft Vibration Damper ................................. 105 (142)
NOTE: If timing belt tensioner needs to be replaced, camshaft Generator Drive Belt Idler Pulley Bolt ............................. 40 (54)
sprockets and rear timing belt cover will need to be removed. Right Engine Mount
Installation: Frame Rail Vertical Fasteners ..................................... 45 (61)
Ensure camshaft and crankshaft timing marks are still To-Engine Support Bracket ......................................... 45 (61)
aligned. See Fig. 1. Set camshafts timing marks together Timing Belt Tensioner (Hydraulic)
by aligning notches on sprockets. Turn exhaust camshaft Mounting Bolt ............................................................ 21 (28)
sprocket clockwise about 1/2 notch below intake camshaft Timing Belt Tensioner (Mechanical)
sprocket. See Fig. 4. Bracket Mounting Bolt ............................................... 45 (61)
Install timing belt starting at crankshaft, around water pump Wheel Lug Nut .......................................................... 100 (135)
sprocket, idler pulley, camshafts sprockets and then around INCH Lbs. (N.m)
tensioner pulley. Timing Belt Cover Bolts
On models with hydraulic timing belt tensioner, install M6 (Outer-To-Inner) ................................................. 40 (4.5)
tensioner on engine block but do NOT final tighten bolts. M6 (Inner-To-Head) ................................................ 105 (12)
Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley in a Water Pump Bolt ......................................................... 106 (12)
clockwise direction. See Fig. 5. With torque applied to
tensioner pulley, push timing belt tensioner against
tensioner pulley bracket and final tighten tensioner bolts.
See TORQUE SPECIFICATIONS. Remove holding pin from
108 CHRYSLER
*2.5L V6
TIMING BELT APPLICATION On all models, raise and support vehicle. Remove right
front wheel. Remove side panel from right wheelwell.
Application Labor Time Belt Part No. Remove accessory drive belts. Remove generator and
2.5L V6 bracket from engine block and set aside. Remove crank-
Avenger & Sebring Coupe shaft vibration damper.
1995-00 ................ 1 2.7 Hours ................... T259 Lower vehicle. Place floor jack under vehicle to support
Cirrus & Stratus weight of engine and transaxle assembly. Remove engine
mount-to-frame through bolt. Remove engine mount-to-en-
1995-00 ................ 1 2.7 Hours ................... T259 gine bracket nuts and bolt. Remove engine mount.
Sebring Convertible Remove 3 bolts attaching engine support bracket to en-
1997-00 ................ 1 2.7 Hours ................... T259 gine block. Top reamer bolt may be heat seized on engine
1
- With Air Cond. add .2 hours. support bracket. Spray lubricant on bolt while removing.
With Pwr. Strng. add .2 hours. NOTE: Reamer bolt head will have a R marking for identi-
fication.
MANUFACTURERS SUGGESTED Remove power steering pump (hoses attached) and
SCHEDULED MAINTENANCE bracket from engine block and set aside. Remove timing
The manufacturer recommends the belt be replaced at 60,000 belt covers.
mile intervals, except in California, Connecticut, and Massa- Rotate crankshaft to align camshaft and crankshaft timing
chusetts. In these states, inspect belt at 60,000 miles and marks. See Figs. 2 and 3.
replace if necessary. If not replaced at 60,000 miles, replace If reusing old timing belt, mark timing belt direction of rota-
at 100,000 miles. tion for installation reference. Loosen timing belt tensioner
pulley bolt. Remove timing belt. Remove automatic
*NOTE: This application is an interference engine. tensioner.
See page A-59 for interference engine cautions. CAUTION: DO NOT rotate crankshaft or camshaft with timing
belt removed.
NOTE: When automatic tensioner is removed from engine, it
TIMING BELT is necessary to compress plunger into tensioner body.
Removal (Cirrus, Sebring Convertible & Stratus):
Disconnect negative battery cable from jumper terminal. Installation (All Models):
Raise and support vehicle. Remove right front wheel. Re- Place automatic tensioner into vise and SLOWLY compress
move accessory drive belt splash shield from right plunger. When plunger is compressed into tensioner body,
wheelwell. install locking pin through body and plunger holes to retain
Remove accessory drive belts. Remove right engine sup- plunger until tensioner is installed. See Fig. 1.
port assembly vertical bolts from bottom side of frame rail Index tensioner in vise the same direction as installed.
(timing belt end of engine). This will ensure proper pin orientation when tensioner is
Lower vehicle. Place floor jack under vehicle to support installed in engine. See Fig. 1.
weight of engine and transaxle assembly. Remove 3 bolts Set crankshaft mark with timing mark on oil pump housing,
attaching engine support assembly to engine block then back off 3 notches before TDC. See Fig. 2. Set cam-
bracket. shaft sprockets by aligning timing marks on sprockets with
Move the A/C drier aside with hoses attached. Remove cool- marks on rear timing belt cover. See Fig. 3.
ant reservoir tank. Remove right engine support assembly.
Remove 3 bolts attaching engine support bracket to en- NOTE: If reusing old timing belt, install in original direction
gine block, and remove bracket. of rotation.
Remove crankshaft vibration damper. Remove power steer- Install timing belt on right (next to firewall) camshaft sprocket
ing pump (hoses attached) and bracket from engine block. first. Install a spring clip to keep belt in position. Keeping
Remove timing belt covers. belt taught, install belt under water pump pulley and then
Rotate crankshaft to align camshaft and crankshaft timing around front camshaft sprocket. Install spring clip on front
marks. See Figs. 2 and 3. sprocket and belt.
If reusing old timing belt, mark timing belt direction of rota- Rotate crankshaft clockwise to TDC. Continue routing belt
tion for installation reference. Loosen timing belt automatic around idler pulley, crankshaft sprocket, and tensioner pul-
tensioner bolts. Remove timing belt. Remove automatic ley. Apply rotating force to crankshaft sprocket in clockwise
tensioner. direction to tension belt. Ensure all timing marks are still
aligned.
CAUTION: DO NOT rotate crankshaft or camshaft with timing Loosen tensioner pulley center bolt. Position tensioner pul-
belt removed. ley with pin holes facing down. Install Adapter (MD998767)
or equivalent, and torque wrench, to tensioner pulley. See
NOTE: When automatic tensioner is removed from engine, it Fig. 4. Apply 39 INCH Ibs. (4.4 N.m) in a counterclockwise
is necessary to compress plunger into tensioner body. direction to tensioner. Tighten tensioner bolt to specifica-
tion, without letting tensioner pulley rotate.
Removal (Avenger & Sebring Coupe):
Disconnect negative battery cable. Remove coolant reser- With torque being applied to tensioner pulley, install auto-
matic tensioner (with locking pin in place) to tensioner pul-
voir bottle. On models with cruise control, remove cruise
ley bracket. Tighten bolts to specification. Pull tensioner
control actuator and set aside.
plunger locking pin.
109
CHRYSLER
*2.5L V6 (Cont.)
Rotate crankshaft 2 revolutions clockwise, and check align-
ment of timing marks. Install tensioner locking pin into au-
tomatic tensioner. Pin should slide in and out with no re-
sistance. Even if locking pin cannot be easily inserted, belt
tension is okay if automatic tensioner plunger projection is
within .149-.177 (3.8-4.5 mm). Projection is measured
between top edge of automatic tensioner housing and arm
of tensioner pulley bracket. Retension timing belt, if neces-
sary.
Install timing belt covers. Install crankshaft vibration damper.
Tighten crankshaft damper bolt to specification.
NOTE: Reamer bolt head will have a R marking for identi-

fication.
Fig. 1: Compressing Tensioner Install engine mount bracket. On Avenger and Sebring
Coupe, when installing engine support bracket to engine
block, tighten top reamer bolt slowly while spraying it with
lubricant. Attach engine mount so arrow on side plate points
toward engine.
On all models, reverse removal procedure to complete in-
stallation. Adjust drive belts to proper tension. See page A-
60 for belt tension ranges.
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)
Fig. 2: Setting Crankshaft Sprocket Engine Mount-To-Frame Through Bolt
Avenger & Sebring Coupe ................................ 72-87 (98-118)
Engine Support Assembly-To-Engine Mount Bracket
Avenger & Sebring .......................................... 47-54 (64-74)
Engine Support Assembly-To-Frame Rail
Avenger & Sebring ........................................... 47-54 (64-74)
Cirrus, Sebring Convertible & Stratus ......................... 45 (61)
Engine Support Bracket-To-Engine Block Bolt
Avenger & Sebring Coupe ................................. 47-54 (64-74)
Generator Mount Bracket-To-Engine Block
Avenger & Sebring Coupe ............................................ 30 (41)
Power Steering Pump Bracket-To-Engine Bolts
Avenger & Sebring Coupe ............................................ 16 (22)
Cirrus, Sebring Convertible & Stratus ........................... 40 (54)
Timing Belt Tensioner Pivot Arm Bolt ............................ 33 (44)
Courtesy of DaimlerChrysler Timing Belt Tensioner Pulley Bolt ............................... 35 (48)
Fig. 3: Aligning Camshaft Sprockets Timing Belt Tensioner-To-Engine Bolt ........................ 17 (23)
Water Pump Bolt ........................................................ 18 (24)
Wheel Lug Nut
Avenger & Sebring Coupe .............................. 65-80 (88-108)
INCH Lbs. (N.m)
Timing Belt Cover Bolts .................................... 89-106 (10-12)
Fig. 4: Tensioning Timing Belt
110 CHRYSLER
3.0L V6 SOHC
TIMING BELT APPLICATION timing marks on front and rear camshaft sprockets and
timing mark on crankshaft sprocket. See Fig. 1.
Belt Remove crankshaft pulleys and vibration damper. Loosen
Labor Component Part timing belt tensioner bolt and remove timing belt.
Application Time Kit No. No. Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit,
3.0L V6 Sundance & TC (1990-96):
Acclaim & Spirit Disconnect negative battery cable. Remove accessory drive
belts. Remove A/C compressor and power steering pump
1989-95 .......... 4.0 Hrs. ..... TCK139 ........... T139 with hoses attached and secure aside (if equipped). Re-
Caravan, Mini Ram Van & Voyager move A/C compressor mounting bracket and drive belt
1987-00 .......... 1 3.8 Hrs. ... TCK139 ........... T139 tensioner. Remove power steering/alternator belt tensioner.
Daytona (Includes Canadian) Raise and support vehicle. Remove right inner fender
1990-93 .......... 4.0 Hrs. ..... TCK139 ........... T139 shield. Remove crankshaft pulleys and vibration damper.
Dynasty (Includes Canadian) Lower vehicle. Support engine with floor jack. Separate right
1988-93 .......... 4.0 Hrs. ..... TCK139 ........... T139 (timing belt side) engine mount from engine mount bracket
located in front of timing belt cover.
LeBaron Slightly raise engine. Remove engine mount bracket. Re-
1990-95 .......... 4.0 Hrs. ..... TCK139 ........... T139 move timing belt covers, noting bolt length for installation
New Yorker reference. Rotate engine and align timing marks on cam-
1988-89 .......... 4.0 Hrs. ..... TCK139 ........... T139 shaft sprockets and crankshaft sprocket. See Fig. 1. If re-
Raider using timing belt, mark direction of timing belt rotation for
1989 ............... 3.5 Hrs. ..... TCK139 ........... T139 installation reference.
Ram 50 Loosen timing belt tensioner bolt. Move timing belt tensioner
away from timing belt. Remove timing belt. Note direction
1990-91 .......... 3.5 Hrs. ..... TCK139 ........... T139 of flange installation on front of crankshaft, in front of crank-
Shadow & Sundance shaft sprocket. Remove flange and crankshaft sprocket from
1992-94 .......... 4.0 Hrs. ..... TCK139 ........... T139 crankshaft (if necessary).
Stealth If removing camshaft sprocket, hold camshaft by engaging
1991-96 .......... 2.0 Hrs. ..... TCK139 ........... T139 Camshaft Sprocket Holder (MB990775) in the holes on front
TC Maserati of camshaft sprocket. Remove camshaft sprocket bolt and
washer. Remove camshaft sprocket.
1990-91 .......... 4.0 Hrs. ..... TCK139 ........... T139 Caravan & Voyager:
Raise vehicle. Remove accessory drive belt splash shield.
1
- With Air Cond. add .2 hours. Remove accessory drive belts. Remove crankshaft pulleys
With Pwr. Strng. add .2 hours. and vibration damper.
Lower vehicle. Support engine weight with floor jack. Re-
NOTE: A timing belt component kit is available for move purge duty solenoid and wiring harness from right
engine mount bracket.
this application. See page I for information on component Remove 2 right engine mount insulator vertical bolts Re-
kits. move the one horizontal fastener. DO NOT remove large
nut from center bolt of insulator rubber. Remove horizontal
MANUFACTURERS SUGGESTED and vertical fasteners from engine side of mount. Remove
engine mount.
timing belt be replaced at 60,000. For 1994-96 model years,
the manufacturer recommends the timing belt be replaced at
60,000 miles, except in California. In California, timing belt
replacement is recommended, but not required at 60,000
miles. Replace the timing belt at 100,000 miles, unless previ-
ously changed.
For 1997-00 model years, the manufacturer recommends the
belt be inspected at 60,000, and replaced if necessary.
Inspect belt at 90,000 miles, and replace if necessary. This
maintenance is NOT required if belt was replaced at 60,000.
Inspect belt at 120,000 miles, and replace if necessary. This
maintenance is NOT required if belt was replaced at 90,000
miles.

TIMING BELT REMOVAL
Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New
Yorker, Shadow, Spirit & Sundance (1987-89):
Disconnect negative battery cable. Support engine and Fig. 1: Locating Timing Belt & Sprockets
transmission with floor jack. Remove front engine mount
bracket. Remove upper (front outer) timing belt cover. Align
CHRYSLER 111

If timing belt is to be reused, place arrow on belt to indicate
direction of belt rotation. Remove timing belt and belt
tensioner.
Stealth:
Remove lower splash shields. Remove cruise control ac-
tuator (if equipped). Remove all drive belts. Unplug electri-
cal connector at power steering pump. Remove A/C
tensioner pulley and mounting bracket.
Remove power steering pump, leaving hoses connected,
and wire aside. Support engine. Remove front engine mount
through-bolt and front engine mount.
NOTE: Apply spray lubricant on reamer bolt during removal

as bolt is sometimes seized in engine support bracket.
Remove engine support bracket bolts in proper sequence.
See Fig. 3. Remove engine support bracket. Remove tim-
ing cover cap, timing belt cover, and gaskets. Using Holder
(MB990767) and Adapter Bolts (MD998719), remove crank-
shaft pulley.
Remove lower timing belt cover, gaskets, and flange. Ro-
tate crankshaft to align all timing marks. See Fig. 1. Loosen
belt tensioner bolt. Rotate belt tensioner counterclockwise
to relieve belt tension.
If reusing timing belt, place arrow on belt to indicate belt
running direction. Remove timing belt and belt tensioner.
TIMING BELT INSPECTION
Inspect timing belt for wear on edges of drive teeth. Inspect
belt for signs of oil contamination, cracks, separation, worn or
Fig. 2: Exploded View Of Timing Belt Components missing teeth, or hardened black surface. Replace belt if worn,
(Raider & Ram 50) damaged or contaminated. Inspect belt tensioner for smooth
rotation. Replace if defective.
Remove engine support bracket from front of engine. Re-
TIMING BELT INSTALLATION
move timing belt covers, noting bolt length for installation
reference. Note direction of flange installation on front of Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New
crankshaft, in front of crankshaft sprocket. Remove flange. Yorker, Shadow, Spirit & Sundance (1987-89):
Rotate crankshaft and align timing marks on camshaft Install belt tensioner and tensioner spring. Install tensioner
sprockets and crankshaft sprocket. See Fig. 1. If reusing spring between water pump retaining pin and tensioner
timing belt, mark direction of timing belt rotation for instal- bracket with hook of spring facing outward. Turn tensioner
lation reference. full counterclockwise in adjustment slot and tighten tem-
Loosen timing belt tensioner bolt. Move timing belt tensioner porarily to hold tensioner in position.
away from timing belt and temporarily tighten bolt. Remove Install timing belt on crankshaft sprocket first while keep-
timing belt. ing belt tight on tension side. See Fig. 1. Install belt on
Raider & Ram 50: radiator side camshaft sprocket. Then, install belt on water
Disconnect negative battery cable. Drain cooling system. pump pulley and rear camshaft sprocket and finally on tim-
Disconnect upper radiator hose. Remove upper radiator ing belt tensioner.
shroud. Remove cooling fan and fan clutch assembly. Re- Apply rotating force to front camshaft sprocket in opposite
move cooling fan pulley. Remove all accessory drive belts. direction of tension side of belt. Ensure all timing marks
Remove power steering pump with pressure and return are aligned. Install crankshaft sprocket flange. Loosen
hoses connected and set aside.
Remove power steering pump brackets. Remove A/C
tensioner pulley and mounting bracket. Remove A/C com-
pressor with hoses connected and mounting bracket. Re-
move cooling fan bracket assembly. Remove timing belt
No. 1 upper outer cover and gaskets. See Fig. 2.
Remove timing belt No. 2 upper outer cover and gaskets.
Remove timing belt lower outer cover and gaskets. Using
Holder (MB998747) or equivalent, and a used V belt, re-
move crankshaft pulley bolt. Remove crankshaft pulley.
NOTE: V belt will be damaged by tool. DO NOT use engine

V belt to hold crankshaft pulley unless belt is to be replaced.
Remove flange. See Fig. 2. Rotate crankshaft and align all
timing marks. See Fig. 1. Loosen belt tensioner bolt and
rotate belt tensioner counterclockwise to release belt ten-
sion. Fig. 3: Engine Support Bracket (Stealth)
112 CHRYSLER
To install remaining components, reverse removal proce-
dure. Ensure timing belt cover bolts are installed in original
location. See Fig. 4. Tighten bolts to specification. Adust
drive belts to proper tension. See page A-60 for belt tension
ranges.
Caravan & Voyager:
If timing belt tensioner spring was removed, install spring
on tensioner arm with end of hook facing out (away from
engine).
Ensure all timing marks are aligned. See Fig. 1. Install
timing belt on crankshaft sprocket while holding timing belt
tight on tension side. See Fig. 1. If reusing timing belt, en-
sure timing belt is installed in original direction of rotation.
Install timing belt on front (radiator side) camshaft sprocket,
water pump pulley, rear camshaft sprocket and then on
timing belt tensioner. Ensure timing belt is installed in this
order and there is no slack in belt.
Install flange on front of crankshaft sprocket with fiat side
against timing belt and offset side toward front of crank-
shaft. Loosen timing belt tensioner bolt, allowing spring
tension to be applied on timing belt tensioner and timing
belt.
Slowly rotate crankshaft clockwise 2 full revolutions. DO
Courtesy of DaimlerChrysler NOT rotate crankshaft counterclockwise. Realign all timing
Fig. 4: Identifying Timing Belt Cover Bolt Lengths marks. Tighten timing belt tensioner bolt to specification.
(Except Raider, Ram 50 & Stealth) See TORQUE SPECIFICATIONS table.
Install timing belt covers. Ensure bolts are installed in origi-
tensioner from temporary position and allow it to apply ten- nal locations. See Fig. 4. Install engine support bracket.
sion to timing belt. Turn crankshaft 2 full turns in a clock- Install right side engine mount. Install crankshaft vibration
wise direction ONLY. damper.
NOTE: Turn crankshaft smoothly and ONLY in a clockwise direction. dure. Adjust drive belts to proper tension. See page A-60 for
Again line up all timing marks and tighten tensioner against belt tension ranges.
belt. Tighten tensioner locking bolt to specification. See
CAUTION: Engine support bracket reamer bolt must be tightened
TORQUE SPECIFICATIONS. To complete installation, re-
slowly while spraying lubricant on bolt.
verse removal procedures. Adjust drive belts to proper ten-
sion. See page A-60 for belt tension ranges. Raider & Ram 50:
Install belt tensioner and spring. Ensure spring is secured
CAUTION: When reusing timing belt, ensure timing belt is installed on pin of water pump and engaged in hole of belt tensioner
in original direction of rotation. with hook of spring pointing away from cylinder block.
Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit, Rotate belt tensioner counterclockwise as far as possible
Sundance & TC (1990-96): and temporarily tighten bolt. Align all timing marks with No.
Rotate timing belt tensioner counterclockwise and tempo- 1 cylinder at TDC of compression stroke. See Fig. 1.
rarily tighten bolt. Ensure all timing marks are aligned. See Install timing belt on crankshaft sprocket and then left cam-
Fig. 1. Install timing belt on crankshaft sprocket while hold- shaft sprocket with all slack removed from tension side of
ing timing belt tight on tension side. If reusing timing belt,
ensure timing belt is installed in original direction of rota-
tion.
Install timing belt on front (radiator side) camshaft sprocket,
water pump pulley, rear camshaft sprocket and then on
timing belt tensioner. Ensure timing belt is installed in this
order.
Apply rotating force on front (radiator side) camshaft
sprocket in opposite direction to apply pressure on tension
side of timing belt. Ensure all timing marks align. See Fig.
1.
Install flange on front of crankshaft sprocket (if removed)
with flat side against timing belt and offset side toward
front of crankshaft. Loosen timing belt tensioner bolt, al-
lowing spring tension to be applied on timing belt tensioner
and timing belt.
Rotate crankshaft clockwise 2 full revolutions. DO NOT ro-
tate crankshaft counterclockwise. Realign all timing marks.
Tighten timing belt tensioner bolt to specification. See
TORQUE SPECIFICATIONS table. Fig. 5: Identifying Timing Belt Cover Bolt Lengths
(Raider & Ram 50)
CHRYSLER 113

belt. Route timing belt onto water pump pulley, right cam-
shaft sprocket and tensioner. Remove any slack from belt
by rotating left and then right camshaft sprockets counter-
clockwise. Ensure all timing marks are aligned. Install
flange on crankshaft. Loosen belt tensioner bolts slightly
and allow tensioner to apply belt tension.
Using Crankshaft Socket (MD998716), rotate crankshaft 2
revolutions clockwise. DO NOT rotate counterclockwise.
Realign all timing marks. Tighten belt tensioner bolts to
specification. Using belt tension gauge, measure belt ten-
sion halfway between crankshaft sprocket and camshaft
sprocket on side opposite belt tensioner.
Belt tension should be 57.3-83.8 Ibs. (26-38 kg). To install
remaining components, reverse removal procedure. Install
proper length bolts in timing belt covers. See Fig. 5. Tighten
tension ranges.
Stealth:
Install belt tensioner and spring. Ensure spring is secured Fig. 6: Identifying Timing Belt Cover Bolt Lengths
on pin of water pump and engaged in hole of belt tensioner, (Stealth)
with hook of spring pointing away from cylinder block. Ro-
TORQUE SPECIFICATIONS (RAIDER & RAM 50)
tate belt tensioner counterclockwise as far as possible.
Temporarily tighten bolt. Align all timing marks with No. 1 Application Ft. Lbs. (N.m)
cylinder at TDC of compression stroke. See Fig. 1. Camshaft Sprocket Bolt .................................... 58-72 (79-98)
Install timing belt onto crankshaft sprocket, rear cylinder Crankshaft Pulley Bolt
bank camshaft sprocket, water pump pulley, front cylinder Montero & Raider ................................... 108-116 (146-157)
bank camshaft sprocket, and timing belt tensioner. Ensure Pickup .................................................... 130-137 (176-186)
belt is installed in original direction of rotation, and all tim- Left Engine Support Bracket Bolt ...................... 15-21 (20-30)
ing marks are aligned. Install flange onto crankshaft. Rear Engine Support Bracket Bolt .................... 13-18 (18-25)
Loosen belt tensioner bolts slightly, and allow tensioner to Right Engine Support Bracket Bolt
apply belt tension. 10 X 22 mm .................................................... 25-36 (34-49)
Using Crankshaft Socket (MD998716) or equivalent, rotate 10 X 40 mm .................................................... 25-36 (34-49)
crankshaft 2 revolutions clockwise. DO NOT rotate coun- 12 X 22 mm & 12 X 32 mm ............................. 47-61 (64-83)
terclockwise. Realign all timing marks. Tighten belt Timing Belt Tensioner Bolt ............................... 16-21 (22-29)
tensioner bolts to specification. See TORQUE SPECIFICA- Water Pump Bolt .............................................. 14-20 (19-27)
TIONS. Using belt tension gauge, measure belt tension INCH Lbs. (N.m)
halfway between crankshaft sprocket and camshaft Timing Belt Cover Bolt ...................................... 84-108 (9-12)
sprocket on side opposite belt tensioner. Timing Belt Cover Cap Bolt .............................. 84-108 (9-12)
NOTE: Engine support bracket reamer bolt must be tightened TORQUE SPECIFICATIONS (STEALTH)
slowly. Apply lubricant onto bolt during installation.
Belt tension should be 44-66 lbs. (20-30 kg). To install Automatic Tensioner Bolt ............................................ 17 (23)
remaining components, reverse removal procedure. Install Camshaft Sprocket Bolt .............................................. 66 (90)
bolts into proper holes. Install covers and engine support Crankshaft Pulley Bolt
bracket. See Figs. 3 and 6. Tighten bolts to specification. 1991 ....................................................... 108-116 (146-157)
See TORQUE SPECIFICATIONS. Adjust drive belts to proper 1992-94 ................................................................ 136 (185)
tension. See page A-60 for belt tension ranges. Engine Support Bracket Bolt
TORQUE SPECIFICATIONS (EXCEPT RAIDER, RAM 50 & 10 X 40 mm .................................................... 47-54 (64-73)
STEALTH) Except 10 X 40 mm ..................................... 76-83 (103-113)
Timing Belt Tensioner Arm Bolt .................................. 31 (42)
Application Ft. Lbs. (N.m) Timing Belt Tensioner Pulley Nut ............................... 36 (49)
A/C Compressor Drive Belt Water Pump Bolt ........................................................ 17 (23)
Idler Pulley Bolt ......................................................... 40 (54) INCH Lbs. (N.m)
Camshaft Sprocket Bolt .............................................. 70 (95) Timing Belt Cover Bolt ...................................... 84-108 (9-12)
Crankshaft Vibration Damper Bolt .......................... 100 (135)
Engine Bracket-To-Engine Bolt ................................... 35 (47)
Engine Mount-To-Frame Bolt ...................................... 50 (68)
Engine Mount Vertical Bolt ........................................ 75 (102)
Timing Belt Tensioner Pulley Bolt ....................... 18-21 (25-28)
Water Pump Bolts .......................................................... 20 (27)
114 CHRYSLER & EAGLE
*1.5L 4-Cylinder SOHC
TIMING BELT APPLICATION Loosen timing belt tensioner bolts. Move tensioner inward
toward water pump. Temporarily tighten bolt in slot side of
Belt tensioner. Remove timing belt from camshaft sprocket. Re-
Labor Component Part move crankshaft pulley, and timing belt.
Application Time 1 Kit No. No. Inspection:
1.5L 4-Cyl. Inspect belt teeth for cracks, damage, or oil contamination.
Colt Inspect all sprockets for damage. Examine belt tensioner
for grease leakage and roughness when pulley is rotated.
1985-86 .......... 2.8 Hrs. ................................ T073 Replace components if defective.
1987-90 .......... 2.8 Hrs. ...... TCK128 .......... T128 Installation:
1991-94 .......... 2.4 Hrs. ...... TCK191 .......... T191 Ensure crankshaft and camshaft timing marks are aligned.
Colt (Canadian) See Fig. 1. If tensioner was removed, ensure spring is
1985-86 .......... 2.8 Hrs. ................................ T073 installed correctly. See Fig. 2. Install timing belt onto crank-
1989-91 .......... 2.8 Hrs. ...... TCK128 .......... T128 shaft and camshaft sprockets. Ensure tension side is tight
1992 & 1995 ... 2.4 Hrs. ...... TCK191 .......... T191 and all timing marks are aligned when camshaft sprocket
is rotated. Install crankshaft pulley. Loosen tensioner mount-
Summit ing bolts. See Fig. 3. Ensure timing belt is not out of posi-
1989-90 .......... 2.8 Hrs. ...... TCK128 .......... T128 tion and has not jumped a sprocket tooth. Tighten tensioner
1991-96 .......... 2.4 Hrs. ...... TCK191 .......... T191 bolts.
Vista (Canadian)
1989-91 .......... 2.8 Hrs. ...... TCK128 .......... T128 CAUTION: If pivot bolt is tightened before side bolt, belt tensioner
may rotate, causing belt to be over tightened.
1992 ............... 2.4 Hrs. ...... TCK191 .......... T191
1
- With Air Cond. add .2 hours. Rotate crankshaft one full revolution clockwise, until crank-
With Pwr. Strng. add .3 hours. shaft sprocket timing mark aligns with TDC position. Re-
check belt tension. To check belt tension, hold belt tensioner
and timing belt together. Apply slight thumb pressure at
NOTE: A timing belt component kit is available for center point of belt tensioner. A tension gauge can also be
this application. See page I for information on component used to check belt tension. See Fig. 4.
kits. just drive belts to proper tension. See page A-60 for belt
tension ranges.
MANUFACTURERS SUGGESTED TORQUE SPECIFICATIONS
SCHEDULED MAINTENANCE Application Ft. Lbs. (N.m)
The manufacturer recommends the belt be replaced every Camshaft Sprocket Bolt
60,000 miles. 1991-85 .......................................................... 47-54 (65-75)
1992-96 ........................................................ 52-74 (70-100)
*NOTE: This application is an interference engine. Crankshaft Pulley Bolt
See page A-59 for interference engine cautions. 1991-96 .......................................................... 10-11 (14-15)
Crankshaft Sprocket Bolt
1985 ............................................................... 37-43 (50-58)
REMOVAL & INSTALLATION 1986-96 ........................................................ 52-74 (70-100)
TIMING BELT Front Cover Bolt
1985-88 ............................................................ 9-10 (12-14)
Removal: Rocker Arm Adjuster Lock Nut
Disconnect negative battery cable. Remove air cleaner 1989-96 .......................................................... 10-13 (14-18)
assembly, then disconnect accelerator cable and oxygen Timing Belt Tensioner Bolt
lead sensor. Mark position of spark plug wires for installa- 1985-96 .......................................................... 14-20 (19-27)
tion, then remove wires from spark plugs. Support engine INCH Lbs. (N.m)
using a suitable engine support bar. Remove left engine Crankshaft Pulley Bolt
mount bracket. Remove all accessory drive belts and pul- 1985-1990 .................................................... 90-102 (10-11)
leys. 1987-88 ..................................................... 108-120 (12-14)
Front Cover Bolt
CAUTION: DO NOT rotate engine counterclockwise (as viewed
1989-96 .......................................................... 84-132 (9-15)
from timing belt end of engine). If reusing timing belt, place reference
mark on timing belt to indicate direction of rotation before removing.
Fuel Rail Bolt
1992-96 .......................................................... 84-108 (9-12)
Remove timing belt covers and gaskets, noting bolt lengths Rocker Cover Bolt
and locations as they are removed. Rotate engine clock- 1989-96 ........................................................ 13-17 (1.5-1.9)
wise to align timing mark on camshaft sprocket with mark Timing Belt Cover Bolt
on cylinder head. Ensure all timing marks are aligned. See 1989-96 .......................................................... 84-108 (9-12)
Fig. 1. Water Pump Pulley Bolt
1986-88 ..................................................... 108-120 (12-14)
1989-96 .............................................................. 72-84 (8-9)
CHRYSLER & EAGLE 115
*1.5L 4-Cylinder SOHC (Cont.)
Fig. 4: Checking Timing Belt Tension With A Gauge

*2.0L 4-Cylinder DOHC, Except VIN Y
TIMING BELT APPLICATION For 1995-97 vehicles, the manufacturer recommends the belt
be replaced every 60,000 miles except in California. In Califor-
Belt nia, timing belt replacement is recommended, but not required,
Labor Component Part at 60,000 miles. In California, replace timing belt at 100,000
Application Time Kit No. No. miles.
2.0L 4-Cyl. DOHC (4G6) For 1998 vehicles, the manufacturer recommends the belt be
Laser & Talon replaced every 60,000 miles except in California, Connecticut
and Massachusetts, timing belt replacement is recommended
1990-94 ....... 1 & 2 3.6 Hrs. ... TCK167 ........ 3 T167 but not required at 60,000 miles. In these states, replace tim-
1990-94 ....... 1 & 2 3.6 Hrs. ........................... 4 T168 ing belt at 100,000 miles.
Talon Turbo
1995-98 ....... 1 & 2 3.6 Hrs. ... TCK167 ........ 3 T167 *NOTE: This application is an interference engine.
1995-99 ....... 1 & 2 3.6 Hrs. ........................... 4 T168 See page A-59 for interference engine cautions.
2000 GTX (Canadian)
1989-93 ....... 1 & 2 3.6 Hrs. ... TCK167 ........ 3 T167 REMOVAL & INSTALLATION
1989-93 ....... 1 & 2 3.6 Hrs. ........................... 4 T168
1
- Balance shaft labor time included in camshaft NOTE: Replacement procedures includ revised information from
Chrysler technical service bulletin 09-01-94; January 28, 1994.
labor time.
2
- With Air Cond. add .2 hours. TIMING BELT & BALANCE SHAFT BELT
With Pwr. Strng. add .2 hours. Removal:
3
Timing belt. Disconnect negative battery cable. Remove engine under-
4
Balance shaft belt. cover. Place wooden block between jack and oil pan and
raise engine slightly. Remove engine mount assembly near
NOTE: A timing belt component kit is available for timing belt cover.
Remove clamp for power steering return hose near timing
belt cover. Remove all drive belts and tensioner bracket.
kits. See Fig. 1. Remove power steering and water pump pul-
leys. Rotate crankshaft clockwise so that No. 1 cylinder is
MANUFACTURERS SUGGESTED at TDC of compression stroke. Remove crankshaft pulley.
SCHEDULED MAINTENANCE CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure
For 1990-94 vehicles, the manufacturer recommends the belt timing marks are aligned. If reusing timing belts, mark timing
be replaced every 60,000 miles. belts for direction of rotation.
Courtesy of Mitsubishi Motor Sales of America
Fig. 1: Exploded View Of Timing Belts & Components

*2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)

Fig. 2: Aligning Timing Belt A Marks (1990-93 Models)
Fig. 4: Timing Belt B (Balance Shaft Belt) Components

Remove upper timing belt cover and gasket. Remove stub
bolt of engine support bracket and remove center timing
belt cover. Remove lower timing belt cover.
NOTE: Camshaft sprocket dowel pins will be in 12 oclock position

when timing marks are correctly aligned.
Ensure camshaft, crankshaft and oil pump sprocket timing
marks are aligned. See Figs. 2 and 3. Loosen tensioner
pulley center bolt. Move tensioner to relieve timing belt ten-
sion. Remove timing belt. Remove timing belt auto
tensioner. See Fig. 1.
Remove plug from left side of cylinder block. Install a .31"
(8.0 mm) diameter Phillips screwdriver into the hole against
balance shaft. See Fig. 5. Screwdriver must go in at least
2.36 (60 mm) or more. If screwdriver will only go in about
Fig. 5: Holding Balance Shaft Stationary
.79-.98 (20-25 mm), turn sprocket one revolution and align
timing mark. Keep screwdriver in place until timing belt is
installed. This ensures that balance shaft driven by oil
pump sprocket remains in correct position.
To remove timing belt B (balance shaft belt), hold crank-
shaft sprocket stationary with a spanner wrench. Remove
crankshaft sprocket bolt. Using gear puller, remove outer
crankshaft sprocket.
Remove crankshaft sensing blade (if equipped). See Fig.
4. Loosen timing belt B tensioner bolt. If reusing timing
belt B, mark direction of belt rotation for reassembly refer-
ence. Remove timing belt B.
Inspection:
Inspect timing belts for damaged teeth and cracking. En-
sure belts are not contaminated with oil. Check tensioners
Fig. 6: Inspecting Timing Belt Auto Tensioner
for free rotation and grease leakage. Replace components
if damaged or if grease leakage exists.
Check timing belt auto tensioner for leaks. Hold timing belt
auto tensioner upright. Measure rod protrusion above edge
of housing. See Fig. 6. Length should be .47 (12 mm).
Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto
tensioner rod moves more than .039 (1 mm), replace the
auto tensioner.
Installation:
Retract rod into auto tensioner housing by placing auto
tensioner assembly in a soft-jawed vise. Close vise
SLOWLY to push rod back into auto tensioner housing.
When pin hole in cylinder aligns with pin hole in rod, insert
set pin. Replace tensioner assembly if rod can be retracted
easily into housing. Install auto tensioner on engine with
set pin in place.
Align balance shaft and crankshaft timing marks with rear
cover. See Figs. 7 and 8. Install timing belt B on sprock-
ets. If using old belt, install belt in original direction of rota-
Courtesy of Mitsubishi Motor Sales of America tion. Ensure there is no slack in tension side of belt.
Fig. 7: Aligning Timing Belt B (1990-92 Models)
CAUTION: Ensure tensioner pulley shaft does not rotate when
bolt is tightened or excessive pressure will be applied to tim-
ing belt.
Install timing belt B tensioner so center of tensioner pul-
ley is to the left and above of retaining bolt center. See Fig.
9. Rotate tensioner inward toward timing belt until belt is
tight. Tighten tensioner retaining bolt without letting
tensioner pulley rotate out of position. Check belt deflec-
tion at designated area. Belt deflection should be .20-.28"
(5.0-7.0 mm). Readjust timing belt if belt deflection is not
within specification.


CAUTION: Install crankshaft sensing blade and crankshaft sprockets
Rotate crankshaft 6 complete turns clockwise. Wait 15 min-
utes without turning crankshaft. Measure distance between
in correct positions or timing belt may be damaged.
top of auto tensioner body and tensioner arm. The distance
Install crankshaft sensing blade (if equipped) in front of should be .15-.18 (3.8-4.5 mm). See Fig. 16, Dimension
crankshaft sprocket B, with offset in proper direction. See A. If distance is not correct, timing belt tension will have to
Fig. 10. Install crankshaft sprocket A. Apply light coat of be readjusted. If distance is correct, go to FINAL ASSEM-
engine oil to crankshaft sprocket bolt threads, and tighten BLY.
bolt to specification. See TORQUE SPECIFICATIONS. In- Timing Belt Tension Adjustment (1993-98):
stall idler pulley (if removed). Lift tensioner pulley upward to apply tension on timing belt.
Ensure camshaft, crankshaft and oil pump timing marks The 2 pin holes in the center of the tensioner must face
are still aligned. See Figs. 2 and 3. DO NOT remove screw- down. See Fig. 12. Screw the Set Screw (MD998738) into
driver from side of engine block until timing belt is installed. engine support bracket until it makes contact with tensioner
arm. At that point, screw the set screw in a few more threads
NOTE: Intake and exhaust camshafts use same camshaft sprocket. and remove the set pin from the auto tensioner. Remove
Camshaft sprockets are provided with 2 timing marks. For exhaust the set screw. Tighten timing belt tensioner pulley center
camshaft sprocket, use timing mark on right with dowel pin facing bolt to 35 ft. lbs (48 N.m).
up. On intake camshaft sprocket, use timing mark on the left Remove screwdriver from side of engine block and install
with dowel pin hole on top. plug. To tension timing belt, rotate crankshaft about 1/4
Rotate camshaft sprocket so dowel pins are upward and turn counterclockwise, then 1/4 turn clockwise until all tim-
away from cylinder head and timing marks are aligned with ing marks align.
cylinder head surface. Timing marks should face each other. Loosen tensioner pulley center bolt. Install Adapter
See Figs. 2 and 3. (MD998767) or equivalent to tensioner eccentric. Install
Install timing belt on intake camshaft sprocket. Install spring torque wrench on adapter. See Fig. 13. Starting with eccen-
clip to retain timing belt on sprocket. See Fig. 11. Place a tric pin holes still facing down, apply 31 INCH Ibs. (3.5 N.m)
wrench on each camshaft sprocket retaining bolt. Rotate of torque counterclockwise on tensioner pulley.
camshafts so timing marks align with each other. Hold tensioner pulley at specified torque, and tighten
Install timing belt over exhaust camshaft. Install spring clip tensioner center bolt to specification. Do not let tensioner
to retain timing belt. Install timing belt over idler pulley, oil pulley turn with bolt. See TORQUE SPECIFICATIONS.
pump sprocket, crankshaft sprocket and tensioner pulley. Rotate crankshaft 2 full revolutions clockwise so that tim-
Remove spring clips from camshaft sprockets. ing marks are aligned. Allow engine to stand for 15 min-
Timing Belt Tension Adjustment (1990-92): utes without turning crankshaft. Distance between top of
Position timing belt tensioner pulley so that the 2 pin holes auto tensioner housing and tensioner arm should be .15-
in the center eccentric are facing to the left (as viewed from .18" (3.8-4.5 mm). See Fig. 16, Dimension A. If distance
timing belt end of engine) of the center bolt. Hand tighten is incorrect, repeat tensioning procedure until distance is
center bolt. correct. Once distance is correct, go to FINAL ASSEMBLY.
Remove screwdriver from balance shaft hole in side of Final Assembly:
engine block. Install plug. To install remaining components, reverse removal proce-
Rotate crankshaft 1/4 turn counterclockwise, then rotate dure. Ensure proper length bolts are installed in timing belt
crankshaft 1/4 clockwise until timing marks are aligned covers. See Fig. 14. See TIMING COVER BOLT LENGTH &
again. No. 1 cylinder should be at TDC of compression TORQUE table. Adjust drive belts to proper tension. See
stroke. page A-60 for belt tension ranges.
Attach Adapter (MD998767) to tensioner pulley eccentric. TIMING COVER BOLT LENGTH & TORQUE
Attach torque wrench to adapter and apply 24 INCH lbs.
Bolt INCH Lbs. (N.m)
(2.7 N.m) of torque in a clockwise direction. See Fig. 15.
A 6 x 16 mm Flange Bolt .............................. 89-106 (10-12)
With torque applied to eccentric, tighten tensioner pulley
B 6 x 18 Flange Bolt ..................................... 89-106 (10-12)
center bolt to 32-40 ft. lbs. (43-55 N.m).
C 6 x 25 Loose Washer Bolt ................................... 58 (6.5)
Insert Set Screw (MD998738) through inner timing belt cover D 6 x 25 Flange Bolt .................................... 89-106 (10-12)
until it contacts tensioner arm. See Fig. 12. Slowly rotate
E 6 x 45 Flange Bolt ..................................... 89-106 (10-12)
set screw until set pin can be removed. Remove set screw
from engine.

Fig. 9: Installing Timing Belt B Tensioner
Fig. 10: Installing Crankshaft Sprocket & Crankshaft
Sensing Blade

Fig. 11: Installing Timing Belt On Intake Sprockets
Fig. 15: Adjusting Timing Belt Tension (1990-92)

Fig. 12: Installing Set Screw On Tensioner Pulley

Fig. 16: Measuring Timing Belt Auto Tensioner Protrusion
Auto Tensioner Bolt .................................................... 17 (24)
Balance Shaft Sprocket Bolt ......................................... 33 (46)
Crankshaft Sprocket Bolt ............................. 80-94 (108-127)
Courtesy of Mitsubishi Motor Sales of America Drive Belt Tensioner Pulley Bracket ..................... 17-20 (23-26)
Fig. 13: Adjusting Timing Belt Tension (1993-98) Engine Mount-To-Body
Through Bolt (1993-98) ..................................... 72-87 (98-118)
Engine Mount-To-Body
Through Bolt (1990-92) ...................................... 43-58 (60-80)
Engine Mount-To-Engine
Bolt/Nut (1993-98) ..................................................... 49 (67)
Bolt/Nut (1990-92) ........................................... 36-47 (50-65)
Idler Pulley Bolt ........................................................... 27 (38)
Timing Belt B (Balance Shaft)
Tensioner Bolt .................................................... 11-16 (15-20)
Timing Belt Tensioner Pulley Center Bolt ................... 35 (48)
Water Pump Bolt .......................................................... 10 (14)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................... 89-106 (10-12)
Water Pump Pulley Bolt ................................................ 80 (9)
Fig. 14: Installing Timing Belt Cover Bolts
2.0L 4-Cylinder SOHC

TIMING BELT APPLICATION On all vehicles, position No. 1 cylinder at TDC of compres-
sion stroke. Loosen pulley bolts. Remove drive belts. Re-
Belt move crankshaft, water pump and power steering pulleys.
Labor Component Part Remove upper and lower front timing belt covers.
Application Time Kit No. No. On 1989-91 models, remove tensioner pulley bracket.
2.0L 4-Cyl. SOHC Relieve camshaft timing belt tensioner pressure and se-
Colt Vista cure tensioner toward water pump. If camshaft timing belt
is to be reused, mark belt with an arrow indicating direction
1984-86 of rotation and remove camshaft timing belt.
Balance Shaft ..... 1 ..................................... T090 Rotate crankshaft in direction of rotation and align timing
Camshaft ............ 2 2.8 Hrs. ........................ T089 marks. See Fig. 1. Remove crankshaft sprocket attaching
1987-91 bolt. Loosen main tensioner pivot and disengage spring
Balance Shaft ..... 1 ..................................... T159 from boss on water pump. Remove tensioner assembly.
Camshaft ............ 2 2.8 Hrs. . TCK158A ...... T158 Remove balance shaft belt (belt A).
Ram 50 Remove camshaft sprocket, then crankshaft sprocket and
flange. Remove plug from lower left side of cylinder block,
1983-86 then insert screwdriver into hole to hold balance shaft in
Balance Shaft ... 1 ..................................... T090 position while removing oil pump sprocket nut. See Fig. 2.
Camshaft ........... 3 2.3 Hrs. ........................ T089 Loosen right side balance shaft sprocket bolt, then remove
1987-89 balance shaft belt tensioner. Remove balance shaft timing
Balance Shaft ... 1 ..................................... T159 belt (belt B).
Camshaft ........... 3 2.3 Hrs. . TCK158A ...... T158 Inspection:
Vista (Canada) Inspect back of belt for hardness, non-elasticity and glossy
surface. If no mark is produced when fingernail is forced
1989-91 into it, replace belt. Check for rounded sides on belt, flak-
Balance Shaft ... 1 ..................................... T159 ing, peeling, cracking and separating rubber. Cracks are
Camshaft ........... 2 2.8 Hrs .. TCK158A ...... T158 most evident at base of tooth.
2000GTX (Canada) Installation:
1989-92 Install timing belt B, ensuring tension side has no slack.
Balance Shaft .. 1 ..................................... T159 Align crankshaft and balance shaft sprocket timing marks
with marks on timing case. See Fig. 3. Install tensioner B
Camshaft ......... 2 2.8 Hrs. ........................ T155 so only light pressure is on belt. Ensure flange on tensioner
1
- Balance Shaft labor time included in camshaft is mounted away from engine and finger-tighten bolt. En-
labor time. sure that the pulley is to left of installation bolt and pulley
2
- With Air Cond. add .2 hours. flange faces front of engine. See Fig. 4.
With Pwr. Strng. add .2 hours. Lift tensioner with finger tip until slack is removed from
tension side of belt. Tighten tensioner bolt, being careful to
3
- With Air Cond. add .7 hours. prevent turning shaft. Ensure timing marks are in align-
With Pwr. Strng. add .2 hours ment. Tighten right silent shaft bolt.
Check belt tension by pressing center of tension side in-
NOTE: A timing belt component kit is available for ward, using index finger and measuring belt deflection.
Deflection should be .195-.265" (5.0-7.0 mm). Readjust if
this application. See page I for information on component not within specification.
kits. Ensure camshaft timing belt sprockets align with timing
marks. Ensure tensioner is fully toward water pump and
MANUFACTURERS SUGGESTED install camshaft timing belt (belt A) in order of crankshaft
sprocket, oil pump sprocket and camshaft sprocket. En-
SCHEDULED MAINTENANCE sure tension side of belt has no slack. Loosen tensioner
The manufacturer recommends the belt be replaced at 60,000 mounting bolt and nut and allow tensioner spring to ten-
mile intervals. sion belt.
Tighten slot side bolt and then tighten nut. Ensure all timing
REMOVAL & INSTALLATION marks are in correct alignment. Turn crankshaft clockwise
one revolution. Loosen mounting nut and bolt to allow
TIMING BELT tensioner to readjust. Tighten slot side bolt, then tighten nut.
Removal: Reverse removal procedure to complete reassembly. Adjust
Disconnect negative battery cable. On vehicles equipped drive belts to proper tension. See page A-60 for belt tensiion
with A/C, remove upper radiator shroud and cooling fan/ ranges.
clutch assembly. On 1989-91 models, support engine and
remove upper engine mount located near timing belt cover.
2.0L 4-Cylinder SOHC (Cont.)
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)
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
Left Lower Rear Cover Bolt ............................. 22-30 (30-41)
Timing Belt Tensioner Nut Fig. 2: Locking Balance Shaft In Place
1983-85 .......................................................... 16-21 (22-28)
1986-91 .......................................................... 32-39 (42-53)
Water Pump Bolt
Except 8 X 65 mm ............................................ 9-11 (12-15)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
All Except Left Lower Rear Cover Bolt ............ 84-108 (9-12)
Fig. 3: Aligning Balance Shaft Sprocket
Fig. 4: Installing Balance Shaft Tensioning Pulley

*3.2L & 3.5L V6

TIMING BELT APPLICATION Rotate crankshaft to align crankshaft sprocket timing mark
with TDC mark on oil pump housing. Align camshaft sprock-
Application Labor Time Belt Part No. ets with marks on rear covers. See Figs. 1 and 2.
3.2L V6
Concord & Intrepid (Includes Canadian) CAUTION: When timing belt tensioner is removed from engine,
always store tensioner with plunger facing up.
1998-00 .............. 1 2.8 Hours .................... T295
3.5L V6 Remove timing belt tensioner. Store with plunger facing up.
Concord & Intrepid (Includes Canadian) Remove timing belt.
1993-94 .............. 1 2.7 Hours .................... T219 Installation:
1995-97 ................ 1 2.7 Hours .................... T255 When tensioner is removed from engine, it is necessary to
compress plunger into tensioner body. Place timing belt
2000 ................... 1 2.7 Hours .................... T295 tensioner in vise with holes in plunger and housing aligned.
LHS & 300M SLOWLY compress plunger. See Fig. 3. Total bleed down
1994 ................... 1 2.7 Hours .................... T219 of plunger should take about 5 minutes. When pin holes
1995-97 .............. 1 2.7 Hours .................... T255 are aligned, install locking pin through tensioner and
1998-00 .............. 1 2.7 Hours .................... T295 plunger.
New Yorker Ensure camshaft and crankshaft sprocket timing marks
are still aligned. If camshaft timing marks are not aligned,
1994 ................... 1 2.7 Hours .................... T219 always rotate camshafts towards nearest timing marks.
1995-96 .............. 1 2.7 Hours .................... T255 DO NOT turn camshafts a full revolution. This could cause
Vision valves to contact pistons.
1993-94 .............. 1 2.7 Hours .................... T219 Install timing belt starting at crankshaft sprocket, going in a
1995-97 .............. 1 2.7 Hours .................... T255 counterclockwise direction. After belt is installed on right
camshaft sprocket, keep tension on belt until it is past
1
- With Air Cond. add .2 hours. tensioner pulley.
With Pwr. Strng. add .2 hours. Holding tensioner pulley against belt, install tensioner into
housing and tighten bolts to specification. See TORQUE
MANUFACTURERS SUGGESTED SPECIFCATIONS. When tensioner is in place, pull locking
pin to allow tensioner to extend to pulley bracket.
105,000 miles up to the 1999 model year. For 2000 model
years, the manufacturer recommends the timing belt be re-
placed at 100,000 miles for Federal vehicles, and 105,000
miles for California vehicles.
*NOTE: The 3.2L is an interference engine. See page

A-59 for interference engine cautions.

TIMING BELT
CAUTION: The following procedure can only be used if camshaft
sprockets have NOT been loosened or removed. If camshaft sprockets
have been removed, special tools and timing procedure are required.
Consult service information for procedure.
Removal:
Disconnect negative battery cable from jumper terminal.
Remove upper radiator crossmember. Remove electric cool-
ing fan module with fans.
Remove accessory drive belts. Hold crankshaft damper
stationary while removing center bolt. Use gear puller to
remove crankshaft damper.
Remove lower timing belt cover. Remove stamped steel
(right side) timing belt cover. DO NOT remove the sealer on
the stamped steel cover, it is reusable.
Remove cast (left side) timing belt cover. If reusing old tim-
ing belt, mark belt direction of rotation for reinstallation.
CAUTION: Align camshaft sprockets between marks on rear belt

covers before removing timing belt or damage to valves and Courtesy of DaimlerChrysler
pistons may occur. Fig. 1: Aligning Camshaft Sprocket Timing Marks
*3.2L & 3.5L V6 (Cont.)
Fig. 3: Compressing Tensioner
Timing Belt Cover Bolts
M8 ............................................................................ 21 (28)
M10 .......................................................................... 40 (54)
Courtesy of DaimlerChrysler Timing Belt Tensioner ................................................ 21 (28)
Fig. 2: Removing/Installing Timing Belt Timing Belt Tensioner Pulley Assembly ....................... 45 (61)
INCH Lbs. (N.m)
Rotate crankshaft sprocket 2 revolutions and check timing Timing Belt Cover Bolts (M6) .................................... 106 (12)
marks on camshafts and crankshaft. Marks should line up Upper Radiator Attaching Screws ............................. 123 (14)
within their respective locations. If marks do not line up, Water Pump Bolts .................................................... 106 (12)
repeat procedure. See Fig. 1.
Install timing belt covers and crankshaft damper. Install
accessory drive belts. To complete installation, reverse re-
Start engine and allow to idle for about one minute. If noise
is present in timing belt tensioner, air has possibly entered
tensioner. To remove air, run engine at 1600-2000 RPM for
10 minutes to purge air.
CHRYSLER, EAGLE & MITSUBISHI 125
*1.6L 4-Cylinder DOHC

Check belt teeth for cracks, damage and oil contamination.
Belt Part No. Inspect all sprockets for damage. Check tensioner pulley
1.6L 4-Cyl. DOHC and idler pulley for grease leakage and roughness in rota-
Colt & Summit tion. Replace components if damaged.
1989-90 ................. 3.6 Hours ..................... T165 Inspect auto tensioner for leaks. Replace, if necessary. In-
Colt 100, Colt 200 & Vista (Canada) spect tensioner pulley and idler pulley for smooth rotation.
Replace if bearings are worn.
1989-90 ................. 3.6 Hours ..................... T165
Mirage CAUTION: Install flange and crankshaft sprocket in correct direction
1989 & 1991-92 ..... 3.6 Hours ..................... T165 to prevent damage to timing belt.
1
- With Air Cond. add .2 hours. Installation:
With Pwr. Strng. add .3 hours. Rotate timing belt tensioner pulley so that the 2 pin holes
are to the left of the center bolt. See Fig. 4. Tighten center
bolt finger tight. Leave Allen wrench or pin installed in auto
MANUFACTURERS SUGGESTED tensioner.
SCHEDULED MAINTENANCE Rotate camshaft sprockets so dowel pins face upward and
The manufacturer recommends the belt be replaced every timing marks on sprockets align. See Fig. 2. Outer marks
60,000 miles. on sprockets should be aligned with cylinder head surface.
When exhaust camshaft sprocket is released, camshaft
* NOTE: This application is an interference engine. will rotate one tooth in counterclockwise direction. When
installing timing belt, ensure this rotation is compensated
See page A-59 for interference engine cautions. for.
Rotate crankshaft and align timing marks on crankshaft
REMOVAL & INSTALLATION and oil pump sprockets. If installing old timing belt, ensure
it is installed in original direction of rotation.
NOTE: Replacement procedures include revised information Install timing belt around intake camshaft sprocket. Install
from Chrysler technical service bulletin 09-01-94; January 28, spring-type paper clip on timing belt and camshaft sprocket
1994. to hold belt on sprocket. Clip should be installed below
cylinder head surface, on outer side of camshaft sprocket.
TIMING BELT Install box wrench on both camshaft sprocket bolts. Install
Removal: timing belt around exhaust camshaft sprocket while hold-
Raise and support vehicle. Remove lower left engine com- ing camshaft sprocket bolt to align timing mark on cam-
partment splash shield. Support weight of engine from shaft sprocket with timing mark.
above with Suppport Fixture (C-4852 or 7137) or equiva- Install another spring-type paper clip on timing belt and
lent. On timing belt end of engine, remove engine mount exhaust camshaft sprocket to hold belt on sprocket. Install
bracket connecting engine to body. clip below cylinder head surface, on outer side of camshaft
Loosen, but do not remove water pump pulley bolts. Re- sprocket.
move generator and power steering pump drive belts. Re- Install timing belt in the following order: around idler pulley,
move water pump pulley. oil pump sprocket, crankshaft sprocket and tensioner pul-
ley. Remove both spring-type paper clips. Rotate tensioner
NOTE: It is necessary to lower engine slightly to remove the crankshaft pulley inward toward timing belt until belt is NOT sagging.
pulley. Temporarily tighten center bolt on tensioner pulley. Ensure
all timing marks are aligned.
Remove accessory drive belt tensioner pulley bracket. See
Fig. 1. Remove A/C compressor drive belt (if equipped). CAUTION: Ensure all timing belt teeth are engaged with teeth
Remove water pump pulley. Remove crankshaft pulley-to- on camshaft, oil pump and crankshaft sprockets.
crankshaft sprocket bolts. Remove crankshaft pulley. It is
NOT necessary to remove crankshaft pulley center bolt. To adjust belt tension, rotate crankshaft 1/4 turn counter-
Remove upper and lower timing belt covers. clockwise, then rotate clockwise until No. 1 cylinder is at
TDC. Ensure timing marks are aligned. Loosen center bolt
CAUTION: Crankshaft may need to be rotated up to 6 revolutions on tensioner pulley.
before all sprockets are properly aligned. Note pin holes in tensioner pulley. Use socket wrench to
rotate tensioner pulley. Using INCH lb. torque wrench and
Rotate engine clockwise (as viewed from timing belt end of Socket Wrench (MD998752), apply a clockwise torque of
engine) to align all timing marks so No. 1 cylinder is at TDC 24 INCH Ibs. (2.7 N.m) on tensioner pulley. See Fig. 5. With
of compression stroke. See Fig. 2. If reusing belt, mark belt torque applied to tensioner pulley, tighten tensioner pulley
with original rotation direction. center bolt to 32-41 ft. Ibs. (43-55 N.m).
Remove rubber plug from inner timing belt cover. Install SLOWLY rotate set screw until Allen wrench or pin can be
Set Screw (MD998738) into engine support bracket until it removed from auto tensioner. Remove set screw.
contacts auto tensioner arm. See Fig. 3. Remove auto Rotate crankshaft clockwise 6 complete revolutions and
tensioner. Loosen timing belt tensioner pulley center re- leave in this position for approximately 15 minutes. After 15
taining bolt. minutes, measure distance between bottom edge of
Compress auto tensioner push rod by SLOWLY rotating tensioner arm and top of auto tensioner body. Distance
Set Screw (MD998738) until hole in auto tensioner aligns should be .15-.18" (3.8-4.5 mm). See Fig. 7, Dimension
with hole in auto tensioner body. Push rod may need to be A.
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.
126 CHRYSLER, EAGLE & MITSUBISHI
*1.6L 4-Cylinder DOHC (Cont.)
Courtesy of DaimlerChrysler Corp.



If distance is not correct, loosen timing belt tensioner pul-
ley center bolt. Use Set Screw to compress auto tensioner
again. Readjust timing belt tension using Socket Wrench
(MD998752) and INCH lb. torque wrench until correct dis-
tance of .15-.18" (3.8-4.5 mm) is obtained.
Remove set screw. Install rubber plug in rear timing belt
cover. Install upper and lower timing belt covers. Ensure
timing belt cover bolts are installed in correct location. See
Fig. 6.
Install crankshaft pulley. Install A/C compressor belt (if
equipped). Install accessory drive belt tensioner bracket.
Install water pump pulley. Install generator and power steer-
ing pump drive belts. Adjust drive belts to correct tension.
Fig. 3: Retracting Auto Tensioner Rod See page A-60 for belt tension ranges.
Install engine mount bracket on timing belt end of engine.
Remove engine support fixture. Install lower splash shield.
Accessory Drive Belt
Tensioner Pulley Bracket Bolt ......................... 17-20 (23-27)
Auto Tensioner Bolt .......................................... 14-20 (19-27)
Crankshaft Pulley-To-Sprocket Bolt .................. 14-22 (19-30)
Crankshaft Sprocket Center Bolt .................. 80-94 (109-127)
Fig. 4: Positioning Timing Belt Tensioner Pulley
Engine Mount Bracket
To-Body Through Bolt ........................................ 43-58 (60-80)
To-Engine Bracket Bolt/Nut ............................... 36-47 (50-65)
Timing Belt Cover
Left Lower Rear Cover Bolt ............................. 22-30 (30-41)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ....................................... 84-106 (10-12)


1.8L 4-Cylinder
Inspect timing belts for damaged teeth or cracks. Ensure
Belt belts are not contaminated by oil. Check tensioners for
Labor Component Part freedom of rotation. Replace components if damaged.
Application Time 1 Kit No. No. Installation:
1.8L 4-Cyl. Coat outer diameter of right silent shaft spacer with engine
Eclipse & Laser oil. Install spacer with chamfered side toward oil seal. In-
stall right silent shaft sprocket. Align crankshaft sprocket
1990-94 B and right silent shaft timing marks. See Fig. 5. Install
Balance Shaft .... 2 .................................... T159 timing belt B on sprockets. Ensure belt is installed in
Camshaft ......... 2.4 Hrs. .. TCK158 .......... T158 original direction of rotation and no slack exists in belt.
Talon
1993-94 CAUTION: Ensure right silent shaft spacer is installed with chamfered
side toward oil seal, or damage to oil seal will result.
Balance Shaft .... 2 .................................... T159
Camshaft ......... 2.4 Hrs. .. TCK158 .......... T158
CAUTION: When tightening bolt, ensure tensioner does not rotate,
1
- With Air Cond. add .2 hours. or excessive pressure will be applied to timing belt.
2
Balance shaft labor time included in Install timing belt tensioner B so center of pulley is lo-
cated left of tensioner bolt. See Fig. 6. Ensure flange on
camshaft labor time. tensioner pulley is toward front of engine. Rotate tensioner
inward toward timing belt until belt is tight. Tighten tensioner
NOTE: A timing belt component kit is available for bolt.
this application. See page I for information on component Check belt deflection at designated area. See Fig. 6. Belt
deflection should be .20-.28" (5.0-7.1 mm). Readjust tim-
kits. ing belt if belt deflection is not within specification.
Install flange in front of crankshaft sprocket B, with offset
MANUFACTURERS SUGGESTED toward crankshaft. See Fig. 1. Install crankshaft sprocket
A. install camshaft and oil pump sprockets. Tighten bolts
SCHEDULED MAINTENANCE to specification. See TORQUE SPECIFICATIONS.
The manufacturer recommends the belt be replaced every Install tensioner spring, tensioner spacer and timing belt
60,000 miles. A tensioner. Ensure upper end of tensioner spring con-
tacts water pump. Rotate tensioner toward water pump,
REMOVAL & INSTALLATION and temporarily tighten nut.
Ensure all timing marks are aligned. See Fig. 2. When
TIMING BELT aligning oil pump sprocket timing marks, remove plug from
cylinder block. See Fig. 3. Insert a .31" (8.0 mm) diameter
CAUTlON: To prevent engine damage, DO NOT rotate crankshaft Phillips screwdriver into plug hole.
counterclockwise (as viewed from timing belt end of engine). If screwdriver can only be inserted .79-.98" (20.0-24.9 mm),
Removal: rotate oil pump sprocket one revolution, and realign timing
Disconnect negative battery cable. Disconnect power steer- mark. Insert screwdriver, and ensure it can be inserted at
ing hose clamp. Remove engine undercover. Place wooden least 2.36" (59.9 mm). DO NOT remove screwdriver until tim-
block between jack and oil pan. Raise engine slightly. ing belt is installed.
Remove engine mount assembly near timing belt cover. Install timing belt A on sprockets. Ensure no slack exists
Remove all drive belts and tensioner pulley bracket. See on tension side of belt. See Fig. 2. Install timing belt on
Fig. 1. Remove power steering, water pump and damper crankshaft sprocket A, oil pump sprocket, and then on
pulleys. Remove adapter and crankshaft pulley. camshaft sprocket. If reused, ensure belt is installed in
original direction of rotation.
NOTE: Ensure timing marks are aligned. Mark direction of rotation Loosen tensioner nut to allow spring tension to be applied
of all timing belts. to timing belt. Ensure all timing marks are aligned. Re-
move screwdriver and install plug. To apply tension on tim-
Remove upper and lower timing belt covers and gas- ing belt, rotate crankshaft clockwise so camshaft sprocket
kets. Remove access cover. Remove crankshaft sprocket moves 2 teeth past timing mark on rear timing belt cover.
A bolt and washer. Rotate crankshaft clockwise (as See Fig 7. DO NOT rotate crankshaft counterclockwise.
viewed from timing belt side of engine), and align timing
mark on camshaft sprocket with timing mark on rear up- CAUTION: DO NOT tighten tensioner spacer nut before tightening
per timing belt cover. See Fig. 2. tensioner bolt, or timing belt tensioner will rotate and apply
Loosen timing belt tensioner bolt for timing belt A. Move excessive pressure on timing belt.
tensioner toward water pump, and tighten tensioner bolt. Re-
move timing belt. Rotate tensioner inward toward timing belt. Ensure timing
Remove timing belt tensioner, tensioner spacer and tensioner belt fully engages camshaft sprocket. Tighten timing belt
spring. See Fig. 1. Remove camshaft sprocket. Remove plug tensioner bolt. Tighten tensioner spacer nut. At midway loca-
from side of cylinder block, and install a .31" (8.0 mm) diam- tion between camshaft sprocket and oil pump sprocket, push
eter Phillips screwdriver to hold left silent shaft. See Fig. 3. timing belt A outward toward lower timing belt cover. Note
Remove oil pump sprocket nut, and remove sprocket. Re- clearance between timing belt and cover. See Fig. 8. Clear-
move crankshaft sprocket A and flange. Remove timing ance should be .47" (12.0 mm). Timing belt may need to be
belt tensioner B. If timing belt B is to be reused, mark readjusted.
direction of timing belt rotation for reassembly reference.
Remove timing belt B.

Fig. 1: Exploded View Of Timing Belts & Related Components
To complete installation, reverse removal procedure. En-

sure proper length bolts are installed in designated areas
in timing belt covers. See Fig. 9. Adjust drive belts to proper
A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27)
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 Fig. 2: Aligning Timing Belt A Timing Marks
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Valve Cover Bolt .................................................... 48-60 (5-7)
90C02590 Courtesy of Chrysler Corp.

Fig. 3: Holding Silent Shaft In Stationary Position
Fig. 4: Installing Crankshaft Sprockets Fig. 7: Applying Tension To Timing Belt A
Fig. 8: Checking Timing Belt A Tension

Fig. 5: Aligning Timing Belt B Timing Marks
Fig. 9: Identifying Timing Belt Cover Bolt Locations

1.8L 4-Cylinder VINs C & D

1.8L 4-Cyl.
Colt
1992-94 ................ 2.4 Hours .................... T201
Colt Vista
1992-94 ................ 2.4 Hours .................... T201
Expo
1992-94 ................ 2.4 Hours .................... T201
Mirage
1993-96 ................ 2.4 Hours .................... T201
1997-01 ................ 2.4 Hours .................... T288
Summit
1992-96 .............. 2.4 Hours .................... T201
Summit Wagon
1992-96 .............. 2.4 Hours .................... T201
1
Chrysler & Eagle: The manufacturer recommends the belt be
replaced every 60,000 miles.
Mitsubishi: For 1992-93 models, the manufacturer recom-
mends the belt be replaced at 60,000 miles.
For 1994-96 models, the manufacturer recommends the belt
nia, 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 Fig. 2: Installing Flange
be replaced every 60,000 miles except in California, Connecti-
cut, and Massachusetts. In California, Connecticut, and Mas- ing belt end of engine) until cylinder No. 1 is at TDC of
sachusetts, timing belt replacement is recommended, but not compression stroke, and timing mark on camshaft sprocket
required, at 60,000 miles. In these states, replace timing belt and crankshaft sprocket align with timing mark on engine.
at 100,000 miles, unless previously changed. See Fig. 1.
For 2001 models, the manufacturer recommends the belt be If timing belt is to be reused, mark direction of rotation be-
replaced every 60,000 miles except in California, Massachu- fore removing. Loosen timing belt tensioner bolt. Using a
setts and Vermont. In California, Massachusettes and Ver- screwdriver, move tensioner away from timing belt. Tighten
mont, timing belt replacement is recommended, but not re- bolt to secure tensioner. Remove timing belt.
quired, at 60,000 miles. In these states, replace timing belt at Inspection:
100,000 miles, unless previously changed. Check belt teeth for cracks, damage and oil contamination.
Inspect all sprockets for damage. Check belt tensioner for
REMOVAL & INSTALLATION grease leakage or roughness in tensioner rotation. Re-
place components if damaged.
TIMING BELT Installation:
Removal: Install timing belt tensioner, leaving bolt loose. Using a
Disconnect negative battery cable. On Expo models, re- screwdriver, push tensioner toward engine mount. Tighten
move condenser tank. On all models, remove A/C and timing belt tensioner bolt.
power steering hose mounting bracket from upper en- Align camshaft sprocket and crankshaft sprocket timing
gine mount at timing belt cover. Remove all accessory marks with timing marks on engine.
drive belts. Using End Yoke Holder (MB990767) and Crank- Install timing belt. Loosen timing belt tensioner to apply
shaft Pulley Holder (MD998718) or equivalent, remove spring pressure to timing belt. Ensure timing marks are
crankshaft pulley bolt and pulley. still aligned.
Tighten timing belt tensioner bolt. Rotate camshaft in re-
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed verse direction and ensure that there is no slack in timing
from timing belt end of engine). belt. Rotate crankshaft 2 complete revolutions clockwise
Remove upper and lower timing belt covers. Remove (as viewed from timing belt end of engine) and ensure
flange. Rotate crankshaft clockwise (as viewed from tim- timing marks are still aligned.
1.8L 4-Cylinder VINs C & D (Cont.)
Ensure timing belt teeth are properly seated in sprockets.
Install flange. See Fig. 2. To complete installation, reverse
removal procedure. Ensure proper length bolts are installed
in designated areas in timing belt covers. See Fig. 4. Ad-
tension ranges.
Crankshaft Center Pulley Bolt ..................... 80-94 (109-127)
Front Cover Bolt ............................................... 11 -13 (15-18)
Timing Belt A Tensioner Bolt .......................... 16-22 (22-30)
Timing Belt B Tensioner Bolt ......................... 11 -16 (15-24)
INCH Lbs. (N.m) Fig. 4: Identifying Timing Belt Cover Bolt Locations
Valve Cover Bolt .................................................... 48-60 (5-7)

Fig. 3: Exploded View of Timing Belt Components
*2.0L 4-Cylinder DOHC, VIN Y

2.0L 4-Cyl. DOHC, VIN Y
Avenger, Neon,
& Sebring Coupe
1995-99 ................ 1 3.6 Hours .................... T246
Eclipse (Non-Turbo)
1995-99 ................ 1 3.6 Hours .................... T246
Talon (Non-Turbo)
1995-98 ................ 1 3.6 Hours .................... T246
1
Chrysler: On Neon models, the manufacturer recommends
replacing the timing belt at 105,000 miles.
On Avenger and Sebring Coupe models, the manufacturer
recommends the belt be replaced every 60,000 miles except
in California, Connecticut, and Massachusetts. In California, Courtesy of Mitsubishi Motor Sales of America
Connecticut, and Massachusetts, timing belt replacement is Fig. 1: Aligning Timing Marks & Adjusting Belt Tension
recommended, but not required, at 60,000 miles. In these (Mechanical Timing Belt Tensioner)
states, replace timing belt at 100,000 miles.
Eagle: For 1995-96 model years, the manufacturere recom-
mends the belt be replaced every 60,000 miles, except in
California. In California, timing belt replacement is recom-
mended, but not required, at 60,000 miles. In California, re-
place timing belt at 100,000 miles, unless previously changed.
belt be replaced every 60,000 miles except in California, Con-
necticut, and Massachusetts. In California, Connecticut, and
Massachusetts, timing belt replacement is recommended,
but not required, at 60,000 miles. In these states, replace
timing belt at 100,000 miles, unless previously changed.
Mitsubishi: For 1995-97 model years, the manufacturer rec-
ommends the belt be replaced every 60,000 miles except in
California. In California, timing belt replacement is recom-
mended, but not required, at 60,000 miles. In California, re-
place timing belt at 100,000 miles, unless previously changed.
but not required, at 60,000 miles. In these states, replace Fig. 2: Aligning Timing Marks
timing belt at 100,000 miles, unless previously changed. (Hydraulic Timing Belt Tensioner)
bracket from front of engine. Remove timing belt cover. Ro-

tate engine clockwise to align the camshaft and crankshaft
See page A-59 for interference engine cautions. timing marks. See Fig. 1.
REMOVAL & INSTALLATION CAUTION: To prevent pistons from hitting valves, do not rotate
TIMING BELT Install 8 mm Allen wrench into timing belt tensioner. See
Removal (Mechanical Timing Belt Tensioner): Fig. 1. Insert long end of a 3 mm Allen wrench into pin hole
On Avenger and Sebring, remove coolant reservoir and place in the front of tensioner. Slowly rotate tensioner counter-
out of way. On all models, raise and support vehicle. Re- clockwise with 8 mm Allen wrench while pushing lightly on
move right inner splash shield. Remove center bolt from the 3 mm Allen wrench, until it slides into the locking hole.
crankshaft pulley. Use gear puller to remove crankshaft If reusing old timing belt, mark belt with arrow to indicate
pulley. direction of rotation. Remove timing belt.
Remove power steering pump (hoses attached) and
mounting bracket from engine. Move out of way. NOTE: Mechanical timing belt tensioner is serviced as an assembly.
Lower vehicle. Place jack under engine for support. Re- To prevent premature timing belt failure and engine damage,
move right side engine mount. Remove engine mount do not separate tensioner pulley from tensioner bracket.
*2.0L 4-Cylinder DOHC, VIN Y (Cont.)
Loosen timing belt tensioner to remove timing belt. If reus-
ing old belt, mark belt with arrow to indicated direction of
rotateion. Remove timing belt.
Remove tensioner from engine. It will be necessary to com-
press the center plunger and lock it in place.
Place tensioner in a soft-jawed vise. Align the hole in the
end of the tensioner center plunger with the hole in the end
of the tensioner body. Slowly compress the tensioner, and
when holes are aligned, insert a locking pin in the tensioner.
NOTE: The following revised information regarding the tensioner

pulley pivot bolt is from Chrysler technical service bulletin 09-
06-96; March 29, 1996. Also Mitsubishi technical service bulletin
96-11-004; May 1996.
Timing Belt Tensioner Bracket Precaution:
On models with hydraulic timig belt tensioner, do not
loosen, tighten, or remove timing belt tensioner pivot bolt.
Bolt is installed at factory with special threadlocking com-
pound that is not reusable. If tensioner pivot bolt is dis-
Courtesy of Mitsubishi Motor Sales of America turbed, entire bracket assembly must be replaced. The
tensioner pulley center bolt MAY be removed and installed.
Fig. 3: Aligning Crankshaft Timing Mark
Inspection:
(Hydraulic Timing Belt Tensioner Shown; Mechanical
Tensioner Similar)
Inspection: the belt is not cracked, separated or showing canvas fiber.
Check belt teeth for damage or oil contamination. Inspect Inspect all sprockets for damage. Check tensioner pulley
belt for glossy, hardened or non-elastic surface. Ensure and idler pulley for signs of grease leakage or roughness
the belt is not cracked, separated or showing canvas fiber. in rotation. Replace components if damaged.
Inspect all sprockets for damage. Check tensioner pulley Installation (Hydraulic Timing Belt Tensioner):
and idler pulley for signs of grease leakage or roughness Ensure camshaft and crankshaft timing marks are aligned.
in rotation. Replace components if damaged. Rotate crankshaft pulley sprocket 1/2 tooth counterclock-
Installation (Mechanical Timing Belt Tensioner): wise from TDC location. See Fig. 3.
Ensure camshaft and crankshaft timing marks are aligned.
Rotate crankshaft pulley sprocket 1/2 tooth counterclock-
wise from TDC location. See Fig. 3.
Install timing belt starting from crankshaft pulley sprocket,
go around water pump sprocket, idler pulley, camshaft
sprockets, and then around tensioner pulley. Move crank-
shaft sprocket to TDC to take up belt slack.
Remove Allen wrench from timing belt tensioner pulley. Ro-
tate crankshaft clockwise 2 revolutions. Check alignment
of camshaft and crankshaft timing marks. If timing marks
do not align, remove timing belt and realign timing marks.
Continue installation in reverse of removal procedure. Ad-
tension ranges.
On Neon models only, connect scan tool to Data Link Con-
nector (DLC) under lower left edge of instrument panel.
Follow scan tool instructions to access the cam/crank re-
learn procedure. Perform cam/crank relearn procedure.
Removal (Hydraulic Timing Belt Tensioner):
Raise and support vehicle. Remove right inner splash
shield. Remove center bolt from crankshaft pulley. Use gear
puller to remove crankshaft pulley.
Remove power steering pump (hoses attached) and
mounting bracket from engine. Move out of way.
Lower vehicle. Place jack under engine for support. Re-
move right side engine mount. Remove engine mount Courtesy of Mitsubishi Motor Sales of America
bracket from front of engine. Remove timing belt cover. Ro- Fig. 4: Adjusting Timing Belt Tension
tate engine clockwise to align the camshaft and crankshaft (Hydraulic Timing Belt Tensioner)
timing marks. See Fig. 2.

*2.0L 4-Cylinder DOHC, VIN Y (Cont.)

Install timing belt starting from crankshaft pulley sprocket, TORQUE SPECIFICATIONS
go around water pump sprocket, idler pulley, camshaft
sprockets, and then around tensioner pulley. Move crank-
shaft sprocket to TDC to take up belt slack. Install timing
belt tensioner, but do not final tighten fasteners yet.
Engine Mount Bracket-To-Engine Nut/Bolt ..................... 30 (41)
With 21 ft. lbs. (28 N.m) of torque applied to tensioner pul-
Engine Mount-To-Body Bracket
ley, move tensioner against pulley bracket and tighten bolts
Through Bolt ..................................................... 72-87 (98-118)
to specification. See TORQUE SPECIFICATIONS. See Fig.
Engine Mount-To-Engine Mount Bracket
4.
Nut/Bolt ........................................................................ 64 (86)
Remove tensioner plunger locking pin. Pretension is cor-
Engine Mount-To-Frame Rail Bolt (Neon) ...................... 40 (54)
rect when locking pin can be removed and installed again.
Power Steering Pump Bolts ........................................... 29 (39)
Rotate crankshaft clockwise 2 revolutions and check tim-
ing belt alignment marks. Reset belt if marks are not
Hydraulic Belt Tensioner .............................................. 30 (41)
aligned. Install timing belt covers.
Continue installation in reverse of removal procedure. Ad-
Mechanical Belt Tensioner ........................................... 21 (28)
Timing Belt Tensioner Pulley Bolt
tension ranges.
Hydraulic Belt Tensioner ............................................... 50 (68)
On Neon models only, connect scan tool to Data Link Con-
INCH Lbs. (N.m)
nector (DLC) under lower left edge of instrument panel.
Timing Belt Cover Bolt .............................................. 106 (12)
Follow scan tool instructions to access the cam/crank re-
Water Pump Bolt ...................................................... 106 (12)
learn procedure. Perform cam/crank relearn procedure.
2.4L 4-Cylinder
Align crankshaft and balance shaft sprocket timing marks
Application Labor Time Belt Part No. with the marks on the timing case. See Fig. 2. Install bal-
2.4L 4-Cyl. ance shaft timing belt over crankshaft and balance shaft
Colt, Colt Vista & Colt Wagon (Canada) sprockets. When installing timing belt, be sure tension side
1992 of belt has no slack. Install balance shaft belt tensioner.
Balance Shaft ............ 1 ............................ T159 Assemble tensioner so that pulley is to the left of the instal-
lation bolt and pulley flange is facing the front of engine.
Camshaft ........... 2 2.4 Hours .................... T204 Raise the tensioner toward belt by hand. Apply sufficient
1993 pressure so that tension side of belt is taut, then tighten
Balance Shaft ............ 1 ............................ T159 tensioner bolt. Ensure that tensioner does not rotate with
Camshaft ........... 2 2.4 Hours .................... T230 bolt as it is tightened, as excessive tension will be placed
1994 on the belt. Ensure that timing marks are still aligned, then
Balance Shaft ............ 1 ............................ T168 check belt tension. See Fig. 2. There should be approxi-
Camshaft ........... 2 2.4 Hours .................... T230 mately .20-.28" (5.0-7.0 mm) slack on tension side of belt
when belt is moved by hand.
Expo Install crankshaft sprocket flange with the raised side fac-
1992 ing outward, then install crankshaft sprocket. Measure pro-
Balance Shaft ............ 1 ............................ T159 trusion of auto-tensioner plunger from tensioner housing.
Camshaft ........... 2 2.4 Hours .................... T204 Protrusion should be .47" (11.9 mm). Position timing belt
1993-95 tensioner in a soft jawed vise, then carefully compress
Balance Shaft ............ 1 ............................ T168 plunger. After plunger has been compressed, insert a .055
(1.4 mm) pin or wire through tensioner body to hold plunger
Camshaft ........... 2 2.4 Hours .................... T230
in place.
Summit Remove auto-tensioner from vise and install on engine.
1992 Ensure crankshaft and camshaft timing marks are aligned.
Balance Shaft ............ 1 ............................ T159 See Fig. 1. With oil pump sprocket timing marks aligned,
Camshaft ........... 2 2.4 Hours .................... T204 remove plug from side of engine and insert a screwdriver,
1993-96 with a shaft diameter of .31" (8.0 mm), into the hole. See
Balance Shaft ............ 1 ............................ T168 Fig. 3. If screwdriver can be inserted 2.4" (61.0 mm) or
more, alignment is correct.
Camshaft ......... 2 2.4 Hours .................... T230 If screwdriver can only be inserted .8-1" (20.3-25.4 mm),
1
- Balance Shaft labor time included in camshaft rotate oil pump sprocket one revolution and realign timing
labor time. marks. Ensure screwdriver can be inserted 2.4" (61.0 mm)
2
- With Air Cond. add .2 hours. or more. Leave screwdriver inserted in hole until after tim-
ing belt has been installed.
With Pwr. Strng. add .2 hours. Install camshaft timing belt, first over crankshaft sprocket,
then oil pump sprocket, idler pulley, camshaft sprocket and
MANUFACTURERS SUGGESTED tensioner pulley. Hold belt so there is no slack on tension
SCHEDULED MAINTENANCE side. Apply counterclockwise force on camshaft sprocket to
aid in tensioning belt. Ensure that all timing marks remain
The manufacturer recommends the belt be replaced every aligned. Carefully position timing belt tensioner pulley
60,000 miles. against timing belt, then tighten center bolt. Rotate crank-
shaft pulley 1/4 turn counterclockwise, then turn clockwise,
REMOVAL & INSTALLATION aligning crankshaft and camshaft timing marks.
TIMING BELT Loosen tensioner pulley retaining bolt, then position socket
tool and a suitable torque wrench to the pulley. See Fig. 4.
Removal:
Tighten to specification. Tighten retaining bolt while holding
Disconnect negative battery cable. Loosen left front wheel the pulley in position. Install set screw tool through left hand
lug nuts, then raise and support vehicle with jack stands. engine support bracket. Engine may need to be raised slightly
Remove left front wheel and tire assembly. Remove left
to install set screw tool. Tighten set screw tool until it contacts
front inner splash shield through the wheel well. Remove tensioner arm, then tighten tool slightly more. Remove pin or
coolant reservoir. Support engine with jack and wooden wire retaining auto-tensioner plunger, then remove set screw
block placed under the oil pan. Remove right side engine
tool.
mount. Rotate engine in the clockwise direction two turns. After approxi-
Remove accessory drive belts and pulleys. Remove timing mately 15 minutes, measure auto-tensioner plunger protrusion
belt upper and lower front covers. Rotate crankshaft in normal
from tensioner housing. Plunger protrusion should be .15-.18"
direction of rotation and align timing marks. See Fig. 1. Re- (3.8-4.6 mm). See Fig. 5, Dimension A. If protrusion is not within
move auto-tensioner assembly, then remove camshaft tim- limits, readjust timing belt tension.
ing belt.
Remove crankshaft sprocket bolt, then crankshaft sprocket Install timing belt lower and upper front covers, and tighten
bolts to specification. Install crankshaft pulley and water
and flange. Remove balance shaft timing belt tensioner pump pulley, and tighten attaching bolts to specification.
pulley bolt, then remove tensioner pulley. Remove balance
Install drive belt tensioner pulleys. Install A/C compressor,
shaft timing belt. Ensure balance shaft (silent shaft) power steering pump and alternator drive belts. Adjust drive
sprocket and crankshaft sprocket timing marks are prop- belts to proper tension. See page A-60 for belt tension
erly aligned. See Fig. 2.
ranges. Check and adjust ignition timing as necessary.

Install right side engine mount, and tighten bolts/nuts to speci-
fication. After completing installation of engine mount, remove
jack and wooden block supporting engine. Install coolant res-
ervoir. Install left front inner splash shield. Install left front wheel
and tire assembly, then lower vehicle. Connect negative battery
cable.
Crankshaft Pulley Bolts .............................................. 18 (25)
Right Side Engine Mount Bolt/Nuts ............................ 42 (58)
Through Bolt Attaching Nuts ....................................... 25 (34)
Through Bolt Nut ........................................................ 51 (70)
INCH Lbs. (N.m)
Tensioner Pulley Bolt ................................................. 31 (3.5)
Timing Belt Front Cover Bolts ........................ 84-108 (9.6-12)
Water Pump Pulley Bolts ........................................... 78 (8.9)
Fig. 3: Checking Oil Pump Sprocket Timing Mark

Alignment
Fig. 1: Aligning Camshaft Timing Belt Marks
Courtesy of Chrysler Corp.

Fig. 5: Measuring Timing Belt Auto-Tensioner Protrusion
Fig. 2: Aligning Balance Shaft Marks

138 CHRYSLER & MITSUBISHI
*2.3L 4-Cylinder Diesel
2.3L 4-Cyl. Turbo Diesel
Pickup
1983-85
Balance Shaft ...... 1.8 Hours ..................... T092
Camshaft ............. 1.8 Hours ..................... T091
Ram 50
1983-85
Balance Shaft ...... 1.8 Hours ..................... T092
Camshaft ............. 1.8 Hours ..................... T091
1
The manufacturer recommends the belt be replaced every Fig. 2: Removing Silent Shaft Sprockets
50,000 miles.
Installation:
REMOVAL & INSTALLATION Install crankshaft sprocket and flange ensuring flange on
crankshaft sprocket B is installed correctly. See Fig. 3.
TIMING BELTS & SPROCKETS Mount injection pump sprocket, if removed, and tighten nut
Removal: to specifications.
Disconnect negative battery cable. Remove drive belts, fan, Install flange to injection pump sprocket, noting flange holes
pulleys, and timing belt covers. Position cylinder No. 1 at are offset to aid in correct installation. Lightly oil left silent
TDC of compression stroke and ensure timing marks are shaft spacer and insert spacer with chamfered end toward
in alignment. See Fig. 1. seal.
Mark belts indicating direction of rotation. Loosen nuts and Install both silent shaft sprockets. Tighten nut and bolt to
bolts securing belt tensioners. Pivot tensioners toward water specifications. Keep silent shafts from turning by using
pump and secure. Remove timing belts and all necessary method described in removal procedure.
sprockets. Position and secure tensioner B fully toward water pump.
Remove silent shaft sprockets by removing plug from right Align timing marks on crankshaft sprocket and silent shaft
side of block and cover from left side of block. Insert screw- sprockets. See Fig. 4. Install timing belt B, noting refer-
driver and socket extension into holes to hold silent shafts ence mark if refitting old belt.
in place. See Fig. 2. 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.
Tighten nut first, then tighten bolt. DO NOT tighten bolt first.
Using index finger, press belt at center of tension side inward
and measure belt deflection. Deflection should be .16-.20" (4-
5 mm).
Position and secure camshaft timing belt tensioner fully
toward water pump. Align camshaft, crankshaft and injec-
tion pump timing marks. See Fig. 1. Install timing belt on
pulleys in order of crankshaft sprocket, injection pump
sprocket and camshaft sprocket.
Ensure tension side of belt is taut and injection pump
sprocket does not turn. If reusing old belt, make certain belt
is installed according to rotation reference mark.

139
CHRYSLER & MITSUBISHI
*2.3L 4-Cylinder Diesel (Cont.)
While keeping belt taut, loosen tensioner mounting bolts
and allow tensioner spring pressure to tighten belt. Ensure
timing belt and camshaft sprocket are still in mesh.
Tighten upper slot-side, bolt first. Then tighten lower ful-
crum-side, bolt. Tightening bolts out of specified sequence
will over-tighten belt. After tightening tensioner mounting
bolts, check sprocket alignment.
Turn crankshaft clockwise until second tooth past timing mark
on camshaft sprocket is in alignment with triangle timing
mark. Turn crankshaft counterclockwise and realign timing
marks.
Using forefinger, press belt on tension side of belt between
camshaft sprocket and injection pump sprocket. Measure
belt deflection. Deflection should be .16-.20 (4-5 mm).
tension ranges.
TIGHTENING SPECIFICATIONS Fig. 4: Aligning Timing Belt B Marks
Belt Tensioner Bolts ......................................... 16-21 (22-29)
Camshaft Sprocket Bolts .................................. 47-54 (64-73)
Crankshaft Sprocket Bolt .......................... 123-137 (167-186)
Front Case Bolts
1983-84 .......................................................... 15-19 (20-26)
Silent Shaft Sprocket Bolt .................................. 25-28 (34-39)
INCH Lbs. (N.m)
Front Case Bolts
1985 .......................................................... 108-120 (12-14)
Valve Cover Bolts .................................................. 44-53 (5-6)
Fig. 3: Installing Crankshaft Sprocket

2.4L 4-Cylinder
Belt
2.4L 4-Cyl. SOHC
Pickup
1990-92
Balance Shaft ... 1 ..................................... T159
Camshaft .......... 22.3 Hrs. . TCK124 .......... T124
1993-96
Balance Shaft ... 1 ..................................... T168
Camshaft .......... 2 2.3 Hrs. .......................... T229
Ram 50
1990-92
Balance Shaft ... 1 ..................................... T159
Camshaft .......... 22.3 Hrs. . TCK124 .......... T124
1993
Balance Shaft ... 1 ..................................... T168
Camshaft .......... 2 2.3 Hours ....................... T229
1
- Balance Shaft labor time included in Camshaft
labor time. Fig. 1: Aligning Front Timing Belt
2
Remove camshaft sprocket (if necessary). Remove oil pump
NOTE: A timing belt component kit is available for sprocket access plug from cylinder block. See Fig. 2. Insert a
.31 (8.0 mm) diameter Phillips screwdriver to block left silent
this application. See page I for information on component shaft.
kits. Remove oil pump sprocket nut, and remove sprocket. Re-
move front crankshaft sprocket and flange. Note direction
MANUFACTURERS SUGGESTED and order of installation for reassembly reference.
SCHEDULED MAINTENANCE Remove rear timing belt tensioner assembly. Remove rear
timing belt (belt B).
The manufacturer recommends the belt be replaced every Inspection:
60,000 miles. Check belt teeth for cracks, damage and contamination.
Inspect sprockets for damage. Check belt tensioner for
REMOVAL & INSTALLATION leakage and roughness in rotation. Replace components
if damaged.
Removal: Install rear crankshaft sprocket and flange. Install right si-
Disconnect negative battery cable. Remove radiator shroud, lent shaft sprocket and spacer. Spacer should be installed
cooling fan and pulley. Remove all drive belts and crank- with chamfered end into oil seal. Align timing marks. See
shaft pulley. Remove upper timing belt covers and gaskets. Fig. 3. Install rear timing belt (belt B) on sprockets.
Note bolt length and location. Install rear tensioner. Hold tensioner tightly against belt
while tightening bolts. Ensure deflection is .20-.28" (5.0-
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed 7.1 mm). See Fig. 4. Install camshaft sprocket. Tighten
from timing belt end of engine). If timing belt is to be reused, camshaft sprocket bolt to specification. See TORQUE
mark direction of rotation before removing. SPECIFICATIONS.
Remove crankshaft sprocket bolt and washer. Rotate Install front timing belt tensioner, tension spring and spacer.
crankshaft clockwise (as viewed from timing belt end of Ensure spring is properly engaged against water pump
engine) until cylinder No. 1 is at TDC of compression case. Rotate tensioner toward water pump, and tempo-
stroke. Align timing mark on camshaft sprocket with mark rarily tighten bolts. Ensure timing marks are aligned. See
on cylinder head. See Fig. 1. Fig. 1. Install front timing belt (belt A) on crankshaft.
Loosen timing belt tensioner adjustment bolt, and move Apply pressure on tension side of timing belt while install-
tensioner toward water pump. Tighten bolt to secure ing belt (in order) on crankshaft, oil pump and camshaft
tensioner. Remove front timing belt (belt A) and tensioner. sprockets. Loosen tensioner to apply spring pressure to
DO NOT rotate crankshaft after timing belt has been re- timing belt.
moved. 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.
CHRYSLER & MITSUBISHI 141

To check belt tension, apply slight thumb pressure and
measure deflection between camshaft and oil pump
sprocket. Belt deflection should be .55" (14.0 mm). See
Fig. 5. To complete installation, reverse removal proce-
dure.
tension ranges.
Engine Support Bracket Bolt ............................. 36-47 (49-64)
Timing Belt A Tensioner Bolt .......................... 16-22 (22-30) Fig. 4: Installing Timing Belt B Tensioner (Typical)
Timing Belt B Tensioner Bolt .......................... 11-16 (15-22)
Water Pump Bolt
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Valve Cover Bolt .................................................... 48-60 (5-7)
Fig. 5: Checking Timing Belt A Tension (Typical)
Fig. 3: Aligning Rear Timing Belt

*3.0L V6 DOHC
Application Labor Time1 Belt Part No. * NOTE: This application is an interference engine.
3.0L V6 DOHC See page A-59 for interference engine cautions.
Diamante
1992-96 ................ 3.8 Hours .................... T195 REMOVAL & INSTALLATION
Stealth
1991-96 TIMING BELT
Non-Turbo ........ 3.4 Hours .................... T195 Removal (Diamante):
Turbo ................. 3.6 Hours .................... T195 Disconnect negative battery cable. Remove left front and
3000GT left side splash shields. Using engine hoist, lift engine to
remove weight from engine mounts. Remove alternator
1991-98 and drive belt tensioner assembly. Remove engine sup-
Non-Turbo ........ 3.4 Hours .................... T195 port bracket. Disconnect power steering connections. On
Turbo ................. 3.6 Hours .................... T195 1993-96 models, remove camshaft position sensor and
1
- With Air Cond. add .2 hours. crankshaft position sensor. Remove crankshaft pulley. On
With Pwr. Strng. add .2 hours. vehicles with ABS, remove overflow tank and bracket. Re-
move generator/air conditioning idler pulley.
MANUFACTURERS SUGGESTED NOTE: Remove remaining engine mount bracket bolts in sequence.
SCHEDULED MAINTENANCE Lubricate reamer bolt with penetrating oil before and during
removal. See Fig. 1.
Chrysler: Up to 1993 model year, the manufacturer recom-
mends the belt be replaced every 60,000 miles. For 1994-96 Remove timing belt covers. Turn crankshaft clockwise to
model years, the manufacturer recommends replacing the align all timing marks. Loosen center bolt on tensioner
timing belt at 60,000 miles, except in California. In California, pulley to relieve belt tension. Remove timing belt. Mark ro-
belt replacement is recommended, but not required at 60,000 tation direction if belt is to be reused.
miles. Replace belt at 100,000 miles, unless previously
changed.
Mitsubishi: For 1991-93 model years, the manufacturer rec-
ommends the belt be replaced every 60,000 miles.
belt be replaced every 60,000 miles except in California. In
California, timing belt replacement is recommended, but not
required, at 60,000 miles. Replace timing belt at 100,000
belt be replaced every 60,000 miles except in California and
Massachusetts. In California and Massachusetts, timing belt
replacement is recommended, but not required, at 60,000
miles. Replace timing belt at 100,000 miles, unless previ-
ously changed.
but not required, at 60,000 miles. In these states, replace
timing belt at 100,000 miles, unless previously changed.
Fig. 1: Removing Engine Support Bracket Bolts

CHRYSLER & MITSUBISHI 143
*3.0L V6 DOHC (Cont.)

Removal (Stealth & 3000GT): Rotate timing belt tensioner pulley until pin holes are lo-
Disconnect negative battery cable. Remove lower splash cated above center bolt. See Fig. 7. Push tensioner pulley
shields. Remove cruise control actuator (if equipped). Re- against belt, and tighten center bolt. Ensure all timing marks
move drive belts. Remove alternator. Remove drive belt are aligned, and remove clips.
tensioner. Rotate crankshaft 1/4 revolution counterclockwise. Rotate
Using Holder (MB990767) and Adapter Bolts (MD998754) crankshaft clockwise until timing marks are realigned.
or equivalent, remove crankshaft pulley. See Fig. 2. Dis- Loosen tensioner center bolt. Using Tensioner Pulley
connect brake fluid level sensor. Remove upper timing belt Socket (MD998767) or equivalent, apply approximately 90
covers. Support engine. Remove front engine mount INCH Ibs. (10 N.m) torque to tensioner pulley to prevent it
through-bolt and front engine mount. from turning. See Fig. 7. Retighten center bolt to specifica-
tion. See TORQUE SPECIFICATIONS. Ensure tensioner
NOTE: Engine support bracket reamer bolt may be seized. Apply pulley does not rotate while tightening center bolt.
penetrating lubricant to bolt during remove. Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes.
Remove drive belt idler pulley. Remove engine support Verify wire can still be moved easily, or automatic tensioner
bracket bolts in sequence. See Fig. 1. Remove engine sup- rod projects from tensioner body .15-.18" (3.8-4.5 mm). If
port bracket. Remove timing belt upper and lower covers, wire does not move easily, or rod projection is not to speci-
noting length and location of cover bolts. fication, repeat previous five steps. Remove wire.
Rotate crankshaft to align all timing marks. See Fig. 3. NOTE: Lubricate engine support bracket reamer bolt while
Loosen tensioner center bolt. Remove timing belt. it is tightened slowly.
Installation (Diamante, Stealth & 3000GT):
Place automatic tensioner assembly in a soft-jawed vise. To complete installation, reverse removal procedure. In-
Slowly close vise to press rod back into tensioner until both stall bolts into correct timing belt cover holes. Install bolts
rod and housing holes are aligned. Install a .055" (1.40 into engine support bracket in reverse order of removal
mm) diameter wire through both holes. sequence. See Fig. 1. Tighten bolts to specification. See
Remove tensioner from vise, and install assembly with TORQUE SPECIFICATIONS. Adjust drive belts to proper
wire in place. Install crankshaft sprocket (if removed). Align tension. See page A-60 for belt tension ranges.
timing marks on crankshaft and camshaft sprockets. See TORQUE SPECIFICATIONS
Fig. 3.
CAUTlON: Turning camshaft sprockets while No. 1 cylinder is Automatic Tensioner Bolt ............................................ 17 (23)
at TDC may damage valve and piston. Use care when aligning Camshaft Sprocket Bolt .............................................. 66 (90)
timing marks. Crankshaft Pulley Bolt ............................................ 136 (185)
Engine Support Bracket Bolt
To lower No. 1 piston from TDC and prevent valve and pis-
10 X 40 mm .................................................... 47-54 (64-73)
ton contact, turn crankshaft back 3 sprocket teeth (mea-
Except 10 X 40mm ..................................... 76-83 (103-113)
sured at timing mark). Starting with front bank of cylinders,
Timing Belt Tensioner Arm Bolt .................................. 31 (42)
verify intake and exhaust camshaft timing marks are not
within shaded area of figure. See Fig. 4.
Water Pump Bolt ........................................................ 17 (23)
WARNING: Use care when aligning timing marks. When camshaft INCH Lbs. (N.m)
sprocket timing marks are in indicated area, camshaft is under Timing Belt Cover Bolt ...................................... 84-108 (9-12)
valve spring pressure and may rotate suddenly, pinching hand
between sprockets.
If camshaft sprocket timing mark is within indicated area,
carefully rotate camshaft sprocket until timing mark is lo-
cated in nearest safe area. See Fig. 4.
Rotate either camshaft sprocket clockwise to align timing
marks as shown in illustration. See Fig. 5. If camshaft
sprocket is rotated past timing mark, rotate it counterclock-
wise to realign it. Repeat procedure for other front bank
camshaft sprocket.
NOTE: If necessary, crankshaft sprocket may be turned one tooth

counterclockwise to aid belt installation.
Repeat previous three steps and this step for rear cylinder
bank camshafts. Align crankshaft timing mark. Install tim-
ing belt onto sprockets in sequence. See Fig. 6. Use spring-
type paper clips to secure belt on sprockets. Use wrenches
on camshaft sprocket bolts to prevent camshafts from turn-
ing during belt installation.
Fig. 4: Aligning Timing Marks To Prevent Valve & Piston

Damage
Fig. 7: Adjusting Timing Belt Tensioner
Fig. 5: Aligning Timing Marks - Final Alignment

DAEWOO 145

Application Labor Time 1 Belt Part No.
1.6L 4-Cyl. DOHC
Lanos
1999-2001 ............. 2.3 Hours ..................... T310
1 With Air Cond. add .2 hours.
The manufacturer recommends replacing the belt at 60,000
miles, except in California. In California, inspect the belt at
60,000 miles and replace the belt at 102,000 miles.


Courtesy of Daewoo Motor America, Inc.
TIMING BELT Fig. 1: Removing A/C Compressor Drive Belt
Removal:
Disconnect negative battery cable. Disconnect intake air
temperature sensor connector from intake air duct. Dis-
connect the air intake tube from the throttle body. Discon-
nect the breather tube from the valve cover. Remove the air
filter housing.
Raise and support the vehicle. Remove right front wheel.
Remove right front splash shield from wheelwell. Remove
accessory drive belts. See Fig. 1.
Remove power steering pump pulley bolts (if equipped).
Remove power steering pump pulley. Remove crankshaft
pulley center bolt. Remove crankshaft pulley. Lower vehicle.
Remove upper and lower timing belt covers. See Fig. 2.
Remove power steering pump mount bolts (if equipped).
Set power steering pump aside with hoses attached.
Using crankshaft center bolt, rotate crankshaft one full turn
clockwise (as viewed from timing belt end of engine).
Align mark on crankshaft sprocket with notch at bottom of
rear timing belt cover. See Fig. 3. Ensure camshaft sprocket
timing marks face each other. See Fig. 4.
CAUTION: Engine damage could result if camshaft sprockets Courtesy of Daewoo Motor America, Inc.
are not properly aligned with notches on valve cover.
Fig. 2: Timing Belt Covers
Slightly loosen water pump bolts. Using Timing Belt Ad-
juster (J-42492), rotate water pump counterclockwise to
relieve tension on the timing belt. See Fig. 5. Remove tim-
ing belt.
Installation:
Ensure crankshaft and camshaft timing timing marks are
still aligned. Install the timing belt. See Fig. 6. Turn water
pump clockwise until the adjust arm pointer on the auto-
matic tensioner aligns with the notch on the automatic
tensioner bracket. See Fig. 7. Tighen water pump bolts.
Using crankshaft center bolt, turn crankshaft clockwise (as
viewed from timing belt end of engine) 2 full revolutions.
Loosen water pump bolts.
Rotate water pump until the adjust arm pointer on the auto-
matic tensioner is aligned with the pointer on the auto-
matic tensioner bracket. See Fig. 8. Final tighten water pump
bolts. See TORQUE SPECIFICATIONS table.
Remove crankshaft sprocket center bolt. Install power steer-
ing pump (if equipped). Tighten bolts to specification. In-
stall timing belt covers. Install crankshaft pulley. Tighten Courtesy of Daewoo Motor America, Inc.
center bolt to specification. Fig. 3: Aligning Crankshaft Sprocket Timing Mark

146 DAEWOO
Install power steering pump pulley (if removed). Install ac-
cessory drive belts. Install right front splash shield. Install
right front wheel. Install air filter housing. Connect air in-
take temperature sensor connector. Connect negative bat-
tery cable. Adjust the drive belts to correct tension. See
Crankshaft Pulley Center Bolt
Step 1 ............................................................................ 70 (95)
Step 2 ............................................................ Plus 30 Degrees
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)
Fig. 4: Aligning Camshaft Sprocket Timing Marks
Fig. 7: Aligning Timing Belt Tensioner WIth Notch

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

Fig. 6: Timing Belt Routing Fig. 8: Aligning Timing Belt Tensioner With Pointer
DAEWOO 147

TIMING BELT APPLICATION Loosen water pump attaching bolts. On water pump ec-
centric, use special tool (J-33039-A) or equivalent to re-
Belt lease tension. Remove crankshaft pulley. Remove timing
Labor Component Part belt from camshaft and crankshaft sprockets.
Application Time1 Kit No. No. Installation (2.0L):
1.6L 4-Cyl. Align timing marks on camshaft and crankshaft sprockets
Optima with marks on timing belt rear cover. Place timing belt on
camshaft and crankshaft sprockets and tensioner. Use
1988-91 .......... 2.9 Hrs. ................................. T148 special tool (J-33039-A) or equivalent to rotate water pump
2.0L 4-Cyl. eccentric until tensioner touches stop. Slightly tighten wa-
Optima ter pump attaching bolts.
1988-89 .......... 2.9 Hrs. ................................. T081 Rotate crankshaft clockwise 2 revolutions. Rotate water
1990-91 .......... 2.9 Hrs. ...... TCK163 ........... T163 pump eccentric counterclockwise until hole in tensioner
arm is in line with hole in base. Tighten water pump at-
1
- With Air Cond. add .5 hours. taching bolts and make sure tensioner holes are still
aligned. To complete installation, reverse removal proce-
NOTE: A timing belt component kit is available for dure. Adjust drive belt to proper tension. See page A-60 for
this application. See pageI for information on component
kits.
Water Pump Bolts ..................................................... 18 (24)

TIMING BELT
Removal (1.6L):
belts. Remove power steering pump. Remove timing belt
cover. Remove air cleaner. Mark all hoses for installation
reference and disconnect hoses from valve cover. Remove
valve cover. Remove timing belt.
Installation (1.6L):
Align camshaft sprocket mark with mark on rear timing belt
cover. Install timing belt. To complete installation, reverse Fig. 1: Exploded View Of Timing Belt & Related Components
removal procedure. Adjust drive belts to proper tension. (2.0L)
Removal (2.0L):
Disconnect negative battery cable. Remove drive belt. Re-
move power steering pump and bracket. Remove serpen-
tine drive belt tensioner as an assembly. Remove timing
148 DAEWOO
2.0L 4-Cyl. DOHC
Nubira
1999-2001 ............. 1.8 Hours ..................... T309

REMOVAL & INSTALLATION Daewoo Motor America, Inc.

Fig. 1: Supporting Engine Assembly
TIMING BELT
Removal:
nect the breather tube from the valve cover. Remove the air
filter housing.
serpentine accessory drive belt.
Remove crankshaft pulley bolts. It is NOT necessary to
remove crankshaft sprocket center bolt. Remove crankshaft
pulley. Lower vehicle.
Support engine assembly from above with Support Fixture
(J-28467-B). See Fig. 1. Remove engine mount bracket
from timing belt end of engine. See Fig. 2.
Remove front timing belt cover. Using crankshaft center
bolt, rotate crankshaft one full turn clockwise (as viewed
from timing belt end of engine).
rear timing belt cover. See Fig. 3. Align camshaft sprocket Daewoo Motor America, Inc.
timing marks with notches on valve cover. See Fig. 4. Fig. 2: Removing Engine Mount Bracket
CAUTION: Engine damage could result if camshaft sprockets
Loosen the automatic tensioner bolt. Use an Allen wrench
to rotate tensioner and relieve tension on timing belt. See
Fig. 5. Remove timing belt.
Installation:
still aligned. Install the timing belt. See Fig. 6. Turn the
timing belt tensioner clockwise to tension the timing belt.
Turn tensioner until the pointer aligns with the notch on the
rear timing belt cover. Tighten automatic tensioner bolt. See
Using crankshaft center bolt, turn crankshaft clockwise (as
Ensure timing belt tensioner pointer is still aligned with
notch.
If timing belt tensioner is correctly aligned, install timing
belt cover. Install the engine mount bracket on the timing
belt end of engine. Install crankshaft pulley. Install serpen-
Daewoo Motor America, Inc.
tine accessory drive belt. Install right front splash shield.
Install right front wheel. Fig. 3: Aligning Crankshaft Sprocket Timing Mark
Install air filter housing. Connect air intake temperature
sensor connector. Connect negative battery cable.
DAEWOO 149

Camshaft Sprocket Bolt
Step 1 ............................................................................ 37 (50)
Crankshaft Sprocket Center Bolt
Step 1 .......................................................................... 96 (130)
Step 2 ....................................................... Plus 40-50 Degrees
Engine Mount Bracket Bolt ............................................. 44 (60)
Timing Belt Idler Pulley Bolt/Nut ..................................... 18 (25)
Water Pump Bolt ............................................................ 15 (20)
Wheel Lug Nuts ....................................................... 88 (120)
INCH Lbs. (N.m)
Daewoo Motor America, Inc. Timing Belt Cover Bolt .................................................. 53 (6)
Daewoo Motor America, Inc.

Daewoo Motor America, Inc. Fig. 6: Timing Belt Routing
Fig. 5: Identifying Timing Belt Tensioner
150 DAEWOO
2.2L 4-Cyl. DOHC
Leganza
1999-2001 ............. 1.8 Hours ..................... T305

REMOVAL & INSTALLATION Courtesy of Daewoo Motor America, Inc.
Fig. 1: Supporting Engine Assembly

TIMING BELT
Removal:
nect the breather tube from the valve cover. Remove reso-
nator from throttle body. Remove air filter housing.
serpentine accessory drive belt.
Remove crankshaft pulley bolts. It is NOT necessary to
remove crankshaft sprocket center bolt. Remove crankshaft
pulley. Lower vehicle.
Support engine assembly from above with Support Fixture
(J-28467-B). See Fig. 1. Remove engine mount bracket
from timing belt end of engine. See Fig. 2. Courtesy of Daewoo Motor America, Inc.
Remove power steering hose clamp bolt, and position hose Fig. 2: Removing Engine Mount Bracket
away from timing belt cover. Remove front timing belt cover.
See Fig. 7. Using crankshaft center bolt, rotate crankshaft
one full turn clockwise (as viewed from timing belt end of
engine).
rear timing belt cover. See Fig. 3. Align camshaft sprocket
timing marks with notches on valve cover. See Fig. 4.
CAUTION: Engine damage could result if camshaft sprockets

Loosen the automatic tensioner bolt. Use an Allen wrench
to rotate tensioner and relieve tension on timing belt. See
Fig. 5. Remove timing belt.
Installation:
still aligned. Install the timing belt. See Fig. 6. Turn the Courtesy of Daewoo Motor America, Inc.
timing belt tensioner counterclockwise to tension the tim-
ing belt. Turn tensioner until the pointer aligns with the Fig. 3: Aligning Crankshaft Sprocket Timing Mark
notch on the rear timing belt cover. Tighten automatic
tensioner bolt. See TORQUE SPECIFICATIONS table.
Install right front splash shield. Install right front wheel.
Install air filter housing and resonator. Connect air intake
Using crankshaft center bolt, turn crankshaft clockwise (as temperature sensor connector. Connect negative battery
cable.
Ensure timing belt tensioner pointer is still aligned with
notch.
If timing belt tensioner is correctly aligned, install timing
belt cover. Install the engine mount bracket on the timing
belt end of engine. Position power steering hose in place
and install clamp bolt. Install crankshaft pulley. Install ser-
pentine accessory drive belt.
DAEWOO 151

Step 1 ............................................................................ 37 (50)
Step 1 .......................................................................... 96 (130)
Step 2 ....................................................... Plus 40-50 Degrees
Engine Mount Bracket Bolt ............................................. 44 (60)
Timing Belt Idler Pulley Bolt/Nut ..................................... 18 (25)
Courtesy of Daewoo Motor America, Inc. Timing Belt Tensioner Bolt ......................................... 18 (25)
Fig. 4: Aligning Camshaft Sprocket Timing Marks Water Pump Bolt ............................................................ 15 (20)
Wheel Lug Nuts ....................................................... 88 (120)
INCH Lbs. (N.m)
Power Steering Hose Clamp Bolt .................................... 71 (8)

Fig. 7: Timing Belt Cover

152 DAIHATSU
*1.0L 3-Cylinder
Inspect idler pulley for smooth rotation. Replace if neces-
Belt Part No. sary.
1.0L 3-Cyl. Inspect idler pulley tension spring for damage. Check ten-
Charade sion spring free length and tension. Replace spring if free
1988-92 ................. 1.8 Hours ..................... T178 length and tension are not within specification. See TIM-
ING BELT PULLEY SPECIFICATIONS.
1
TIMING BELT PULLEY SPECIFICATIONS
Application Specification
MANUFACTURERS SUGGESTED Camshaft Belt Pulley Diamter .................... 4.72 (119.9 mm)
SCHEDULED MAINTENANCE Crankshaft Belt Pulley Diameter ...................... 2.33 (59.3 mm)
The manufacturer recommends the belt be replaced every Idler Pulley Tension Spring Free Length .......... 2.13 (54.0 mm)
60,000 miles. Spring Tension ................................................ 3.6 Lbs. @ 2.56


TIMING BELT
Removal:
Disconnect negative battery cable. Loosen accelerator cable
lock nut. Remove accelerator cable from throttle body and
clamp. Remove vent hose from valve cover. Remove air
cleaner assembly, and mark all hoses for installation ref-
erence.
Remove alternator electrical connector. On models
equipped with A/C, loosen idler pulley mounting nut. Loosen
adjusting bolt, and remove drive belt. On all models, re-
move alternator drive belt.
Remove right lower engine cover. Using a wooden block
and jack, apply slight pressure to oil pan to release pres-
Fig. 1: Removing Engine Front Mounting Bracket Nuts
sure from front mounts. Remove front mount bracket-to-
mount nuts. Remove front mount bracket-to-cylinder head
bolts. Remove the 3 front engine mounting bracket-to-cyl-
inder head attaching bolts. See Fig. 1 and Fig. 2. Slightly
lower jack and remove front mount bracket.
Remove water pump pulley. Working from left side
fenderwell, place socket on crankshaft pulley bolt, and ro-
tate crankshaft so No. 1 cylinder is at TDC of compression
stroke. Ensure timing mark on flywheel aligns with mating
mark on bellhousing. See Fig. 3.
Remove oil filter cap. Ensure exhaust valve rocker on No. 1
cylinder is free. If rocker is not free, rotate crankshaft 360
degrees (1 turn), and align timing marks.
Insert screwdriver through bellhousing to hold ring gear,
and remove crankshaft pulley retaining bolt. Remove crank-
shaft pulley. Remove upper and lower timing belt covers.
Remove flange on front of crankshaft pulley. See Fig. 4.
If reusing timing belt, mark belt rotation direction. Loosen Fig. 2: Removing Cylinder Head Mounting Bracket
idler pulley bolt. Position pulley as far left as possible, and
tighten pulley bolt. Remove timing belt. Remove idler pul-
ley and spring.
If replacing belt pulleys, remove crankshaft belt pulley and
flange. For camshaft belt pulley, remove pulley retaining
bolt. Pulley can be held by installing rod through pulley hole
and resting it against rib on cylinder head. Using Pulley
(09213-87701-000) remove camshaft belt pulley.
DAIHATSU 153
Inspect all belt pulleys for wear in belt areas. Measure di-
ameter of crankshaft and camshaft belt pulleys. Replace
pulleys if measurements are not to specification.
Installation:
Install camshaft belt pulley. Tighten retaining bolt to speci-
fication. See TORQUE SPECIFICATIONS. Install crankshaft
belt pulley and inner flange in proper direction. See Fig. 4.
Install idler pulley and tension spring. Position pulley as far
left as possible. Align camshaft and crankshaft mating
marks. See Fig. 5. Install timing belt on engine. If installing
used belt, ensure it is installed in original rotation direc-
tion. If installing new belt, align the mark on back of belt
with mating mark on each pulley.
After belt is installed, loosen idler pulley to apply spring
tension on idler pulley. Temporarily tighten idler pulley bolt.
Temporarily install bolt in crankshaft and rotate crankshaft
COUNTERCLOCKWISE 2 complete revolutions until No. 1
piston is at TDC. The F mark on camshaft drive pulley
should be toward top when No. 1 piston is at TDC. Fig. 4: Installing Crankshaft Pulley & Flanges
Loosen idler pulley bolt to apply spring tension against
timing belt. Tighten idler pulley bolt to specification. Ensure
all timing marks align.
Install outer flange on crankshaft pulley, with protruding
side toward crankshaft belt pulley. To complete installa-
tion, reverse removal procedure. Adjust drive belts to proper
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)
Fig. 5: Aligning Crankshaft & Camshaft Mating Marks
Fig. 3: Aligning Flywheel Timing Marks

154 DAIHATSU
TIMING BELT APPLICATION Removal (1.6L):
Belt Part No. sembly. Loosen and remove drive belts. Remove radiator
1.3L 4-Cyl. reserve tank. Disconnect clutch cable clamps from upper
Charade radiator shroud.
1988-92 ................. 1.8 Hours ..................... T181 Disconnect fan clutch. Remove radiator fan shroud and fan
1.6L 4-Cyl. clutch. Remove water pump pulley and belt. Remove crank-
shaft pulley attaching bolts and remove pulley. Remove 8
Rocky timing belt cover bolts.
1990-92 ................. 2.3 Hours ..................... T182 Remove timing belt cover. Rotate engine until F mark on
1
- With Air Cond. add .3 hours. camshaft sprocket aligns with timing indicator on cylinder
head cover. See Fig. 2. If reusing belt, mark arrow on belt to
indicate direction of rotation.
MANUFACTURERS SUGGESTED Loosen timing belt tensioner bolt, and move tensioner away
SCHEDULED MAINTENANCE from belt. Tighten timing belt tensioner, and remove timing
belt from engine.
Inspection (1.3L & 1.6L):
60,000 miles.
Inspect timing belt for wear and defects. Check timing belt
* NOTE: This application is an interference engine. tensioner for smooth rotation. Ensure tensioner contact
surface is clean and not damaged. Check camshaft for
See page A-59 for interference engine cautions. smooth rotation. Check sides of belt. If belt side is dam-
aged, check sprocket flange.
TIMING BELT
Removal (1.3L):
Disconnect negative battery cable. Remove air conditioner
drive belt and idler assembly (if equipped). Remove air
conditioner compressor, leaving hoses attached.
Remove power steering pump from engine. Mark and re-
move all hoses attached to air cleaner. Remove air cleaner.
Remove oil pressure switch wire harness brackets, and
pull wire toward throttle body.
Loosen water pump pulley bolts. Remove water pump pul-
ley and belt. Slightly raise engine, and disconnect engine
mount bracket and insulators. Remove service hole cover
to access crankshaft pulley bolts. See Fig. 1. Remove crank-
shaft pulley by removing 4 small attaching bolts.
Remove upper and lower timing belt covers. Rotate engine
until F mark on camshaft sprocket aligns with timing mark
on cylinder head cover. See Fig. 2. If reusing belt, mark
arrow on belt to indicate direction of rotation.
Loosen timing belt tensioner bolt, and move tensioner away
from belt. Tighten timing belt tensioner. Remove timing belt
from engine. Remove cylinder head cover.
Fig. 2: Locating Timing Belt Alignment Marks
Fig. 1: Locating Service Hole Cover (Charade)
Fig. 3: Adjusting Timing Belt

DAIHATSU 155
Check for dirt or contamination on sprocket teeth. Measure Check belt tension. At midpoint, belt should deflect 0.2" (5
sprocket diameter. Camshaft sprocket should be 4.717" mm) with a pushing force of 1.8-3.5 Ibs. (0.8-1.6 kg). To
(119.8 mm). Crankshaft sprocket should be 2.335' (59.37 complete installation, reverse removal procedure. Adjust
mm). Clean and/or repair as necessary. drive belts to proper tension. See page A-60 for belt tension
Installation (1.3L & 1.6L): ranges.
Install crankshaft timing belt sprocket (if removed). Ensure TORQUE SPECIFICATIONS
recessed side of crankshaft sprocket flange faces engine
block. Ensure crankshaft sprocket timing notch (drilled mark) Application Ft. Lbs. (N.m)
aligns with timing indicator on engine. See Fig. 2. Tighten A/C Idler Pulley Bolt .......................................... 23-35 (31-47)
crankshaft timing belt sprocket bolt to 65-72 ft. lbs. (88-98 Camshaft Sprocket Bolts .................................. 11-16 (15-22)
N.m). Crankshaft Pulley Bolts .................................... 15-22 (20-30)
Install camshaft timing belt sprocket (if removed). Tighten Crankshaft Sprocket Bolt .................................. 65-72 (88-98)
camshaft sprocket bolts to 11-16 ft. lbs. (15-22 N.m). Apply Timing Belt Tensioner Bolt ................................. 2-32 (30-44)
Sealant (Three Bond 1104) or equivalent, to cylinder head Water Pump Bolts ............................................ 11-16 (15-22)
near camshaft bearing cap contact areas. Install cylinder INCH Lbs. (N.m)
head cover. Ensure camshaft and crankshaft sprockets are Timing Belt Cover Bolts ........................................ 18-35 (2-4)
aligned. See Fig. 2. Water Pump Pulley Bolt ........................................ 53-80 (6-9)
Install timing belt on sprockets. If installing used belt, en-
sure there are 35 teeth between sprocket timing notches
(drilled marks), and belt rotates in same direction. If install-
ing new belt, align marks on belt with timing notches (drilled
marks) on sprockets. See Fig. 2. Loosen tensioner lock
bolt to apply tension to timing belt. Tighten tensioner lock
bolt. Rotate crankshaft clockwise 1.9 turns until F mark
on camshaft comes within 3 teeth of indicator mark on
engine. See Fig. 3.
CAUTION: DO NOT allow engine to rotate counterclockwise during

timing belt adjustment.
Loosen tensioner lock bolt, and rotate crankshaft until F
mark aligns with indicator mark on engine. Tighten timing
belt tensioner lock bolt to 22-32 ft. lbs. (30-44 N.m). Ensure
both timing marks are aligned with indicators.
Fig. 5: Timing Belt Components - 1.6L
Fig. 4: Timing Belt Components - 1.3L

156 EAGLE
2.2L 4-Cylinder
2.2L 4-Cyl.
Medallion
1989 ................... 2.3 Hours .................... T140

TIMING BELT
Removal:
Remove hood. Disconnect negative battery cable. Drain
coolant and discharge A/C system. Remove grille, radiator
support and facia panel. Disconnect cooling fan and
thermoswitch wires. Remove radiator, cooling fan and A/C
condenser.
Loosen power steering pump belt. Remove timing belt
cover. Loosen serpentine drive belt adjustment bolt and
nut. Loosen belt and remove from water pump pulley. Re-
move water pump pulley bolt and pulley. Remove water Fig. 1: Checking Timing Belt Tensioner Clearance
pump attaching bolts. Remove water pump, gasket, timing
belt and timing belt tensioner.
Installation:
Use feeler gauge to measure clearance between interme-
diate shaft cover and timing belt tensioner. Clearance should
be .004" (.10 mm). See Fig. 1. Turn adjusting screw to
adjust clearance. Position camshaft sprocket timing index
in line with static timing mark. Position crankshaft so No. 1
piston is at TDC of compression stroke. Remove plug in
cylinder block and insert TDC Rod (Mot. 861) into TDC hole
in crankcase. Install timing belt. See Fig. 2.
Position timing belt cover over sprockets and check cam-
shaft timing mark with index on cover. Remove TDC rod
and install plug in cylinder block. Rotate camshaft clock-
wise 2 complete revolutions. DO NOT rotate counterclock-
wise. Remove timing belt cover and loosen timing belt
tensioner bolts a maximum of 1/4 turn.
Spring loaded timing belt tensioner will automatically ad-
just to correct position. Ensure clearance between timing
belt tensioner and intermediate shaft cover is .004" (.10
mm). Tighten lower timing belt tensioner bolt. Tighten up-
per bolt. Test belt tension with Tension Gauge (Ele 343).
Deflection should be .216-.276" (5.5-7.0 mm). Install water
pump with new gasket. Loosen timing belt tensioner bolts
and allow tensioner spring to tighten timing belt. Retighten
timing belt tensioner bolts.
Install timing belt cover, water pump pulley and water pump
pulley bolt. Reverse removal procedures to complete in-
stallation. Adjust the drive belts to proper tension. See page
TORQUE SPECIFICATIONS Fig. 2: Installing Timing Belt
FIAT 157
TIMING BELT APPLICATION NOTE: If camshaft is turned independently of engine, valves
Application Labor Time1 Belt Part No. may hit pistons causing engine damage.
1.3L 4-Cyl. Remove right guard from under engine. Remove timing
128 belt cover. Loosen alternator and remove alternator/water
1973-78 ................ 2.3 Hours .................... T018 pump drive belt. Loosen air pump and remove drive belt.
1979 ..................... 2.4 Hours .................... T018 Remove valve cover and check that camshaft lobes of No. 4
X1/9 cylinder are pointing up. Remove distributor. Loosen idler
pulley lock nut. Remove timing belt starting at idler pulley.
1974-78 ................ 2.3 Hours .................... T018 Installation (X1/9):
1.5L 4-Cyl. Install timing belt making sure that teeth are properly en-
Strada gaged in sprockets. Start installation of timing belt at crank-
1979-82 ................ 2.0 Hours .................... T069 shaft pulley. Release idler pulley lock nut and retighten af-
X1/9 ter tension is on belt.
1979-83 ................ 2.0 Hours .................... T069 NOTE: Never allow engine to rotate backwards, or slack will develop
1
- With Air Cond. add .2 hours. in belt and belt will jump timing.
Rotate engine 2 turns in direction of engine rotation. Loosen
MANUFACTURERS SUGGESTED idler pulley lock nut to ensure all slack is removed. Re-
SCHEDULED MAINTENANCE tighten lock nut. Rotate engine until No. 4 cylinder is in
firing position (cam lobe up). Install remaining components
The manufacturer recommends the belt be replaced at the in reverse of removal order. Adjust drive belts to proper
following intervals: tension. See page A-60 for belt tension ranges.
On 1974-78 models, replace belt every 36,000 miles. TORQUE SPECIFICATIONS
On 1979 1.3L 4-Cylinder, replace belt every 36,000 miles.
On 1979-83 1.5L 4-Cylinder, replace belt every 30,000 miles. Application Ft. Lbs. (N.m)
* NOTE: This application is an interference engine. Crankshaft Pulley/Sprocket Nut .............................. 101 (137)
See page A-59 for interference engine cautions. Timing Belt Tensioner Pulley Nut ............................... 33 (45)

TIMING BELT
NOTE: This procedure is with engine in vehicle. If a timing belt
is loosened or removed to perform repair work, it should always
be replaced.
Removal (128 & Strada):
Disconnect negative battery cable. Remove right guard and
loosen timing belt cover retaining screws, from under ve-
hicle. Remove timing belt cover. Check timing by aligning
index marks on top and bottom of camshaft sprocket with
index marks on engine mounting and upper case. Index on
crankshaft sprocket should be in alignment with index on
crankshaft seal case.
Put vehicle in low gear and apply hand brake to prevent
crankshaft from turning. Remove fan belt, loosen tensioner
pulley retaining nut and relieve tension. Remove timing
belt.
Installation (128 & Strada):
Install new belt, making sure belt and sprocket teeth engage
correctly. Tighten pulley support nut. Recheck timing. Install
remaining components. Adjust drive belts to proper tension.
Removal (X1/9):
Disconnect negative battery cable. Rotate No. 4 cylinder
into firing position at top dead center. Position transmis- Fig. 1: Aligning Timing Marks
sion into 4th gear, to prevent crankshaft from turning. Apply
parking brake.
158 FIAT
TIMING BELT APPLICATION NOTE: Anytime tension is relieved from timing belt, timing belt
Application Labor Time1 Belt Part No. must be replaced.
1.6L 4-Cyl. Install timing belt make sure not to move sprockets. Ensure
124 hole in auxiliary shaft pulley is lined up with tensioner pulley
1971-74 ................ 1.9 Hours .................... T020 bolt.
1.8L 4-Cyl. To adjust timing belt tension, loosen idler pulley tensioner
nut and allow pulley to tension timing belt. Rotate crank-
Brava
shaft pulley 2 full turns and recheck timing marks. Tighten
1974-78 ................ 2.4 Hours .................... T020 tensioner nut and bracket bolt. Adjust drive belts to proper
124 tension. See page A-60 for belt tension ranges.
1974-78 ................ 1.9 Hours .................... T020 TORQUE SPECIFICATIONS
131
1975-78 ................ 1.9 Hours .................... T020 Application Ft. Lbs. (N.m)
1
- With Air Cond. add .2 hours. Tensioner Nut ............................................................. 33 (45)
The manufacturer recommends that belt be replaced every
25,000 miles or 24 months (1974-77 Models) or every 25,000
miles (1978 models).


TIMING BELT
Removal & Installation:
Disconnect negative battery cable. Drain cooling system
and remove upper radiator hose. Remove upper section of
air duct. Remove spark plugs. Rotate crankshaft until
marks on both camshaft sprockets are aligned with fixed
pointer on front of engine. See Fig. 1 or 2. Number 4 piston
should now be at TDC firing position. Place transmission in
4th gear and apply parking brake to prevent crankshaft from
turning.
CAUTION: Do not turn crankshaft or camshafts independent

of each other as valves may hit pistons.
Remove lower engine protection plate. Remove all drive Fig. 1: Camshaft & Crankshaft Timing Marks (1.8L)
belts. Disconnect coolant extension union at cylinder head.
Loosen timing belt idler pulley nut and mounting bracket
bolt and release timing belt tension. On 1.6L engines be-
fore No. 42577, pry pulley to release tension. Tighten pul-
ley nut and bracket bolt, and remove belt.
FIAT 159
Courtesy of Fiat Motor Co.
Fig. 2: Aligning Timing Marks (1.6L)

160 FIAT
*2.0L 4-Cylinder
2.0L 4-Cyl.
Brava
1979-83 ................ 2.4 Hours .................... T068
Spider 2000
1979-82 ................ 3.1 Hours .................... T068
1
30,000 miles.


TIMING BELT
WARNING: Timing belts must not be reused once tension is relieved.
Crankshaft and/or camshafts must not be turned with belt removed Fig. 1: Camshaft & Crankshaft Timing Marks
due to resultant valve and/or piston damage.
Removal:
Disconnect negative battery cable and drain cooling system.
Remove spark plugs and set engine to fire (TDC) on No. 4
cylinder. Crankshaft and camshaft timing marks must be
aligned with indicators. See Fig. 1. Remove upper radiator
hose from T union, then unbolt and remove union from the
cylinder head.
Remove hot air hose from exhaust manifold to air intake. Re-
move all drive belts from crankshaft pulley. Remove water pump
pulley bolts and remove pulley. Remove outer timing belt cover.
Lock crankshaft to prevent turning and remove crankshaft
pulley. Remove lower timing cover. Loosen belt tensioner
to release belt tension. Remove timing belt.
Installation:
Turn auxiliary sprocket to align hole in sprocket with sprocket
bolt and spring retaining bolt. Install belt and adjust
tensioner, then turn crankshaft 2 full turns and recheck ten-
sion and timing. To complete installation, reverse removal
procedures. Adjust drive belts to proper tension. See page
Timing Belt Tensioner Nut .......................................... 33 (45)
Fig. 2: Sprocket Alignment For Timing Belt Installation
FORD 161
1.3L 4-Cylinder
Belt
Application Time1 Kit No. No.
1.3L 4-Cyl. VIN H
Aspire
1994-97 .......... 2.0 Hrs. ................................ T185
Festiva
1988-89 .......... 2.0 Hrs. ...... TCK141 .......... T141
1990-93 .......... 2.0 Hrs. ................................ T185
1

kits.
SCHEDULED MAINTENANCE Fig. 1: Removing Right Inner Fender Panel
For Aspire, the manufacturer recommends the belt be replaced

every 60,000 miles on Federal vehicles, and 105,000 miles
on California vehicles. For Festiva, the manufacturer recom-
mends the belt be replaced every 60,000 miles.

TIMING BELT
Removal:
Disconnect negative battery cable. Remove accessory belts.
Remove water pump pulley. Remove right inner fender panel
to gain access to crankshaft pulley. See Fig. 1. Remove
outer crankshaft pulley attaching bolts, then outer stiffener
and spacer. Remove inner pulley and baffle plate. Remove
bolts retaining upper and lower cover halves to engine front.
Remove both covers. See Fig. 2.
NOTE: Always rotate engine in direction of normal operation.

Rotating crankshaft backwards may cause belt to jump timing.
Mark timing belt direction of rotation for installation refer-
ence. Remove timing belt tensioner pulley bolt. Remove
tensioner pulley, spring, and spring cover. Remove timing Fig. 2: Timing Belt Upper & Lower Covers
belt.
CAUTION: Never twist, turn inside out, or bend timing belt. Keep
belt away from grease and oil.
A/C Compressor Bolt ....................................... 29-40 (39-54)
Installation: Camshaft Pulley Bolt .......................................... 9-13 (12-17)
Ensure timing belt and sprockets are clean and not worn or Camshaft Sprocket Bolt .................................... 36-45 (49-61)
damaged. Align crankshaft and camshaft timing marks. Crankshaft Pulley Bolts .................................... 10-13 (12-17)
See Fig. 3. Position belt onto sprockets, in original running Crankshaft Sprocket Bolt .............................. 80-87 (108-118)
direction. Install timing belt tensioner spring, spring cover, Power Steering Adjuster Nut ............................. 27-38 (37-52)
and pulley. To complete installation, reverse removal pro- Timing Belt Tensioner Adjuster Bolt ................. 14-19 (19-26)
cedure. Tighten all bolts and nuts to specification. See Water Pump Pulley Bolts .................................. 36-45 (49-61)
TORQUE SPECIFICATIONS. Adjust drive belts to proper
tension. See page A-60 for belt tension ranges. INCH Lbs. (N.m)
Camshaft Cover ................................................. 71-97 (8-11)
Timing Belt Cover Bolt ........................................ 71-97 (8-11)
Valve Cover Bolt .................................................... 44-79 (5-9)
162 FORD
Fig. 3: Aligning Camshaft & Crankshaft Timing Marks

FORD 163
1.6L 4-Cylinder DOHC

Belt Application Ft. Lbs. (N.m)
Labor Component Part A/C Compressor Bolt ....................................... 29-40 (39-54)
Camshaft Pulley Bolt ........................................ 37-45 (49-61)
Application Time Kit No. No. Crankshaft Pulley Bolts .................................... 10-13 (12-17)
1.6L 4-Cyl. -- DOHC Crankshaft Pulley Center Bolt ................... 115-123 (157-167)
Capri Power Steering Adjuster Nut ............................. 27-38 (37-52)
1991-94 ........ 3.6 Hrs. ...... TCK179 .......... T179 Timing Belt Tensioner Adjuster Bolt ................. 14-19 (19-26)
NCH Lbs. (N.m)
NOTE: A timing belt component kit is available for Camshaft Cover ................................................. 71-97 (8-11)
this application. See page I for information on component Valve Cover Bolt .................................................... 44-79 (5-9)
kits. Water Pump Pulley Bolt ...................................... 71-97 (8-11)
60,000 miles.
TIMING BELT
NOTE: Always rotate engine in direction of normal operation.
Rotating crankshaft backwards may cause belt to jump timing.
Removal:
hicle. Remove right front tire and wheel assembly. Remove
right front splash guard. Lower vehicle. Remove spark plugs
and set No. 1 cylinder to TDC of compression stroke. Re-
move accessory drive belts. Remove dipstick. Remove wa-
ter pump pulley. Remove crankshaft pulley, damper and
baffle plate. See Fig. 2.
Remove upper timing belt cover. Remove center and lower
timing belt covers. Remove timing belt tension spring.
Loosen timing belt tension pulley. Support engine with floor
jack. Remove right engine mount. After marking timing belt
direction of rotation, remove timing belt. See Fig. 2.
Installation:
Ensure sprockets, tensioner, and idler pulleys are clean
and not worn, deformed, or damaged. Align timing marks
on camshafts and crankshaft. Intake cam should have let-
ter I aligned with arrow on belt cover. Exhaust cam should
have letter E aligned with arrow on belt cover. Crankshaft Fig. 1: Aligning Camshaft & Crankshaft Timing Marks
key should align with arrow. See Fig. 1.
TECHNICAL SERVICE BULLETIN
CAUTION: DO NOT clean pulleys, tensioner, or idler pulleys with
solvents. Wipe them clean only. REVISION
Unloaded free length of timing belt tension spring should NOTE: Information on revised service procedure is from Ford
be 2.315" (58.8mm). Replace spring as necessary. Tighten technical service bulletin 94-17-5; August 24, 1994. This bulletin
tension pulley with tension spring fully extended. If reusing supercedes 94-15-10; July 21, 1993.
timing belt, install belt in original direction of rotation. Keep
tension on opposite side of tensioner as tight as possible. SWISH NOISE FROM TIMING BELT
Rotate crankshaft 2 full turns. Inspect alignment of timing
Issue: Some 1990 1.6L and 1.6L engines built up to 10/1/
marks. If any mark is not aligned, remove timing belt and
1990 may exibit a swish noise from the timing belt. This is
reset timing. Loosen tension pulley retaining bolt to allow
caused be a belt guide plate that does not maintain correct
tension spring to tighten belt. Tighten tension pulley to speci-
timing belt alignment.
fication. See TORQUE SPECIFICATIONS. Rotate engine 2
Action: A revised timing belt guide plate and pulley boss is
full turns. Verify timing mark alignment.
available to correct the noise. See Fig. 4. This procedure will
Measure timing belt tension between camshaft pulleys.
also require replacement of the crankshaft and associated
Belt deflection should be 0.33-0.45" (8.5-11.5 mm). See
hardware.
Fig. 3. If incorrect, loosen tension pulley and repeat proce-
This procedure is also recommended when replacing a dam-
dure. If correct tension cannot be achieved, replace ten-
aged crankshaft to prevent timing belt noise.
sion spring. To complete installation, reverse removal pro-
cedure. Adjust drive belts to proper tension. See page A-60
164 FORD
1.6L 4-Cylinder DOHC (Cont.)
Courtesy of Ford Motor Co.

Fig. 4: New & Revised Timing Belt Pulley
TIMING BELT PULLEY PARTS (1990)
Part Name Part No.
Crankshaft ............................................................ F1JY-6303-A
Fig. 2: Exploded View Of Timing Belt & Components 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

When replacing the timing belt and crankshaft, all associated
parts MUST be replaced as a set. See TIMING BELT PULLEY
PARTS (1990) table for reference. The crankshaft pulley cen-
ter bolt listed in the TORQUE SPECIFICATION table is the
revised bolt torque. Use Crankshaft Pulley Holder (T92C-6316-
AH).
FORD 165

TIMING BELT APPLICATION Raise and support vehicle. Remove right front splash shield.
Remove retaining bolt and crankshaft pulley. Remove timing
Belt belt.
Application Time1 Kit No. No. CAUTION: DO NOT rotate crankshaft or camshaft with timing belt
removed. If camshaft must be rotated, install crankshaft pulley
1.6L 4-Cyl. SOHC
and position crankshaft with cylinder No. 1 at 90 degrees BTDC.
Escort, EXP, Lynx, LN7
1981-85 ............... 2.2 Hrs. ..... TCK067....... T067 Installation:
Tracer Install timing belt over sprockets in counterclockwise di-
rection, starting at crankshaft.
1987-90 ............... 2.2 Hrs. ..... TCK141....... T141
1.9L 4-Cyl. SOHC CAUTION: Maintain tension on timing belt between crankshaft
Escort, EXP and camshaft sprockets when installing belt over remaining sprockets.
1985-90 ............... 2.2 Hrs. ..... TCK067....... T067 Loosen belt tensioner bolt. Allow belt tensioner to apply
1991 tension on timing belt. Rotate crankshaft 2 full revolutions
thru: 3-25-91 ..... 2.2 Hrs. ..... TCK067....... T067 clockwise and realign timing marks. DO NOT rotate crank-
from: 3-26-91 .... 2.2 Hrs. ..... TCK194....... T194 shaft counterclockwise. Tighten belt tensioner bolt to speci-
1992-96 ............... 2.2 Hrs. ..... TCK194....... T194 fication. To install remaining components, reverse removal
Lynx procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. Adjust drive belts to proper tension. See
1985-87 ............... 2.2 Hrs. ..... TCK067....... T067 page A-60 for belt tension ranges.
Tracer
1991-96
to: 3-25-91 ......... 2.2 Hrs. ..... TCK067....... T067
from: 3-26-91 .... 2.2 Hrs. ..... TCK194....... T194
1

kits.
60,000 miles.
* NOTE: The 1.6L engine is an interference engine.


TIMING BELT
Removal:
belt. Remove timing belt cover. Rotate crankshaft clockwise,
and align timing mark on camshaft sprocket with timing mark
on cylinder head. See Fig. 1. Ensure crankshaft sprocket tim-
ing mark aligns with oil pump housing timing mark.
Loosen timing belt tensioner bolt. Pry timing belt tensioner
away from timing belt, and tighten tensioner bolt. Remove
spark plugs. Support engine with floor jack. Remove en-
gine mount at timing belt end of engine. 91H07180 Courtesy of Ford Motor Co.
165
166 FORD
96E14831 Courtesy of Ford Motor Co.

Fig. 2: Removing Timing Belt Tensioner Pulley (Tracer)
Fig. 3: Releasing Timing Belt Tension (Except Tracer)
A/C Compressor Mounting Bolt ........................ 15-22 (20-30)
Belt tensioner Bolt ............................................ 17-22 (23-30)
Crankshaft Pulley Bolt .................................. 81-96 (110-130)
Power Steering Pump Bolt ................................ 30-41 (41-56)
Water Pump Bolt .............................................. 15-22 (20-30)
INCH Lbs. (N.m) Fig. 5: Aligning Camshaft Sprocket Marks (Tracer)
Timing Belt Cover Nut .......................................... 44-62 (5-7)
Valve Cover Bolt ................................................ 44-106 (5-12)
FORD 167
Fig. 7: Aligning Crankshaft Sprocket Timing Marks

(Tracer)
Fig. 6: Installing Timing Belt (Tracer)

168 FORD
1.6L & 2.0L 4-Cylinder Capri & Pinto
TIMING BELT APPLICATION ment bolt and pivot bolt to specification. Adjust drive belts to
proper tension. See page A-60 for belt tension ranges.
Belt Part No.
1.6L 4-Cyl.
Capri Application Ft. Lbs. (N.m)
1972 ...................... 1.3 Hours ..................... T013 Belt Tensioner .................................................. 32-36 (42-48)
Crankshaft Pulley ............................................. 39-43 (54-60)
2.0L 4-Cyl. Timing Belt Cover ................................................. 7-9 (10-12)
Capri Water Pump Bolts
1971-74 ................. 1.3 Hours ..................... T013 8 mm .............................................................. 12-15 (15-21)
Pinto 10 mm ............................................................ 26-31 (35-41)
1971-74 ................. 1.3 Hours ..................... T013
1

TIMING BELT
Removal:
belts. Ensure that crankshaft is at TDC of No. 1 cylinder
compression stroke. See Fig. 1. Remove camshaft belt
cover. Loosen belt tensioner adjustment bolt and force
tensioner to one side to relieve belt tension. Hold tensioner
in this position and tighten bolt to hold tensioner. Lift belt off
sprockets.
NOTE: DO NOT rotate crankshaft or camshaft with belt removed.

Installation:
Place new belt over sprockets and loosen tensioner ad-
justment bolt to place tension on belt. Rotate crankshaft 2 Fig. 1: Visual Camshaft Timing Check
complete turns to place timing marks in proper position
and to remove all slack from belt. Torque tensioner adjust-
FORD 169

Belt
1.8L 4-Cyl.
Escort & Tracer
1991-96 .......... 2.8 Hrs. ...... TCK179 .......... T179
1

kits.
60,000 miles.
TIMING BELT
NOTE: Mark direction of timing belt rotation if timing belt is
to be reused.

170 FORD
Fig. 4: Identifying Crankshaft Pulley & Guide Plates
Fig. 5: Checking Timing Belt Deflection

Removal:
belts. Remove upper timing belt cover. See Fig. 1. Remove
water pump pulley. Raise and support vehicle. Remove right
front wheel. Remove right upper and lower splash shield.
Remove middle and lower timing belt covers. Rotate crankshaft
clockwise until No. 1 piston is at TDC. Ensure camshaft timing
marks are aligned. See Figs. 2 and 6.
Remove crankshaft pulley and hub. Mark direction of timing belt
rotation if timing belt is to be reused. Loosen timing belt tensioner
bolt, and remove timing belt.
CAUTION: DO NOT rotate camshafts with timing belt removed,

as engine damage could result.
Installation:
Temporarily position belt tensioner with spring fully extended, Courtesy of Ford Motor Co.
and tighten tensioner bolt. Ensure timing marks on crank-
shaft sprocket and oil pump align. See Fig. 3. Fig. 6: Identifying Camshaft Sprocket Timing Marks
CAUTION: Ensure I and E camshaft sprocket timing marks Rotate crankshaft clockwise 1 5/6 revolutions. Align crankshaft
are facing up. Camshaft sprockets may be stamped with more timing mark with tension set mark (at approximately 10 oclock
than one mark. position). See Fig. 3. Loosen tensioner bolt. Apply tension to the
tensioner. Tighten tensioner bolt to 27-38 ft. lbs. (37-52 N.m).
Ensure camshaft sprocket timing marks are still aligned. Rotate crankshaft clockwise 2 1/6 revolutions. Ensure tim-
See Figs. 2 and 6. Install timing belt. If reusing timing belt, ing marks align. If timing marks are not aligned, repeat
ensure belt is installed in original direction of rotation. installation procedure. Measure timing belt deflection by
Loosen tensioner bolt. Position tensioner so slack is re- applying 22 lbs. (10 kg) of pressure on timing belt at a point
moved from timing belt. Tighten tensioner bolt. Rotate crank- halfway between camshaft sprockets. See Fig. 5.
shaft clockwise 2 full revolutions. Ensure all timing marks
are aligned. If timing marks are not aligned, remove timing
belt and repeat timing belt tensioning procedure.
FORD 171

Timing belt deflection should be .35-.45" (8.9-11mm). If
deflection is not within specification, loosen tensioner bolt.
Using a pry tool, tighten or loosen tensioner to obtain proper
timing belt deflection. Tighten tensioner bolt.
Belt Tensioner Bolt ........................................... 17-22 (23-30)
Crankshaft Sprocket Bolt .............................. 80-87 (109-118)
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)
Test
172
FORD
TIMING BELT APPLICATION Lower vehicle. Attach engine hoist to lifting eyes. Remove
engine support tool. Disconnect right-hand insulator inter-
Belt Part No. mediate bracket from engine bracket and insulator. Re-
2.0L 4-Cyl. Diesel move bracket. Lower engine and transaxle assembly to
Escort & Lynx floor.
1984-87 To install engine, reverse removal procedures.
Camshaft ............ 6.2 Hours ..................... T103 CAUTION: DO NOT allow front wheels to touch ground.
Injection Pump ... 1.3 Hours ..................... T102
Tempo & Topaz TIMING BELT
1984-86 Removal:
Camshaft ............ 6.2 Hours ..................... T103 With engine out of vehicle, remove front upper timing belt
Injection Pump... 1.3 Hours ..................... T102 cover and flywheel timing mark case.
1
Rotate crankshaft in normal direction of rotation to align
timing marks of flywheel and front camshaft sprocket with
pointers. Loosen tensioner pulley lock bolt to slide timing
MANUFACTURERS SUGGESTED belt off water pump and camshaft.
SCHEDULED MAINTENANCE NOTE: DO NOT allow crankshaft to rotate with timing belt removed.
The manufacturer recommends the belt be replaced every Installation:
100,000 miles. Align camshaft and crankshaft sprockets with their respective
timing marks. See Fig. 1. Remove tensioner spring from front
timing belt upper cover pocket and install in tensioner lever slot
See page A-59 for interference engine cautions. and over crankcase stud. See Fig. 4. Push tensioner lever as far
as possible toward water pump and tighten lock bolt.
REMOVAL & INSTALLATION Install timing belt. With tensioner pulley loose, adjust belt ten-
sion by rotating crankshaft pulley in direction of rotation twice
ENGINE REMOVAL until No. 1 cylinder is at TDC (camshaft timing marks aligned).
Tighten tensioner lock bolt. Adjust belt tension to 33-44 lbs.
NOTE: Engine/transaxle must be removed to replace timing belt. (15-20 kg). Remove tensioner spring and place in front cover
The engine/transaxle is removed as an assembly. pocket.
Removal & Installation:
Disconnect negative battery cable. Mark hinges for reinstallation
and remove hood. Remove air cleaner assembly. Drain coolant.
Remove upper and lower radiator hoses.
Disconnect wiring at cooling fan. Remove shroud and cooling fan
as an assembly. Remove radiator. Discharge A/C system (if
equipped). Disconnect hoses at compressor. Remove cable at
starter.
Disconnect all vacuum lines as necessary. Disconnect
clutch cable at transaxle, injection pump throttle linkage,
and fuel hoses at engine.
Disconnect both engine harness connectors and glow plug
relay connectors at dash panel. Connectors are located un-
der plastic shield on dash panel. Remove and save plastic
retainer pins. Disconnect alternator connector on right-hand
fender apron.
Disconnect power steering hoses at pump (if equipped).
Remove hose bracket from cylinder head. Attach engine
support tool to lifting eye. Raise vehicle. Disconnect ex-
haust bracket at oil pan. Disconnect both exhaust pipes
from manifold. Pull exhaust system from grommets and
set aside. Disconnect speedometer cable from transaxle.
Disconnect heater hoses at water pump inlet tube and at
oil cooler.
Disconnect control arms at body. Remove stabilizer bar
brackets. Remove half-shaft assemblies and install align-
ment plugs in differential side gears. On manual transaxle
models, remove shift stabilizer bar-to-transaxle bolts. Re-
move shift mechanism-to-shift shaft attaching bolt at
transaxle. Fig. 1: Cross Section Of 2.0L Diesel Engine
Remove left-hand rear insulator mount bracket from body
bracket. Remove left-hand front insulator-to-transaxle bolts.
FORD 173

Install front upper cover and flywheel timing mark case.
Install front timing belt lower cover. Install crankshaft pulley
and front timing belt upper cover. Adjust drive belts to proper
tension. See page 381 for belt tension ranges.
REAR TIMING BELT
Removal:
Remove rear timing belt cover and flywheel timing mark
case. Rotate crankshaft until No. 1 cylinder is at TDC (fly-
wheel timing mark at TDC, camshaft sprocket and injec-
tion pump timing marks aligned). See Figs. 2 and 5.
Loosen tensioner lock nut. Turn tensioner clockwise with a screw-
driver to loosen timing belt. Tighten lock nut and remove timing
belt.
Installation:
Install timing belt and adjust belt tension as follows: with
tensioner pulley loose, rotate crankshaft twice until flywheel
TDC timing mark aligns with pointer. Tighten tensioner lock
nut and adjust belt tension to 22-33 lbs. (10-15 kg). Install
timing belt cover and flywheel timing mark case. Adjust drive Fig. 3: Aligning Crankshaft Timing Marks
belts to proper tension.See page A-60 for belt tension ranges.
Camshaft Sprocket (Front & Rear) .............................. 45 (61)
Crankshaft Pulley ................................................... 119 (165)
CV Hub Nut ............................................... 180-200 (244-271)
Insulator Brkt.-To-Body Brkt. Bolts ............. 75-100 (102-136)
Inter. Brkt.-To-Engine Brkt. Bolts ................ 75-100 (102-136)
Roll Restrictor-To-Transaxle Bolts .................... 25-45 (35-61)
Shifter-To-Input Shaft Bolts ................................. 7-10 (10-14)
Shift Stabilizer-To-Transaxle Bolts .................... 23-35 (31-47)
Water Pump ............................................................... 29 (39)
Fig. 4: Installing Front Timing Belt Tensioner Spring
Fig. 5: Aligning Flywheel Timing Marks
Fig. 2: Aligning Camshaft & Injection Pump Timing Marks

174 FORD
Fig. 6: Aligning Camshaft Timing Mark
Fig. 7: Installing Rear Timing Belt

FORD 175
2.0L 4-Cylinder DOHC, Escape

TIMING BELT APPLICATION Rotate crankshaft to just before No. 1 cylinder TDC. See
Fig. 2. Remove stud and install Crankshaft TDC Timing
Application Labor Time Belt Part No. Peg (303-574). See Fig. 3.
2.0L 4-Cyl. VIN 3
Escape NOTE: Make sure second notch in pulley is indexed to lower
cylinder block. See Fig. 2.
2001 ...................... 3.6 Hours ..................... T294
Rotate crankshaft clockwise against peg to bring it to TDC.
MANUFACTURERS SUGGESTED Loosen water pump pulley bolts.
SCHEDULED MAINTENANCE Remove timing belt cover by removing crankshaft pulley,
then remove lower timing belt cover bolts and lower timing
The manufacturer recommends the belt be replaced every belt cover. See Fig. 4. Install Engine Support Bar (303-F072).
120,000 miles. See Fig. 5.
Remove ground strap and engine mount upper bracket
REMOVAL & INSTALLATION and studs. See Fig. 6. Remove upper timing belt cover
bolts and cover. See Fig. 7.
TIMING BELT Remove water pump pulley and accessory drive belt idler
pulley. Install Camshaft Alignment Tool (303-465) and align
CAUTION: DO NOT rotate crankshaft or camshafts with timing camshafts. See Fig. 8.
belt removed, damage to valves and pistons may result.
NOTE: Installation of Camshaft Alignment Tool (303-465) into
Removal:
exhaust camshaft may require camshafts to be rotated slightly
Disconnect negative battery cable. Remove accessory drive clockwise.
belt. Remove air cleaner outlet pipe and ignition wires from
spark plugs. Disconnect throttle cables and cruise control Raise and support vehicle. Remove engine mount lower
actuator cable. Disconnect accelerator cable. Remove valve bracket. See Fig. 9.
cover. See Fig. 1. Loosen timing belt tensioner pulley and allow it to slide
Remove spark plugs. Remove catalytic converter. Remove down to bottom of its travel. Slide timing belt off of camshaft
coolant tube bolt and nut. Position coolant tube to side. and crankshaft sprockets.
CAUTION: DO NOT reuse old timing belt. Replace with a new

belt.
Fig. 1: Removing Valve Cover

Fig. 3: Removing Stud For Installation Of Crankshaft TDC

Timing Peg (303-574)
Fig. 2: Aligning Crankshaft Timing Marks Before TDC
Fig. 4: Removing Lower Timing Belt Cover

176 FORD
2.0L 4-Cylinder DOHC, Escape (Cont.)

Fig. 5: Installing Engine Support Bar (303-F072) Fig. 9: Removing Engine Mount Lower Bracket
Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.
Fig. 6: Removing Engine Mount Upper Bracket Fig. 10: Installing Timing Belt Tensioner
Installation:
Slide crankshaft pulley onto crankshaft. Ensure crankshaft
position is at No, 1 TDC by rotating it clockwise against
Crankshaft TDC Timing Peg (303-574). Ensure second
notch in pulley is indexed to lower cylinder block. See Fig.
2. Remove crankshaft pulley.
Ensure timing belt tensioner is installed correctly with tab
positioned in slot in inner timing cover. See Fig. 10.
Install new timing belt onto timing belt sprockets and ad-
just timing belt tensioner by using a 6 mm Allen wrench to
rotate adjuster counterclockwise and align marks. See
Figs. 11 and 12. Tighten tensioner pulley bolt to specifica-
tion. See TORQUE SPECIFICATIONS table.
Install front engine mount lower bracket. Install accessory
Courtesy of Ford Motor Co. drive belt idler pulley. Install water pump pulley, but hand
Fig. 7: Removing Upper Timing Belt Cover tighten only. Install timing belt covers. Install crankshaft
pulley. Tighten water pump pulley bolts to specification.
See TORQUE SPECIFICATIONS.
Remove Crankshaft TDC Timing Peg (303-574). Install stud.
Install engine mount upper bracket and ground strap. Re-
move Engine Support Bar (303-F072). Install coolant tube,
catalytic converter and remove Camshaft Alignment Tool
(303-465).
Install valve cover and spark plugs. Reconnect accelerator
cable and cruise control actuator cable. Reinstall ignition
wires, air cleaner outlet pipe and accessory drive belt. Re-
connect negative battery cable.
Fig. 8: Installing Camshaft Alignment Tool (303-465)

FORD 177
2.0L 4-Cylinder DOHC, Escape (Cont.)

Accessory Drive Belt Idler Pulley Bolt .......................... 35 (45)
Coolant Tube Attachments ............................................. 15 (20)
Engine Mount Lower Bracket Nuts ................................. 37 (50)
Engine Mount Upper Bracket Nuts ................................. 61 (83)
Engine Mount Upper Bracket Studs .............................. 25 (34)
Exhaust Camshaft Center Plug ..................................... 27 (37)
Ground Strap .................................................................. 25 (34)
Spark Plugs ................................................................... 11 (15)
Stud (For Crankshaft TDC Timing Peg) .......................... 18 (24)
Timing Belt Tensioner Bolt ............................................ 18 (25)
Water Pump Pulley Bolt ................................................. 18 (24)
Courtesy of Ford Motor Co. INCH Lbs. (N.m)
Lower Timing Belt Cover Bolt ....................................... 62 (7)
Fig. 11: Installing Timing Belt On Sprockets Upper Timing Belt Cover Bolt ....................................... 71 (8)
Valve Cover ...................................................................... 80 (9)

178 FORD
2.0L 4-Cylinder VIN 3, 1995-97
TIMING BELT APPLICATION Ensure crankshaft timing marks are aligned. See Fig. 1.
Loosen timing belt tensioner pulley, and allow spring to
Application Labor Time Belt Part No. pull pulley against timing belt. Remove camshaft align-
2.0L 4-Cyl. ment tool. Rotate crankshaft clockwise 2 full revolutions.
Contour & Mystique Tighten timing belt tensioner pulley to specification. See
1995-97 .................. 2.6 Hours ..................... T258 TORQUE SPECIFICATIONS. Align crankshaft timing marks.
See Fig. 1. Ensure camshafts are still aligned by installing
MANUFACTURERS SUGGESTED Camshaft Alignment Tool (T94P-6256-CH) on rear of camshafts.
SCHEDULED MAINTENANCE If crankshaft and camshaft alignment is correct, continue
with installation procedure.
Although the manufacturer does not recommend a specific If camshaft alignment tool cannot be installed on camshafts
scheduled maintenance interval, belt manufacturers suggest with crankshaft at TDC, hold camshaft sprocket with Cam-
the belt be replaced at 60,000 mile intervals. shaft Sprocket Holding Tool (T74P-6256-B) or spanner
wrench. Loosen, but do not remove, camshaft sprocket
REMOVAL & INSTALLATION center bolt. Rotate camshafts until camshaft alignment tool
can be installed on rear of camshafts. Crankshaft MUST
TIMING BELT remain at TDC when aligning camshafts. Tighten cam-
shaft sprocket center bolts to specification. Continue with
CAUTION: DO NOT rotate crankshaft or camshafts with timing
installation procedure.
belt removed, damage to valve/piston may result.
Install timing belt covers. Install crankshaft pulley. Tighten bolt
Removal: to specification. Install valve cover. Install spark plugs.
Noting position for installation reference, disconnect second- Install upper front engine mount. Remove engine support
ary wires from spark plugs. Remove spark plugs. tool. Install water pump pulley. Install serpentine belt idler
Disconnect negative battery cable. Remove air intake resona- pulley and serpentine bolt.
tors. Remove power steering pressure hose bracket from Install coolant recovery reservoir. Continue installation in re-
lifting eye, and position aside. verse of removal procedure.
Support engine from above using Three Bar Engine Support TORQUE SPECIFICATIONS
(D88L-6000-A) or equivalent. Remove upper timing belt cover.
Mark position of upper front engine mount before removal. Application Ft. Lbs. (N.m)
Remove upper front mount. If equipped, disconnect cool- A/C Compressor Mounting Bolt ........................ 15-22 (20-30)
ant level sensor connector from coolant recovery reservoir. Alternator Mounting Bolt .................................... 30-41 (41-56)
Remove retainers attaching recovery reservoir, and posi- Camshaft Sprocket Bolt .................................... 47-53 (64-72)
tion aside. Remove upper front mount insulator. Crankshaft Pulley Bolt .................................. 81-89 (110-121)
Loosen water pump pulley bolts. Remove serpentine drive Serpentine Belt Idler Pulley Bolt ..................................... 35 (48)
belt. Remove drive belt idler pulley from alternator mount- Timing Belt Tensioner Bolt .................................. 26-30 (35-40)
ing bracket. Remove water pump pulley. Upper Front Engine Mount Nuts .......................... 52-70 (70-95)
Remove center timing belt cover. Raise and support ve- Water Pump Bolt .............................................. 12-15 (16-20)
hicle. Remove crankshaft pulley. Remove lower timing belt INCH Lbs. (N.m)
cover. Remove valve cover. Center Timing Belt Cover Bolt .............................. 53-71 (6-8)
Temporarily install crankshaft pulley. Rotate crankshaft to align Lower Timing Belt Cover Bolt ............................... 53-71 (6-8)
timing mark on block with larger notch on pulley. See Fig. 1. Use Spark Plug ................................................... 106-156 (12-18)
Camshaft Alignment Tool (T94P-6256-CH) or equivalent to align Upper Timing Belt Cover Bolt ............................... 27-44 (3-5)
camshafts. See Fig. 2. Install tool in slots on camshafts at rear of Valve Cover ........................................................... 53-71 (6-8)
engine. Water Pump Pulley Bolt .................................. 89-124 (10-14)
Loosen timing belt tensioning pulley. See Fig. 4. Move pulley
to relieve tension on timing belt, and retighten pulley. If reus-
ing timing belt, mark direction of rotation before removal. Re-
move timing belt.
Installation:
Temporarily install crankshaft pulley. Ensure crankshaft pul-
ley timing marks are aligned. See Fig 1. Ensure camshaft
alignment tool is still installed.
Install tensioner and retaining bolt (if necessary). Remove
crankshaft pulley.
Install timing belt on crankshaft sprocket. Working in a clock-
wise direction, install timing belt around camshaft sprockets.
Ensure timing belt span between crankshaft sprocket and
exhaust camshaft is not loose. Ensure timing belt is aligned
on all sprockets.
Install lower timing belt cover. Apply Silicone Gasket Sealer Fig. 1: Aligning Crankshaft Timing Marks
(F1AZ 9562-A) or equivalent to crankshaft keyway. Install
crankshaft pulley. Tighten bolt to specification. See TORQUE
SPECIFICATIONS.
FORD 179
2.0L 4-Cylinder VIN 3, 1995-97 (Cont.)
Courtesy of For Motor Co.
Fig. 2: Installing Camshaft Alignment Tool


180 FORD
2.0L 4-Cylinder VIN 3, 1998-01
TIMING BELT APPLICATION Loosen timing belt tensioner center attaching bolt about 4
turns. Position tensioner locating tab at approximately the
Application Labor Time Belt Part No. 4 oclock position. See Fig. 4. Line up hex key slot in
2.0L 4-Cyl. VIN 3 tensioner adjusting washer with pointer that is located be-
Cougar hind pulley. See Fig. 4.
1999-01 ................. 3.2 Hours ..................... T294
CAUTION: To achieve proper tension when installing timing belt,
Contour & Mystique camshaft sprocket bolts must be loose enough to allow sprockets
1998-00 ................. 3.2 Hours ..................... T294 to turn freely on the camshafts.
Escort ZX2
1998-01 ................. 2.8 Hours ..................... T294 Remove plug from center of exhaust camshaft pulley. Hold
exhaust camshaft with open end wrench on hex portion of
Focus camshaft. See Fig. 3. Loosen, but do not remove, exhaust
2000-01 ................. 2.8 Hours ..................... T294 camshaft sprocket bolt. Loosen, but do not remove, intake
camshaft sprocket bolt.
MANUFACTURERS SUGGESTED If reusing timing belt, mark direction of rotation before re-
SCHEDULED MAINTENANCE moval. Remove timing belt.
To lock crankshaft in correct position, remove plug from
For 1998-00 model years, the manufacturer recommends the lower, left part of engine block. See Fig. 1.
belt be inspected every 120,000 miles. Replace, if necessary. Rotate crankshaft to a few degrees before TDC position.
For 2001 model year, the manufacturer recommends the belt Install locking Crankshaft Position Timing Peg (T97P-6000-
be replaced every 120,000 miles. A) into plug hole. Rotate crankshaft clockwise to lock crank-
shaft against timing peg.
REMOVAL & INSTALLATION Removal (Escort):
TIMING BELT hicle. Remove right front wheel. Remove engine splash
shield from right wheelwell.
CAUTION: DO NOT rotate crankshaft or camshafts with timing Disconnect HO2S electrical connectors. Unbolt catalytic
belt removed, damage to valve/piston may result. converter from exhaust manifold and from muffler inlet pipe.
Removal (Contour, Cougar & Mystique): Remove crossmember bolts and crossmember. Remove
Disconnect negative battery cable. Raise and support ve- catalytic converter bracket bolts. Remove catalytic converter.
hicle. Remove right front wheel. Remove engine splash Lower vehicle. Remove center trim cover from valve cover.
shield from right wheelwell. Remove engine undercover, if Noting installed position for installation reference, discon-
equipped. nect spark plug wires. Remove spark plugs. Remove valve
Loosen, but do not remove, water pump pulley bolts. Turn cover bolts (10). Remove valve cover.
serpentine drive belt tensioner clockwise and remove ser- Loosen, but do not remove, water pump pulley bolts. Turn
pentine drive belt. If belt is to be reused, mark belt with serpentine drive belt tensioner clockwise and remove ser-
arrow to indicate direction of rotation.
Remove water pump pulley. Remove serpentine belt idler
pulley. Remove crankshaft pulley center bolt and remove
pulley.
Remove lower timing belt cover. Working from under ve-
hicle, loosen center bolt of left-hand and right-hand engine
support insulators 2 turns. DO NOT remove center bolts.
Lower vehicle. Remove coolant reservoir tank with hoses
attached, and set aside. Disconnect cruise control cable (if
equipped) from coolant reservoir.
Position floor jack under engine. Raise engine slightly to
release pressure from mounting insulator on front of en-
gine. Marking installed position for installation reference,
remove engine front support insulator from timing belt end
of engine.
Remove power steering pressure hose bracket from en-
gine lifting eye, and position aside. Remove upper and
center timing belt covers.
NOTE: Spark plug removal is necessary for final timing adjustment.

Remove top engine appearance cover from between valve
covers. Remove secondary wires from spark plugs. Work-
ing from the outer ends to the center, loosen valve cover
bolts. Remove valve cover. Remove spark plugs.
Temporarily install crankshaft pulley. Rotate crankshaft to
align timing mark on block with larger notch on pulley. See
Fig. 1. Cylinders No. 1 and No. 4 are at TDC when crank-
shaft pulley Woodruff key points straight up. Courtesy of Ford Motor Co.
FORD 181

pentine drive belt. If belt is to be reused, mark belt with
arrow to indicate direction of rotation.
Remove water pump pulley. Remove serpentine belt idler
pulley. Remove crankshaft pulley center bolt and pulley.
Remove lower timing belt cover. Lower vehicle. Position
floor jack under engine. Raise engine slightly to release
pressure from mounting insulator on front of engine. Mark-
ing installed position for installation reference, remove en-
gine front support insulator.
Remove upper and center timing belt covers.
Fig. 1. To lock crankshaft in correct position, remove plug
from lower, left part of engine block. See Fig. 1. Rotate crank-
shaft to a few degrees before TDC position. Install locking
Crankshaft Position Timing Peg (T97P-6000-A) into plug
hole. Rotate crankshaft clockwise to lock crankshaft against
timing peg.
Loosen timing belt tensioner center attaching bolt about 4
4 oclock position. See Fig. 4. Line up hex key slot in
tensioner adjusting washer with pointer that is located be-
hind pulley. See Fig. 4.

camshaft sprocket bolts must be loose enough to allow sprockets
to turn freely on the camshafts.

Remove plug from center of exhaust camshaft pulley. Hold
exhaust camshaft with open end wrench on hex portion of
Fig. 2: Timing Belt Installed Position
camshaft. See Fig. 3. Loosen, but do not remove, exhaust
camshaft sprocket bolt. Loosen, but do not remove, intake
camshaft sprocket bolt.
If reusing timing belt, mark direction of rotation before re-
moval. Remove timing belt.
Removal (Focus):
Raise and support vehicle. Remove serpentine belt cover
from under vehicle.
Loosen, but do not remove, water pump pulley bolts. Turn
serpentine drive belt tensioner clockwise. If serpentine drive
belt is to be reused, mark belt with arrow to indicate rota-
tion direction. Remove serpentine drive belt.
Courtesy of Ford Motor Co. Remove water pump pulley. Remove serpentine belt idler
Fig. 3: Installing Camshaft Alignment Tool pulley. Remove crankshaft pulley center bolt and remove
pulley.
Remove lower timing belt cover. Lower vehicle. Remove
coolant expansion tank and set aside. Remove power steer-
ing reservoir from shock tower and set aside with hoses
attached.
Position floor jack under engine. Raise engine slightly to
release pressure from mounting insulator on front of en-
gine. Marking installed position for installation reference,
remove engine front support insulator from timing belt end
of engine.
Remove upper and center timing belt covers. Remove top
engine appearance cover from between valve covers. Work-
ing from the outer ends to the center, loosen valve cover
bolts. Remove valve cover. Remove secondary wires and
spark plugs. Remove PCV hose.
Fig. 1. To lock crankshaft in correct position, remove plug
from lower, left part of engine block. See Fig. 1. Rotate crank-
shaft to a few degrees before TDC position. Install locking
Courtesy of Ford Motor Co. Crankshaft Position Timing Peg (T97P-6000-A) into plug
Fig. 4: Aligning Timing Belt Tensioner For Belt Removal hole. Rotate crankshaft clockwise to lock crankshaft against
timing peg.
182 FORD
Loosen timing belt tensioner center attaching bolt about 4
4 oclock position. See Fig. 4. Line up hex key slot in
tensioner adjusting washer with pointer that is located be-
hind pulley. See Fig. 4.

camshaft sprocket bolts must be loose enough to allow sprockets
to turn freely on the camshafts.
Holding exhaust camshaft stationary with Holding Tool (303-
098) or spanner wrench, loosen, but do not remove, ex-
haust camshaft sprocket bolt. Holding intake camshaft
sprocket stationary, loosen, but do not remove, intake cam-
shaft sprocket bolt.
If reusing timing belt, mark direction of rotation before re-
moval. Remove timing belt.
NOTE: Revised installation and timing belt tensioning procedures

are from Ford technical service bulletin 99-25-4; December 13,1999.
Installation (All Models):
Ensure crankshaft pulley timing marks are still aligned and
Crankshaft Position Timing Peg (T97P-6000-A) is still in
place. See Fig 1. Ensure crankshaft remains resting against Courtesy of Ford Motor Co.
timing peg during timing belt installation. Fig. 5: Positioning Tensioner Hex Key Slot
Position cylinder No. 4 to valves overlap position. Install
Camshaft Alignment Tool (T94P-6256-CH) or equivalent to
align camshafts. See Fig. 3. Camshafts may be turned
slightly with open end wrench, in normal direction of rota-
tion, to install tool in slots on camshafts at rear of engine.
CAUTION: Timing belt tensioner locating tab should NOT be

hooked in sheet metal cover during timing belt installation. See
Fig. 4.
Tensioner locating tab should be at approximately the 4
oclock position. See Fig. 4. Line up hex key slot in tensioner
adjusting washer with pointer that is located behind pulley.
See Fig. 4.
Starting from crankshaft pulley, install timing belt on sprock-
ets in counterclockwise direction. Remove all slack from
belt during installation.
CAUTION: Incorrect timing belt tension will cause incorrect valve

timing.
To tension the timing belt, rotate timing belt tensioner tab Courtesy of Ford Motor Co.
counterclockwise and insert tab into slot in rear cover. Po- Fig. 6: Final Timing Belt Tensioning
sition hex key slot in tensioner adjusting washer to the 4
oclock position. See Fig. 5. (68 N.m). Hold exhaust camshaft stationary and tighten
Tighten attaching bolt enough to seat the tensioner firmly exhaust camshaft sprocket bolt to 50 ft. lbs. (68 N.m).
against rear timing cover, BUT still allow the tensioner ad- On Escort ZX2, Contour, Cougar and Mystique, hold intake
justing washer to be rotated with a 6 mm hex key. camshaft with Holding Tool (303-098) or spanner wrench,
Working counterclockwise, tension the timing belt. Ensure and tighten camshaft sprocket bolt to 50 ft. lbs. (68 N.m).
all slack is removed from belt. Using a 6 mm hex key, rotate On Escort ZX2, Contour, Cougar and Mystique, hold ex-
adjusting washer until notch in pointer is centered over haust camshaft with open end wrench. Tighten exhaust
index line on locating tab. See Fig. 6. Pointer will move camshaft sprocket bolt to 44 ft. lbs. (60 N.m). Final tighten
clockwise during adjustment. exhaust camshaft sprocket bolt to 88 ft. lbs. (120 N.m).
While holding adjusting washer in position so that it does On all models, remove camshaft alignment tool. Remove
not rotate, tighten tensioner center attaching bolt to 18 ft. timing peg from side of engine block.
lbs. (25 N.m). Rotate crankshaft 2 revolutions in normal direction of rota-
tion. Align crankshaft pulley with timing mark. Install lock-
NOTE: DO NOT use Camshaft Alignment Tool (T94P-6256-CH) to hold ing Crankshaft Position Timing Peg (T97P-6000-A) into plug
camshafts stationary while tightening camshaft sprocket bolts. hole. Rotate crankshaft clockwise to lock crankshaft against
On Focus models, hold intake camshaft sprocket station- timing peg.
ary, and tighten intake camshaft sprocket bolt to 50 ft. lbs. Camshaft Alignment Tool (T94P-6256-CH) should slide into
slots in rear of camshafts. If not, readjust camshaft pulley
positions.
FORD 183

On all models except Focus, install NEW center plug into TORQUE SPECIFICATIONS
exhaust camshaft sprocket after all timing marks are
aligned and belt is tensioned.
Camshaft Sprocket Bolt (Except Focus)
On all models, install valve covers. Install spark plugs and
Intake .......................................................................... 50 (68)
secondary wiring. Install appearance cover between valve
Exhaust
covers. Connect solenoid valve electrical connector in ap-
Step 1 ....................................................................... 44 (60)
pearance cover (if equipped) and press in rubber seal.
Step 2 ..................................................................... 88 (120)
Install upper and center timing belt covers. Install front en-
Camshaft Sprocket Bolt (Focus)
gine front support insulator. Remove floor jack.
Intake & Exhaust ......................................................... 50 (68)
On Contour, Cougar, and Mystique, attach power steering
Catalytic Converter (Escort)
pipe bracket to engine lifting eye. Install coolant reservoir
Bracket Bolts ..................................................... 41-47 (55-64)
tank. Raise and support vehicle. Verify that center bolt is
To-Exhaust Manifold Bolts ................................. 41-47 (55-64)
centered in right-hand and left-hand lower engine support
To-Muffler Pipe Flange Bolts ............................. 34-39 (46-54)
insulators. Tighten center bolt to specification. See TORQUE
SPECIFICATIONS.
Crossmember Bolts (Escort) ............................ 69-93 (94-126)
On Escort, install catalytic converter and crossmember.
Engine Front Support
On all models, install lower timing belt cover. Install crank-
Insulator Bolt/Nut (Except Focus) ................................. 61 (83)
shaft pulley and tighten bolt to specification. Install serpen-
Engine Front Support (Focus)
tine drive belt idler pulley. Install water pump pulley. Install
To-Engine Bracket Nut ................................................ 59 (80)
serpentine drive belt.
To-Frame Bolts ............................................................ 42 (48)
Install engine splash shield and undercover (if equipped).
Engine Lower Support Insulators (Contour, Cougar & Mystique)
Install right front wheel. Tighten lug nuts to specification.
Right-Hand
When battery is disconnected, some abnormal driveability
Auto. Trans. ............................................................. 88 (120)
symptoms may occur until the PCM relearns its adaptive
Man. Trans. ............................................................... 42 (48)
strategy. The vehicle may need to be driven 10 miles or
Left-Hand
more to complete a relearn cycle.
All Vehicles .............................................................. 88 (120)
Serpentine Drive Belt Idler Pulley Bolt ............................ 35 (40)
Spark Plugs ................................................................... 11 (15)
Timing Belt Tensioner Attaching Bolt ............................. 18 (25)
Water Pump Bolt ........................................................ 13 (18)
Wheel Lug Nut
Escort (Alloy Wheel) .................................... 74-100 (100-135)
Escort (Steel Wheel) ......................................... 66-87 (89-117)
Except Escort ............................................................. 94 (128)
INCH Lbs. (N.m)
Center Timing Belt Cover Bolt .............................. 53-71 (6-8)
Upper Timing Belt Cover Bolt
Except Escort ............................................................... 89 (10)
Escort ............................................................................. 35 (4)
Valve Cover ................................................................... 62 (7)
Valve Cover Appearance Cover ....................................... 62 (7)
184 FORD
2.0L 4-Cylinder SOHC, VIN P
TIMING BELT APPLICATION Installation (Escort & Tracer):
Ensure timing marks are still aligned. Install timing belt. If
Application Labor Time Belt Part No. reusing old belt, ensure it is installed in original direction of
2.0L 4-Cyl. VIN P rotation.
Escort & Tracer Remove drill bit and tighten tensioner bolt. Rotate crank-
1997-01 ................. 2.2 Hours ..................... T283 shaft clockwise 2 revolutions. Recheck timing mark align-
Focus ment. To complete installation, reverse removal procedure.
Removal (Focus)
2000-01 ................. 2.2 Hours ..................... T283 Disconnect negative battery cable. Detach coolant expan-
sion tank and set to one side. Remove power steering fluid
MANUFACTURERS SUGGESTED reservoir from shock tower and set aside with hoses at-
SCHEDULED MAINTENANCE tached.
Turn serpentine belt tensioner clockwise to relieve tension
Up to 2000 model year, the manufacturer recommends that and remove serpentine drive belt. Remove power steering
the timing belt be inspected at 120,000 miles. Replace, if nec- drive belt.
essary. For 2001 model year, the manufacturer recommends Hold power steering pump pulley stationary and remove
that the timing belt be replaced at 120,000 miles. power steering pump center nut. Remove power steering
pump pulley. Remove power steering pump mounting nuts.
REMOVAL & INSTALLATION Set power steering pump aside with hoses attached.
TIMING BELT Raise and support vehicle. Remove right front wheel. Re-
move the lower drive belt cover.
Removal (Escort & Tracer): Remove the crankshaft pulley and vibration damper. Lower
Disconnect negative battery cable. Place cylinder No. 1 to vehicle. Noting position for reassembly reference, discon-
TDC of compression stroke. Remove accessory drive belt
nect spark plug secondary cables from spark plugs.
and tensioner. Remove timing belt cover. Raise and sup- Remove spark plugs. Place jack under engine to support
port vehicle. Remove right hand splash guard. Remove weight. Remove front engine mount and upper timing belt
crankshaft pulley. Align timing marks. See Fig. 1.
cover from timing belt end of engine. Remove center timing
Loosen timing belt tensioner. Using an 8 mm hex wrench, belt cover. Remove engine mount bracket from timing belt
turn tensioner 1/4 turn counterclockwise. Insert 1/8 drill bit end of engine.
to lock tensioner in place. See Fig. 2. If reusing old belt,
mark belt with arrow to indicate original direction of rota-
Turn the crankshaft so that timing marks are aligned. See
Fig. 1. Loosen timing belt tensioner. Using an 8 mm hex
tion. Remove timing belt. wrench, turn tensioner 1/4 turn counterclockwise. Insert 1/
8 drill bit to lock tensioner in place. See Fig. 2. If reusing old
belt, mark belt with arrow to indicate original direction of
rotation. Remove timing belt.
Installation (Focus):
Ensure timing marks are still aligned. Install timing belt in
a counterclockwise direction starting at crankshaft sprocket.
Keep slack out of belt span from crankshaft to camshaft
sprocket. If reusing old belt, ensure it is installed in original
direction of rotation.
Remove drill bit and tighten tensioner bolt. Rotate crank-
shaft clockwise 2 revolutions. Recheck timing mark align-
ment. If not correct, readjust timing belt.
Install engine mount bracket and upper timing belt cover to
engine. Tighten bolts to specification. See TORQUE SPECI-
FICATIONS table. Install lower timing belt cover. Install en-
gine mount to engine and frame. Tighten nuts and bolts to
specification. Remove jack from under engine.
Install spark plugs and secondary cables. Raise vehicle.
Install crankshaft pulley and vibration damper. Tighten cen-
ter bolt to specification.
Install lower drive belt cover. Lower vehicle. Install power
steering pump. Install power steering pump pulley. Tighten
center bolt to specification. See TORQUE SPECIFICATIONS
table. Install serpentine drive belts. Install power steering
fluid reservoir and coolant expansion tank. Connect nega-
tive battery cable.
FORD 185
2.0L 4-Cylinder SOHC, VIN P (Cont.)

Camshaft Sprocket Bolt ................................. 70-85 (95-115)
Engine Mount (Focus)
Bracket-To-Engine ....................................................... 35 (48)
To-Engine Nuts ............................................................ 59 (80)
To-Frame Bolts ............................................................ 35 (48)
Power Steering Pump (Focus)
Mount Bolt .................................................................... 17 (23)
Pulley Bolt ..................................................................... 37 (47)
Spark Plugs .................................................................... 11 (15)
Timing Belt Tensioner Bolt .............................. 15-22 (20-30)
Wheel Lug Nut (Focus) ................................................ 94 (128)
INCH Lbs. (N.m)
Timing Belt Cover Bolt Lower ............................. 71-97 (8-11)
186 FORD
*2.0L & *2.2L 4-Cylinder Probe
Belt
2.0L 4-Cyl.
Probe
1993-97 .......... 2.5 Hrs. ...... TCK228 .......... T228
2.2L 4-Cyl.
Probe
1989-92 .......... 2.3 Hrs. ...... TCK134 .......... T134
1

kits.
For the 2.0L engine, the manufacturer recommends the belt
be replaced at every 60,000 miles, except in California. For
California 2.0L engine, replace belt at 105,000 miles. For the Fig. 2: Exploded View Of Timing Belt Components (2.2L)
2.2L engine, the manufacturer recommends the belt be re-
placed at every 60,000 miles.

Fig. 1: Exploded View Of Timing Belt Components (2.0L)
FORD 187
*2.0L & *2.2L 4-Cylinder Probe (Cont.)
Fig. 3: Camshaft & Crankshaft Timing Marks (2.0L)

Fig. 5: Timing Belt Tensioner & Spring (2.2L)
Remove water pump pulley. Raise and support vehicle.
Remove right front wheel. Remove right upper and lower
splash shield. Remove crankshaft pulley, crankshaft pulley
guide plate. Remove lower timing belt cover. Temporarily
install crankshaft pulley bolt.
NOTE: Mark direction of timing belt rotation if reusing belt.

Rotate crankshaft clockwise and align crankshaft sprocket
timing notch with line on oil pump. Ensure camshaft sprocket
timing marks align. Install Camshaft Pulley Holder (T92C-
6256-AH) or equivalent. Using an Allen wrench, turn timing
chain tensioner and remove tensioner spring. Remove tim-
ing belt.
Installation:
Fig. 4: Camshaft & Crankshaft Timing Marks (2.2L) Install timing belt. Rotate tensioner clockwise with an Allen
wrench, and install tensioner spring. Ensure timing marks on
* NOTE: This application is an interference engine. crankshaft sprocket and engine block align.
See page A-59 for interference engine cautions. Remove camshaft pulley holder, and ensure camshaft
sprocket timing marks are still aligned. Rotate crankshaft
REMOVAL & INSTALLATION clockwise 2 full revolutions. Ensure all timing marks align.
If timing marks do not align, remove timing belt. Repeat
TIMING BELT previous two steps. To complete installation, reverse re-
moval procedure. Tighten bolts to specification. See
CAUTION: DO NOT rotate crankshaft or camshafts with timing TORQUE SPECIFICATIONS. Adjust drive belts to proper
belt removed. Damage to valve/piston may result. tension. See page A-60 for belt tension ranges.
Removal:
belts. Remove spark plug wires and valve cover. Install
Three Bar Engine Support (014-00750) or equivalent.
Slightly raise engine with a jack. Remove right engine
mount. Remove dipstick bolt. Remove upper timing belt
cover.
188 FORD
*2.0L & *2.2L 4-Cylinder Probe (Cont.)
Alternator Mounting Bolt ......................................... 27-38 (52)
Tensioner Bolt .................................................. 27-38 (39-50)
Water Pump Bolt .............................................. 14-19 (19-26)
INCH Lbs. (N.m)

Valve Cover ........................................................... 53-62 (6-7)
Water Pump Pulley Bolt ...................................... 71-89 (8-10)
FORD 189

Belt SCHEDULED MAINTENANCE
Labor Component Part Although the manufacturer does not recommend a specific
Application Time Kit No. No. scheduled maintenance interval, belt manufacturers suggest
2.0L 4-Cyl. OHC the belt be replaced at 60,000 mile intervals.
Ranger REMOVAL & INSTALLATION
1983-88 .......... 12.2 Hrs. ..... TCK014 .......... T014
2.3L 4-Cyl. OHC TIMING BELT
Aerostar
1987 ............... 12.2 Hrs. ..... TCK014 .......... T014 CAUTION: Rotate crankshaft clockwise (in normal rotation direction)
Cougar only. Timing belt may come off if engine is rotated counterclockwise.
1981 ............... 11.3 Hrs. ..... TCK014 .......... T014 Removal:
1984-86 .......... 11.3 Hrs. ..... TCK014 .......... T014 Disconnect negative battery cable. Rotate engine clock-
Courier wise and position cylinder No. 1 on TDC of compression
1977-82 .......... 22.2 Hrs. ..... TCK014 .......... T014 stroke. Ensure O mark on crankshaft pulley aligns with
O mark on outer timing belt cover.
Fairmont & Zephyr Looking through plug hole of outer timing belt cover, ensure cam-
1978-83 .......... 21.6 Hrs. ..... TCK014 .......... T014 shaft sprocket timing mark aligns with cover pointer. See Fig 1.
Granada Remove fan guard, cooling shroud, cooling fan and fan
1981-82 .......... 21.6 Hrs. ..... TCK014 .......... T014 shroud. Remove drive belt, water pump pulley and auto-
LTD & Marquis matic belt tensioner. Discharge A/C System (if equipped)
1983-86 .......... 21.5 Hrs. ..... TCK014 .......... T014 using approved refrigerant recovery equipment. Remove A/
C compressor mounting bracket with power steering pump
Merkur XR4Ti attached, and position aside. Drain cooling system. Re-
1985-89 .......... 11.5 Hrs. ..... TCK014 .......... T014 move upper radiator hose. Remove thermostat housing
Mustang, Mustang II & Capri and gasket.
1974-91 .......... 21.6 Hrs. ..... TCK014 .......... T014 Remove retaining bolt and crankshaft pulley. Remove hub
1992 assembly retaining bolt from crankshaft. Remove outer tim-
With Round Tooth ing belt cover. Ensure camshaft sprocket timing mark aligns
Sprockets ... 11.5 Hrs. ............................... T210 with cover pointer. See Fig. 1.
With SquareTooth
Loosen belt tensioner bolts. Using Camshaft Belt Tensioner
(T74P-6254-A) or equivalent, release spring tension on belt
Sprockets ... 11.5 Hrs. ..... TCK014 .......... T014 tensioner. Rotate belt tensioner away from timing belt and
Mustang tighten bolts.
1993 ............... 21.5 Hrs. ............................... T210 Remove retaining bolts and pull crankshaft sensor from
Pinto & Bobcat dowel pins. See Fig. 1. Remove hub assembly and belt
1974-80 .......... 22.0 Hrs. ..... TCK014 .......... T014 guide. Note direction of belt guide installation. Remove tim-
Ranger ing belt.
Installation:
1983-91 .......... 12.2 Hrs. ..... TCK014 .......... T014 Install crankshaft sprocket (if removed) with recessed area
1992 toward crankshaft. See Fig. 1. Install belt guide with flat
With Round Tooth side toward camshaft sprocket. Install camshaft sprocket
Sprockets ... 12.2 Hrs. ............................... T210 with timing mark outward.
With SquareTooth Install NEW camshaft sprocket bolt and tighten to specifi-
Sprockets ... 12.2 Hrs. ..... TCK014 .......... T014 cation while holding camshaft with camshaft sprocket
holder. See TORQUE SPECIFICATIONS.
1993-94 .......... 12.2 Hrs. ............................... T210
Thunderbird CAUTION: Install NEW camshaft sprocket bolt. DO NOT reuse bolt.
1983-88 .......... 21.3 Hrs. ..... TCK014 .......... T014
1
- With Air Cond. add 1.0 hours.
Align camshaft sprocket timing mark with pointer. Properly
position crankshaft so timing mark aligns with notch in
2
- With Air Cond. add .5 hours front cover casting. See Fig. 3. Install timing belt over crank-
shaft sprocket, then counterclockwise over auxiliary shaft
NOTE: A timing belt component kit is available for and camshaft sprockets. Loosen belt tensioner bolt, allow-
this application. See page I for information on component ing tension to be applied on timing belt.
kits. NOTE: It may be necessary to push belt tensioner against timing belt,
as spring tension may not move belt tensioner against timing belt.
190 FORD
Remove one spark plug from each cylinder. Rotate engine
clockwise (viewed from front of engine) 2 complete revolu-
tions. Tighten timing belt tensioner bolts to specification.
See TORQUE SPECIFICATIONS. Ensure all timing marks
align properly. Install belt guide on crankshaft.
Install crankshaft sensor over dowel pins. Tighten long crank-
shaft sensor bolts to 14-22 ft. lbs. (19-30 N.m). Rotate crankshaft
counterclockwise approximately 45 degrees so outer vane of hub
assembly does not engage with crankshaft sensor positioner.
Install hub assembly and crankshaft pulley. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Install crank-
shaft sensor positioner. See Fig. 2. Rotate crankshaft clock-
wise approximately 90 degrees so outer vane of hub assem-
bly engages with crankshaft sensor positioner. Tighten short
crankshaft sensor bolts to 14-22 ft. lbs. (19-30 N.m).
dure. Tighten bolts to specification. See TORQUE SPECI-
FICATIONS.
Disconnect heater hose from fitting on thermostat housing to
bleed air from cooling system when filling. Fill cooling system
with Ford Coolant (E2FZ-19549-AA) or equivalent, until cool-
ant flows from fitting. Install heater hose. Refill radiator. Adjust
ranges.
Auxiliary Shaft Sprocket Bolt .............................. 29-40 (39-54)
Belt Tensioner
Adjusting Bolt ................................................. 14-22 (19-30)
Pivot Bolt ....................................................... 29-40 (39-54)
Camshaft Plug ................................................. 12-18 (16-24)
Camshaft Sprocket Bolt 1 .................................. 52-70 (71-95) Fig. 1: Exploded View Of Timing Belt & Components
Crankshaft Pulley-To-Hub Assembly Bolt ......... 15-22 (20-30)
Water Pump Bolt 2 ............................................ 14-21 (19-29)
Water Pump Pulley Bolt .................................... 14-22 (19-30)
INCH Lbs. (N.m)
Auxiliary Shaft Cover Bolt .................................. 72-108 (8-12)
Auxiliary Shaft Retainer Plate Bolt ..................... 72-108 (8-12)
Camshaft Retainer Thrust Plate Box ................ 72-108 (8-12)
Outer Timing Belt Cover Bolt ............................ 72-108 (8-12)
Valve Cover Bolt .................................................. 60-96 (6-11)
1
- Install NEW bolt. DO NOT reuse bolt.
2
- Apply thread sealant on bolt threads.
Fig. 2: Positioning Crankshaft Sensor

FORD 191
Fig. 3: Positioning Crankshaft
Fig. 4: Aligning Camshaft & Oil Pump Timing Marks

192 FORD
TIMING BELT APPLICATION Check timing belts for missing teeth, cracking or excessive
wear. Replace timing belt if necessary. Camshaft/injection
Belt Part No. pump timing belt must be removed to access silent shaft
2.3L 4-Cyl. Diesel timing belt.
Ranger
1985-87 NOTE: DO NOT loosen nut near timing scale unless removing
silent shaft timing belt. This nut is for silent shaft timing belt
Balance Shaft ..... 2.2 Hours ..................... T092 tensioner. Loosening this nut may change silent shaft timing
Camshaft ............. 2.2 Hours ..................... T091 belt tension. See Fig. 1.
1
- With Air Cond. add .3 hours. Installation:
With Pwr. Strng. add .3 hours. Fabricate timing belt tensioner, using a pivot nut from rear
brake adjuster and bar stock. See Fig. 3. Release tension
MANUFACTURERS SUGGESTED on tensioner spring, using belt tensioner. Rotate tensioner
SCHEDULED MAINTENANCE toward water pump and tighten top bolt.
Install camshaft/injection pump timing belt. Ensure belt is
Although the manufacturer does not recommend a specific installed to rotate in original rotation. Maintain tension on
scheduled maintenance interval, belt manufacturers suggest belt. Loosen top tensioner bolt to tension timing belt. See
the belt be replaced at 60,000 mile intervals. Fig. 4. Tighten tensioner hold-down bolts. To complete in-
stallation, reverse removal procedure. Adjust drive belts to
* NOTE: This application is an interference engine. proper tension. See page A-60 for belt tension ranges.

TIMING BELT
Removal:
Disconnect negative battery cable. Remove drive belts. Re-
move 5 upper front timing belt cover retaining bolts. Re-
move upper front cover. Remove cooling fan and shroud.
Remove water pump pulley. Remove crankshaft pulley at-
taching bolt. Rotate crankshaft until No. 1 piston is at TDC
on compression stroke.
Remove vibration damper using Damper Remover (T58P-
6316-D) or equivalent. Remove 5 lower front timing belt
cover attaching bolts and remove cover. Loosen timing belt
tensioners and remove belts. Mark direction of rotation on
timing belts before removal.
Fig. 2: Timing Mark Alignment
Fig. 3: Timing Belt Tensioner
Fig. 1: Silent Shaft Timing Belt Tensioner Nut

FORD 193

Crankshaft Pulley Bolts ............................ 123-137 (167-186)
Injection Pump Sprocket Nut ............................ 40-50 (54-68)
Timing Belt Tensioner Nut ................................ 16-21 (22-29)
INCH Lbs. (N.m)
Front Case Bolts ......................................... 108-120 (12-14)
Rocker Cover Bolts ............................................... 48-60 (5-7)
Silent Shaft Chamber Cover Bolts ........................ 36-48 (4-5)
Fig. 6: Removing Tensioner Bolt Access Cover
Fig. 4: Loosening Belt Tensioner Bolts
Fig. 5: Aligning Mark On Timing Cover With Mark On

Camshaft Sprocket
Test
194 FORD
2.3L 4-Cylinder
TIMING BELT APPLICATION release tension. See Fig. 2. Pry tensioner away from timing
belt and tighten bolt to hold tensioner in place. Remove timing
Application Labor Time1 Belt Part No. belt.
2.3L 4-Cyl.
Ranger CAUTION: Always rotate engine in direction of normal rotation
(clockwise as viewed from front of engine). Reverse rotation may
1995-97 ................. 2.2 Hours ..................... T276
cause timing belt to jump time, causing engine damage.
1
- With Air Cond. add 1.0 hours.
With Pwr. Strng. add .3 hours. Installation:
Ensure crankshaft is set at TDC and camshaft sprocket
timing mark and oil pump sprocket timing mark are aligned
MANUFACTURERS SUGGESTED with inner cover timing marks.
SCHEDULED MAINTENANCE Install NEW timing belt. Loosen tensioner bolt. Allow
tensioner to adjust itself, and retighten bolt. Rotate crank-
shaft clockwise 2 complete revolutions to remove slack
60,000 miles.
from belt.
REMOVAL & INSTALLATION Loosen tensioner bolt. Allow tensioner to adjust itself and
retighten bolt. To complete installation, reverse removal
TIMING BELT procedure. Adjust drive belts to proper tension. See page
Removal: A-60 for belt tension ranges.
Remove spark plugs. Ensure crankshaft is set at TDC and TORQUE SPECIFICATIONS
camshaft sprocket timing mark and oil pump sprocket timing Application Ft. Lbs. (N.m)
mark are aligned with inner cover timing marks. See Fig. 1. A/C Compressor Bolts ..................................... 15-21 (21-28)
Remove fan guard. Remove fan shroud and position aside. Alternator Bracket Bolts .................................... 30-40 (41-54)
Remove fan retaining screws, and remove fan and shroud. Alternator Retaining Bolts ................................. 30-40 (41-54)
Rotate drive belt tensioner and remove belt. Camshaft Sprocket Bolt .................................... 50-71 (68-96)
Remove cooling fan and water pump pulley. Discharge A/C Cooling Fan Bolts ............................................. 13-16 (17-23)
system (if equipped) using approved refrigerant recovery/ Crankshaft Damper Bolt ........................... 103-133 (140-180)
recycling equipment. Remove A/C compressor and posi- Oil Pump Sprocket Bolt ..................................... 28-40 (38-54)
tion aside. Remove A/C compressor mounting bracket with Timing Belt Tensioner Adjusting Bolt ................ 14-21 (35-45)
power steering pump attached, and position aside. Timing Belt Tensioner Pivot Bolt ....................... 28-40 (40-55)
Remove timing belt outer cover retaining bolt. Release 7 INCH Lbs. (N.m)
cover interlocking tabs. Remove timing belt cover. Holding Engine Timing Belt Cover Bolt .......................... 71-106 (8-12)
timing belt tensioner with Camshaft Belt Tension Adjuster Spark Plug ........................................................ 80-177 (9-20)
(T74P-6254-A) or equivalent, loosen adjusting bolt and slowly Valve Cover Bolt ................................................ 80-115 (9-13)
Fig. 1: Aligning Camshaft & Oil Pump Timing Marks

FORD 195
2.5L 4-Cylinder
TIMING BELT APPLICATION Remove timing belt outer cover retaining bolt. Release 7
cover interlocking tabs. Remove timing belt cover.
Belt Part No. Rotate crankshaft in normal direction of rotation so that No. 1
2.5L 4-Cyl. cylinder is at TDC of compression stroke. Align camshaft,
Ranger crankshaft and oil pump timing marks. See Fig. 1. Crankshaft
1998-01 ................. 2.2 Hours ..................... T276 keyway should be pointing straight up and circle on crank-
shaft sprocket must align with notch in engine front cover.
1
- With Air Cond. add 1.0 hours. Holding timing belt tensioner with Camshaft Belt Tension Ad-
With Pwr. Strng. add .5 hours. juster (T74P-6254-A) or equivalent, loosen adjusting bolt and
pivot bolt. Slowly release spring tension. Pry tensioner away
MANUFACTURERS SUGGESTED from timing belt and tighten bolt to hold tensioner in place.
Remove timing belt.
SCHEDULED MAINTENANCE Installation:
For 1998-00 model years, the manufacturer recommends the Ensure crankshaft is set at TDC and camshaft sprocket
belt be inspected at 120,000 miles and replaced if necessary. timing mark and oil pump sprocket timing mark are aligned
For 2001 model year, the manufacturer recommends the belt with inner cover timing marks.
be replaced at 120,000 miles. Install timing belt on crankshaft sprocket, oil pump sprocket
and then the camshaft sprocket. Loosen timing belt
REMOVAL & INSTALLATION tensioner bolt.
Allow tensioner to adjust itself against timing belt. DO NOT
TIMING BELT tighten belt tensioner. Slowly rotate crankshaft clockwise 2
Removal: complete turns clockwise (as viewed from front of engine)
Disconnect battery ground cable. Remove exhaust side so No. 1 cylinder is at TDC of compression stroke.
spark plugs. Recheck timing alignment marks. If timing marks are not
Remove fan shroud bolts and position over fan blades. aligned, reposition timing belt. Repeat timing belt
Loosen, but do not remove, water pump pulley bolts. Re- tensioning procedure.
move accessory drive serpentine belt. Tighten timing belt tensioner adjusting and pivot bolts to
Remove fan and clutch assembly retaining screws. Re- specification. See TORQUE SPECIFICATIONS. Install
move fan and clutch assembly. Remove fan shroud. Re- crankshaft pulley. Tighten center bolt to specification.
move water pump pulley. Install timing belt cover. Install exhaust side spark plugs.
On models with A/C, discharge A/C system using approved Install A/C compressor mounting bracket to engine. Install
refrigerant recovery/recycling equipment. Remove A/C com- A/C compressor to mounting bracket. To complete installa-
pressor from mounting bracket. Remove A/C compressor tion, reverse removal procedure. Recharge A/C system.
mounting bracket with power steering pump attached, and TORQUE SPECIFICATIONS
position aside.
A/C Compressor Mount Bolts ............................. 15-21 (21-28)
A/C Compressor Mounting Bracket-To-Engine
M8 Bolt ......................................................................... 18 (25)
M10 Bolt & Stud ............................................................ 35 (48)
Alternator Bracket Bolts .................................... 30-40 (41-54)
Alternator Retaining Bolts ................................. 30-40 (41-54)
Cooling Fan-To-Water Pump Bolts ................... 13-16 (17-23)
Crankshaft Damper Bolt ............................... 93-121 (125-165)
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)

196 FORD
2.5L V6
2.5L V6
Probe
1993-97 ................. 4.0 Hours ..................... T214
1
60,000 miles for Federal vehicles and 105,000 miles for Cali-
fornia vehicles.

TIMING BELT
Fig. 2: Checking & Compressing Automatic Belt Tensioner
belt removed. Damage to valve/piston may result.

FORD 197
2.5L V6 (Cont.)
Removal:
Disconnect negative battery cable. Disconnect engine cool-
ant temperature sensor and temperature gauge sender
connectors from coolant elbow. Disconnect crankshaft po-
sition sensor connector. See Fig. 2. Remove accessory
drive belts. Raise and support vehicle.
Remove A/C belt tensioner bracket. Remove crankshaft
damper bolt using Crankshaft Pulley Holder (T92C-6316-
AH) or equivalent. Remove crankshaft damper. Remove 2
timing belt cover bolts from behind crankshaft damper.
Remove timing belt cover lower bolts. Using Power Steer-
ing Pump Pulley Remover (D85L-6000-A) or equivalent,
remove power steering pump pulley.
Using Water Pump Pulley Remover (T92C-631 2-AH) or
equivalent, remove water pump pulley bolts and pulley.
Lower vehicle. Remove oil dipstick tube. Remove upper
timing belt cover bolts. Remove A/C-alternator belt idler
bracket. Remove left timing belt cover then right cover.
Remove 3 nuts and through-bolt from right engine mount.
Remove right engine mount. Align crankshaft timing
sprocket by turning crankshaft in normal direction of en-
gine rotation only. Remove timing belt tensioner arm by Fig. 4: Positioning Crankshaft To Remove Slack From
removing lower and then upper tensioner arm bolts. Timing Belt
Mark direction of timing belt rotation if reusing belt. Using an Allen
wrench, loosen timing belt tensioner bolt. Remove timing belt. Compress automatic belt tensioner until hole in piston aligns
with second hole in housing. Insert a .06" (1.5 mm) diameter pin,
CAUTION: DO NOT rotate camshafts or crankshaft with timing or drill through hole to keep piston in compressed position. See
belt removed, as engine damage could result. Fig. 1.
Inspection: Ensure camshafts and crankshaft timing marks align. See Fig. 3.
Inspect timing belt for damaged teeth, cracking and oil con- Turn crankshaft counterclockwise until crankshaft timing sprocket
tamination. Ensure upper and lower timing belt idlers ro- is offset from TDC by one tooth. See Fig. 4. Install timing belt.
tate freely. Replace damaged components. Turn crankshaft clockwise until crankshaft timing mark is
Inspect timing belt tensioner for signs of oil leakage. Re- back to TDC. This should put slack on tensioner portion of
place timing belt tensioner if oil leakage exists. belt. Install automatic timing belt tensioner, and tighten bolts
Measure timing belt tensioner rod protrusion (free length) to specification. See TORQUE SPECIFICATIONS. Remove
from end of rod to edge of housing. See Fig. 1. Replace pin from automatic tensioner.
timing belt tensioner if distance is not .55-.63" (14-16 mm). Turn crankshaft 2 complete revolutions. Recheck timing marks
Installation: to ensure timing is still correct. See Fig. 3. To complete instal-
Place timing belt tensioner in a press, using a flat washer to lation, reverse removal procedure. Tighten bolts to specifi-
prevent damage to timing belt tensioner plug. cation. Check ignition timing. Adjust drive belts to proper
A/C Compressor Bracket-To-Cylinder
Block Bolt ........................................................ 28-38 (38-51)
Camshaft Sprocket Bolt ............................. 90-103 (122-140)
Crankshaft Pulley Bolt .............................. 116-122 (157-165)
Engine Mount Nuts ......................................... 54-76 (73-103)
Engine Mount Through-Bolts .......................... 50-68 (86-116)
Front Suspension Crossmember Bolt ........... 69-93 (94-126)
Knock Sensor ................................................... 14-25 (20-34)
Power Steering Pump Bracket Bolt ................... 24-33 (32-46)
Spark Plug ....................................................... 11 -16 (15-23)
Tensioner Pulley Bolt ........................................ 27-33 (37-45)
Water Pump Bolt .............................................. 14-18 (19-24)
Wheel Lug Nut ................................................ 65-87 (88-118)
INCH Lbs. (N.m)
Valley Cover Bolts .............................................. 71 -88 (8-10)
Valve Cover Bolt .................................................... 43-78 (5-8)
Fig. 3: Aligning Camshaft & Crankshaft To TDC

198 FORD
*3.0L V6 SOHC, Villager
TIMING BELT APPLICATION Loosen tensioner lock nut. Using Allen wrench, rotate
tensioner by turning Allen wrench clockwise 70-80 degrees.
Belt Temporarily tighten lock nut. Rotate crankshaft clockwise
Labor Component Part at least 2 revolutions.
Application Time Kit No. No. Return cylinder No. 1 to TDC of compression stroke. Using
3.0L V6 SOHC Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs.
Villager (Mercury) (10.0 kg) pressure to timing belt between right camshaft
sprocket and tensioner. Hold tensioner in position with Allen
1993 ............... 1 3.5 Hrs. .... TCK104 .......... T104 wrench, and loosen tensioner lock nut.
1994-98 .......... 1 3.5 Hrs. .............................. T249
1
kits.
105,000 miles.


TIMING BELT
Removal:
hicle. Remove covers from below engine. Drain cooling Fig. 1: Exploded View Of Timing Belt Components
system. Remove right front wheel and engine side cover.
Remove accessory drive belts. Remove crankshaft pulley
bolt and pulley.
Remove upper radiator hose and water inlet hose. Re-
move A/C compressor idler pulley and bracket. Remove
water pump pulley. Remove upper and lower timing belt
front covers.
Temporarily install crankshaft pulley bolt so crankshaft can
be rotated. Set cylinder No. 1 at TDC of compression stroke
by rotating crankshaft until marks on camshaft sprockets
align with marks on timing belt upper rear cover, and mark
on crankshaft sprocket aligns with mark on front cover hous-
ing. See Fig. 2.
Loosen timing belt tensioner nut. Release tension on belt.
Remove timing belt. Check timing belt tensioner, spring
and timing belt.
Installation:
Ensure cylinder No. 1 is at TDC of compression stroke.
See Fig. 2. Install tensioner and return spring if removed. If
return spring stud was removed, apply thread lock sealant
to threads before installing stud. Insert an Allen wrench
into hole in tensioner, turn tensioner fully clockwise, and
temporarily tighten lock nut. Fig. 2: Installing Timing Belt & Sprocket
Install timing belt with arrow on timing belt facing front of
engine. Align White lines on timing belt with marks on cam-
shaft sprockets and crankshaft sprocket. White lines en-
sure correct number of teeth exist between timing marks
on sprockets.
FORD 199
*3.0L V6 SOHC, Villager (Cont.)

Place a .0138" (.351 mm) feeler gauge at tensioner pulley
and timing belt, and rotate crankshaft until feeler gauge is
centered between tensioner pulley and timing belt. See
Fig. 3. Tighten tensioner lock nut to specification. See
Rotate crankshaft to remove feeler gauge. Rotate crank-
shaft clockwise at least 2 revolutions until cylinder No. 1 is
at TDC of compression stroke. Measure timing belt deflec-
tion halfway between camshaft sprockets.
If deflection is not .51-.59" (13-15 mm), readjust timing belt
tension. To complete installation, reverse removal proce-
dure.
tension ranges.
Crankshaft Pulley Bolt ................................. 90-98 (122-133)
Rocker Shaft Bolts ............................................ 13-16 (16-20)
Timing Belt Tensioner Lock Nut/Bolt ................ 32-43 (43-58)
Water Pump Bolt .............................................. 13-16 (16-20)
INCH Lbs. (N.m)
Timing Belt Cover ................................................. 27-43 (3-5)
200 FORD
3.0L & 3.2L V6 SHO
TIMING BELT APPLICATION NOTE: To prevent timing belt whine on models with 3.0L engine
Application Labor Time Belt Part No. and manual transaxle, the timing belt must be correctly tensioned.
The revised tensioning procedure is from Ford technical service
3.0L V6 SHO bulletin 95-22-10; November 6, 1995.
Taurus
1989-95 ................ 3.0 Hours .................... T248 Installation (3.0L SHO):
3.2L V6 SHO Ensure No. 1 piston is at TDC of compression stroke. En-
sure camshaft timing marks align with timing belt cover
Taurus marks and crankshaft sprocket timing mark aligns with
1993-95 ................ 3.0 Hours .................... T248 mark on oil pump housing. See Fig. 2.
Install timing belt on crankshaft and route around left cam-
MANUFACTURERS SUGGESTED shaft and onto right camshaft sprockets. Ensure used tim-
SCHEDULED MAINTENANCE ing belt is installed in original direction of rotation. Loosen
timing belt tensioner lock nut and leave nut loose.
The manufacturer recommends the belt be replaced every Raise and support vehicle. Install center timing belt cover
100,000 miles. and ensure crankshaft sensor wiring is properly routed.
Install lower timing belt cover. Install crankshaft damper.
REMOVAL & INSTALLATION Tighten bolt to specification. See TORQUE SPECIFICA-
TIONS table.
TIMING BELT Rotate crankshaft until Yellow mark on crankshaft damper
Removal (3.0L SHO): aligns with 0 mark on lower timing belt cover. See Fig. 1.
Remove battery. Remove engine roll damper, located near Remove plastic access cover in lower timing belt cover.
timing belt cover. Disconnect ignition control module. Re- Tighten timing belt tensioner lock nut to 25-37ft. lbs. (34-50
move intake manifold crossover tube. See Fig. 4. Remove N.m). Install plastic access cover.
accessory drive belts. Remove alternator belt tensioner pul- Rotate crankshaft clockwise 60 degrees until White mark
ley and bracket. on crankshaft damper aligns with 0 mark on lower timing
Remove water pump tensioner pulley. Disconnect crank- belt cover. Lower vehicle.
shaft sensor wiring assembly at lower timing belt cover. Ensure camshaft timing marks align with timing belt cover
Remove upper timing belt cover. Ensure transaxle is in marks. See Fig. 2. Install upper timing belt cover. Install
Neutral. intake manifold crossover tubes. Connect ignition electri-
Rotate crankshaft until No. 1 piston is at TDC. Ensure White cal connector.
mark on crankshaft damper aligns with 0 mark on lower Install splash shield and right front wheel. To install re-
timing belt cover and camshaft timing marks align with maining components, reverse removal procedure. Adjust
marks on timing belt cover. See Fig. 1. drive belts to proper tension. See page A-60 for belt tension
Raise and support vehicle. Remove right front wheel and ranges.
splash shield. Using Puller (T67L-3600-A) or equivalent,
remove crankshaft damper. Remove timing belt covers. Dis-
connect crankshaft position sensor wire and grommet from
slot near water pump.
Ensure timing marks align. See Fig. 2. If reusing timing
belt, place reference mark on timing belt, camshaft sprock-
ets, and crankshaft sprocket. Mark direction of belt rotation
for reassembly reference.
Loosen timing belt tensioner lock nut. Rotate tensioner
pulley 180 degrees clockwise using 6mm Allen wrench.
See Fig. 6. Tighten lock nut to hold tensioner in unloaded
position. Lower vehicle. Remove timing belt.
G93G56966
Fig. 1: Crankshaft Pulley Timing Marks Fig. 2: Aligning Timing Marks
FORD 201
3.0L & 3.2L V6 SHO (Cont.)

Removal (3.2L SHO):
Remove battery. Remove engine roll damper, located near
timing belt cover. Disconnect ignition control module. Re-
move intake manifold crossover tube. See Fig. 4. Remove
serpentine drive belt and tensioner.
Remove upper and lower idler pulleys. Using a strap wrench
to hold power steering pump pulley, remove power steer-
ing pump pulley nut and pulley. Remove upper and center
timing belt covers. Disconnect crankshaft sensor wiring
assembly at lower timing belt cover.
Ensure transaxle is in Neutral. Rotate crankshaft until No.
1 piston is at TDC. Ensure White mark on crankshaft damper
aligns with 0 mark on lower timing belt cover and cam-
shaft timing marks align with marks on timing belt cover. Fig. 3: Compressing Timing Belt Tensioner (3.2L)
See Fig. 2.
Raise and support vehicle. Remove right front wheel and
splash shield. Using Puller (T67L-3600-A), remove crank-
shaft damper. Remove lower timing belt cover. Remove
timing belt guide located in front of crankshaft sprocket.
Ensure timing marks align. See Fig. 2.
If reusing timing belt, place reference mark on timing belt,
camshaft sprockets, and crankshaft sprocket. Mark direc-
tion of belt rotation for reassembly reference. Slowly loosen
timing belt tensioner bolt and remove tensioner. Lower ve-
hicle. Remove timing belt.
Installation (3.2L SHO):
Ensure No. 1 piston is at TDC of compression stroke. En-
sure camshaft timing marks align with timing belt cover
marks and crankshaft sprocket timing mark aligns with
mark on oil pump housing. See Fig. 2. Place timing belt
tensioner in a soft jawed vise. Compress tensioner until
hole in tensioner rod aligns with hole in tensioner housing.
Install a 1.5 mm Allen wrench through hole, and lock
tensioner in retracted position. See Fig. 3.
Install timing belt on crankshaft and route belt around left Fig. 4: Exploded View Of Intake Manifold & Brackets
camshaft and onto right camshaft sprockets. Ensure used
timing belt is installed in original direction of rotation.
Install timing belt tensioner while pushing tensioner pulley
toward belt. Install rubber grommets between tensioner
and oil pump. See Fig. 5. Remove Allen wrench from
tensioner. If installing used belt, skip the next step. If in-
stalling new timing belt, go to next step.
Mount Timing Belt Tensioner Tool (T93P-6254B) or equiva-
lent, using power steering pump bracket bolt holes. Using
INCH-lb. torque wrench and Torque Wrench Attachment
(T93P-6254-A) or equivalent, rotate tensioner clockwise to
4.3 INCH lbs. (.5 N.m.). Tighten belt tensioner bolt. Re-
move tensioner tool. Tighten bolts to specification.
Raise and support vehicle. Install timing belt guide and
lower timing belt cover. Install crankshaft damper. Rotate
crankshaft clockwise 60 degrees until White mark on crank-
shaft damper aligns with 0 mark on lower timing belt cover.
Ensure camshaft timing marks align with timing belt cover Fig. 5: Installing Rubber Grommets (3.2L SHO)
marks. See Fig. 2. Ensure crankshaft sensor wiring is prop-
erly routed. Install remaining timing belt covers. To install
remaining components, reverse removal procedure. Ad-
tension ranges.
202 FORD
3.0L & 3.2L V6 SHO (Cont.)
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)
G93F566965
Fig. 6: Adjusting Timing Belt Tension (3.0L)
GEO 203
1.6L 4-Cylinder DOHC, Prizm GSI

TIMING BELT APPLICATION Remove water pump pulley. Remove upper, center and lower
timing belt covers. Remove timing belt guide. Turn crank-
Application Labor Time Belt Part No. shaft so that camshaft and crankshaft timing marks are
1.6L 4-Cyl. DOHC aligned. See Fig. 2. Loosen timing belt idler pulley bolt.
Prizm GSI Remove timing belt.
1990-92 ................ 1 3.1 Hours .................... T176
CAUTION: If timing belt is to be reused, mark direction of timing
1
- With Pwr. Strng. add .4 hours. belt rotation. Place mating marks on belt and sprockets for reference.
Inspection:
MANUFACTURERS SUGGESTED Inspect timing belt for cracks or damaged teeth. Ensure
SCHEDULED MAINTENANCE timing belt is not contaminated with oil. Check belt tensioner
pulley for smooth rotation or grease leaks. Replace dam-
The manufacturer recommends the belt be inspected and aged components.
adjusted at 30,000 mile intervals, and replaced at 60,000 mile
intervals.
Remove spring from timing belt idler pulley. Check free
length of belt tensioner spring. Free length is measured
between inside diameters of hooked portion of spring (not
REMOVAL & INSTALLATION coil length). Replace spring if free length is greater than
1.618 (41.09 mm). See Fig. 3.
Removal: Ensure all timing marks are aligned. See Fig. 2. Install
Disconnect negative battery cable. Raise and support ve- timing belt. If reusing old timing belt, ensure belt is in-
hicle. Turn front wheels all the way to the right. Remove stalled in original rotating direction.
right front wheel. Remove right lower stone shield from If removed, installed timing belt idler pulley spring. Loosen
under vehicle. Remove accessory drive belts. timing belt idler pulley bolt to allow tension to be applied on
Remove center bolt and crankshaft pulley. Lower vehicle. timing belt.
Label spark plug secondary cables for reassembly refer- Temporarily install crankshaft pulley center bolt. Rotate crank-
ence. Disconnect spark plug cables from spark plugs. shaft clockwise 2 revolutions, to TDC. Ensure all timing
Remove PCV valvefrom valve cover. Disconnect accelera- marks are aligned.
tor cable from valve cover. Disconnect wiring harness from Final tighten timing belt idler pulley bolt to specification.
valve cover. Remove valve covers. See TORQUE SPECIFICATIONS. Apply about 4.5 lbs. (2.04
Remove windshield washer reservoir. Remove engine wir- kg) of downward pressure to timing belt between camshaft
ing harness from upper timing belt cover. sprockets. Belt deflection should be about .16 (4 mm) if
Support engine from above using Engine Support Bar (J timing belt tension is correct.
28467-A) or equivalent. Remove engine mount through bolt Remove crankshaft bolt. Install timing belt guide. Install
from mount on timing belt end of engine. upper, center, and lower timing belt covers. Install crank-
shaft pulley. Tighten center bolt to specification. Install wa-
ter pump pulley.
Install engine mount through-bolt and tighten to specifica-
tion. Remove engine support bar. Install valve cover with
new gaskets. Apply GM sealant (part no. 1052917) or
equivalent to valve cover mating surfaces.
Install accessory drive belts. Adjust drive belts to proper
tension. See page A-60 for belt tension ranges. To install
remaining components, reverse removal procedure.
Courtesy of Toyota Motor Sales, U.S.A., Inc.


204 GEO
1.6L 4-Cylinder DOHC, Prizm GSI (Cont.)
Camshaft Sprocket Bolts ............................................... 35 (47)
Engine Mount Through-Bolt ............................................ 64 (87)
Water Pump Pulley Bolt .............................................. 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Valve Cover Nut ............................................................ 53 (6)
Fig. 3: Checking Timing Belt Tensioner Spring Free Length

GEO 205
*1.6L 4-Cylinder Storm SOHC

1.6L 4-Cyl. SOHC
Storm
1990-93 ................ 1.5 Hours .................... T177
1
The manufacturer recommends the belt be replaced at 30,000
mile intervals.


TIMING BELT
Removal:
Disconnect negative battery cable. Remove alternator and
power steering pump drive belts. Using Engine Support
Fixture (J-26900-9) or equivalent, support engine from
above.
Remove engine mount located at timing belt cover. Rotate
crankshaft and position No. 1 cylinder at TDC of compres-
sion stroke. Ensure timing mark on crankshaft pulley aligns
with O timing mark on timing belt cover. Remove timing
Ensure locating dowel on camshaft sprocket is at 12 oclock
position and timing mark is aligned with cylinder head sur-
face. See Fig. 2. Courtesy of General Motors Corp.
Raise and support vehicle. Remove right side undercover. Fig. 1: Timing Belt Components
Remove crankshaft pulley-to-sprocket bolts. See Fig. 1.
Lower vehicle. Ensure timing mark (notch) on rear of crank-
shaft sprocket is aligned with timing mark on oil pump. See
Fig. 4. Loosen belt tensioner bolt 1/2 turn. Rotate belt
tensioner and remove timing belt.
Inspection:
Inspect timing belt for damaged teeth, cracking or oil con-
tamination. Ensure belt tensioner bearing rotates freely.
Replace components if damaged.
NOTE: Revised timing belt tensioning procedure is from GEO

technical service bulletin 91-487-6A; February 26, 1992.
Installation:
Rotate camshaft so locating dowel on camshaft sprocket
is at 12 oclock position and timing mark aligns with cylin-
der head surface. See Fig. 2. Courtesy of General Motors Corp.
Ensure timing mark (notch) on rear of crankshaft sprocket Fig. 2: Aligning Camshaft Sprocket Timing Marks
aligns with timing mark on oil pump. See Fig. 4. Install
timing belt over crankshaft sprocket, tensioner pulley, wa-
ter pump and camshaft sprocket. Loosen belt tensioner pulley bolt. Insert a hex key wrench
Insert a hex wrench into the tensioner pulley hexagonal into tensioner pulley hexagonal hole. Rotate the tensioner
hole. Rotate pulley counterclockwise to tension the belt. pulley counterclockwise to tension the timing belt. Tighten
Hold pulley stationary and temporarily tighten the tensioner tensioner pulley bolt to 37 ft. lbs. (50 N.m).
pulley bolt. Rotate crankshaft back to about 50 degrees BTDC and
Rotate crankshaft 2 revolutions counterclockwise and align back to TDC of No. 4 cylinder. Align crankshaft sprocket
crankshaft and camshaft timing marks. See Figs. 2 and 4. timing mark with mark on oil pump housing. Align cam-
shaft sprocket timing mark with upper surface of cylinder
head.
206 GEO
*1.6L 4-Cylinder Storm SOHC (Cont.)
Courtesy of General Motors Corp.
Fig. 4: Crankshaft Sprocket Timing Mark
Measure timing belt deflection by applying 22 lbs. (98 N) of

force to belt. See Fig. 5. Defection must be .63-.79 (16-20
mm). If deflection is not correct, retension timing belt. En-
sure camshaft sprocket is still aligned correctly.
Install timing belt cover. Install crankshaft pulley. Install
engine undercover. Install right engine mount.
Install accessory drive belts. Adjust drive belts to proper
TORQUE SPECIFICATIONS Courtesy of General Motors Corp.

Crankshaft Pulley-To-Sprocket Bolt ................................ 17 (23) Fig. 5: Tensioning Timing Belt
Crankshaft Sprocket Center Bolt ............................... 87 (118)
Engine Mount
Right Bracket Bolt ..................................................... 29 (39)
Right Through-Bolt ................................................... 50 (68)
Timing Belt Tensioner Pulley Bolt ................................... 37 (50)
Water Pump Bolt ............................................................ 18 (25)
Wheel Lug Nut .......................................................... 87 (118)
INCH Lbs. (N.m)
Crankshaft Pulley-To-Flange Bolt ............................... 89 (10)
Valve Cover Bolt .......................................................... 89 (10)
GEO 207
*1.6L & 1.8L 4-Cylinder DOHC, Prizm

TIMING BELT APPLICATION CAUTION: If timing belt is to be reused, mark direction of timing
Belt belt rotation and place reference marks on timing belt and sprockets
for installation reference.
Application Time Kit No. No. Remove timing belt tensioner bolt, tensioner and tensioner
1.6L 4-Cyl. DOHC, VIN 6 spring. Remove timing belt.
Prizm (Except GSI) Inspection:
1989-97 .......... 1 2.2 Hrs. .... TCK236 .......... T236 Inspect timing belt for damaged teeth or cracking. Ensure
timing belt is not contaminated with oil. Check tensioner
1.8L 4-Cyl. DOHC, VIN 8 pulley for rotation freedom or grease leaks. Replace com-
Prizm (Except GSI) ponents if damaged.
1993-97 .......... 1 2.2 Hrs. .............................. T235 Check free length of idler pulley spring. Free length is mea-
sured between inside edge of hooked portions of spring
1
- With Air Cond. add .4 hours. (not the coil area). See Fig. 4. Replace spring if free length
With Pwr. Strng. add .4 hours. is not as specified. See TENSIONER SPRING FREE
LENGTH.
NOTE: A timing belt component kit is available for TENSIONER SPRING FREE LENGTH
this application. See page I for information on component Maximum Free Length
kits. Year In. (mm)
1989-92 .................................................................. 1.512 (38.4)
MANUFACTURERS SUGGESTED 1993-94 .................................................................. 1.390 (35.3)
1995-97 .................................................................. 1.453 (36.9)
The manufacturer recommends the belt be inspected and Installation:
adjusted at 30,000 mile intervals, and replaced at 60,000 mile Ensure all timing marks are still aligned. See Fig. 3. Install
intervals. timing belt tensioner and spring. Move tensioner to the left
and temporarily tighten bolt.
*NOTE: This application is an interference engine. Install timing belt. If old timing belt is reused, ensure belt is
installed in original rotating direction. Ensure marks on
See page A-59 for interference engine cautions. belt align with camshaft and crankshaft sprockets.
Loosen timing belt tensioner bolt and allow tension to be
REMOVAL & INSTALLATION applied on timing belt. Rotate crankshaft CLOCKWISE 2
revolutions. DO NOT turn crankshaft counterclockwise. En-
TIMING BELT sure all timing marks are aligned. Tighten timing belt
Removal: tensioner bolts to specification. See TORQUE SPECIFICA-
Disconnect negative battery cable. Remove windshield TIONS.
washer reservoir.
On vehicles equipped with cruise control, remove cruise
control actuator cover. Disconnect cruise control electrical
connector and actuator cable. Remove cruise control ac-
tuator from vehicle.
On all vehicles, raise and support vehicle. Remove right
front wheel. Remove right wheel housing. Loosen, but do
not remove, water pump pulley bolts.
Lower vehicle. Remove accessory drive belts. Disconnect
A/C compressor electrical connector. Remove A/C com-
pressor mounting bolts. Set compressor aside with hoses
attached. Remove mounting bracket from engine.
Remove wiring harness from valve cover. Noting position
for reassembly reference, remove spark plug secondary
cables from spark plugs. Remove spark plugs.
Remove PCV valve from valve cover. Remove valve cover.
Turn crankshaft so that 0 mark on crankshaft pulley aligns
with mark on timing case cover. Ensure No. 1 piston is at
TDC of compression stroke. If not, turn crankshaft one full
revolution.
Using Support Fixture (J028467-A) or equivalent, support
engine from above. Remove engine mount from timing belt
end of engine. Remove water pump pulley.
Remove crankshaft pulley. Remove timing belt covers. Not-
ing installed position, remove timing belt guide from crank-
shaft. Courtesy of General Motors Corp.
208 GEO
*1.6L & 1.8L 4-Cylinder DOHC, Prizm (Cont.)
Fig. 2: Aligning Timing Marks & Checking Belt Deflection
Measure timing belt deflection at midway point between

camshaft and crankshaft sprockets. See Fig. 2. With 4.4
Ibs. (1.9 kg) applied on timing belt, defection should be
.20-.24" (5.1-6.9 mm). If belt deflection is not within specifi-
cation, repeat previous step.
CAUTION: Ensure all timing marks are aligned once timing belt
is adjusted.
Install timing belt guide with cupped side facing out. Install
timing belt covers, starting with bottom cover. Install crank-
shaft pulley. Tighten center bolt to specification.
Install water pump pulley. Install engine mount. Install en- Courtesy of General Motors Corp.
gine ground wire (if equipped) to right fender apron. Install Fig 3: Aligning Camshaft & Crankshaft Timing Marks
valve cover with new gasket. Install spark plugs and spark
plug secondary wires.
Install PCV valve and wiring harness on valve cover. Install
A/C compressor mounting bracket (if removed). Install A/C
compressor to bracket. Install accessory drive belts.
Install cruise control actuator (if equipped). Install wind-
shield washer reservoir. To install remaining components,
reverse removal procedure. Adjust accessory drive belts to
Application Ft. Lbs. (N.m) Courtesy of General Motors Corp.
A/C Compressor Bracket-To-Engine Bolt ................... 35 (47) Fig. 4: Checking Timing Belt Tensioner Spring Free Length
A/C Compressor-To-Bracket Bolt ............................... 18 (25)
Timing Belt Tensioner Bolt ............................................. 27 (37)
Water Pump Bolt ........................................................ 11 (15)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Valve Cover Cap Nuts ................................................... 53 (6)
GEO 209
1.6L & 1.8L 4-Cylinder DOHC, Storm

TIMING BELT APPLICATION Loosen belt tensioner bolt to allow tension to be applied
on timing belt. Rotate crankshaft clockwise 2 revolutions.
Application Labor Time Belt Part No. Ensure all timing marks are still aligned. Tighten timing
1.6L 4-Cyl. DOHC belt tensioner pulley bolt to specification. See TORQUE
Storm SPECIFICATIONS.
1990-91 ................ 1 2.0 Hours .................... T169 Install lower timing belt cover. Install engine mount bracket
1.8L 4-Cyl. DOHC on engine. Install crankshaft pulley and tighten center bolt
to specification. Install upper timing belt cover. Install en-
Asuna Sunfire (Canadian) gine mount.
1993 ..................... 1 2.4 Hours .................... T205 To install remaining components, reverse removal proce-
Storm dure. Adjust drive belts to proper tension. See page A-60
1992-93 ................ 1 2.4 Hours .................... T205 for belt tension ranges.
1
- With Air Cond. add .4 hours. TORQUE SPECIFICATIONS
With Pwr. Strng. add .3 hours. Application Ft. Lbs. (N.m)
MANUFACTURERS SUGGESTED Crankshaft Pulley Center Bolt
SCHEDULED MAINTENANCE 1.6L ............................................................................ 87 (118)
1.8L .......................................................................... 108 (147)
The manufacturer recommends the belt be replaced at 60,000 Engine Mount Bracket-To-Engine Bolt ............................ 37 (50)
mile intervals. Engine Mount Through-Bolt ............................................ 50 (68)
Power Steering Pump Mounting Bolt .............................. 15 (20)
REMOVAL & INSTALLATION Serpentine Drive Belt Tensioner Bolt ............................. 30 (40)
Timing Belt Tensioner Pulley Bolt ................................... 31 (42)
TIMING BELT Water Pump Bolt
Removal: 1.6L .............................................................................. 11 (15)
Disconnect negative battery cable. Remove accessory drive 1.8L .............................................................................. 18 (24)
belts or serpentine belt. Raise and support vehicle. Re- Wheel Lug Nut .......................................................... 87 (118)
move right splash shield. INCH Lbs. (N.m)
Rotate crankshaft so that No. 1 cylinder is at TDC of com- Timing Belt Cover Bolt .................................................... 89 (10)
pression stroke. Remove crankshaft pulley.
Lower vehicle. Support weight of engine from above or with
floor jack. Remove engine mount from timing belt end of
engine. Remove timing belt upper cover. On 1.6L engine,
remove timing belt lower cover.
On 1.8L engine, remove serpentine drive belt idler pulley.
Remove exhaust heat shield. Remove power steering
pump mounting bolts. Move pump forward to gain access
to serpentine drive belt tensioner. Remove serpentine drive
belt tensioner from mounting bracket.
On 1.6L and 1.8L engines, remove engine mount bracket
from timing belt end of engine. Remove timing belt lower
cover.
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:
Ensure all timing marks are aligned. See Fig. 1. Install
timing belt. If reusing old timing belt, ensure belt is in-
stalled in original rotating direction.
Install timing belt on crankshaft pulley, then water pump
pulley, timing belt idler pulley, exhaust camshaft sprocket,
intake camshaft sprocket and timing belt tensioner pulley. Courtesy of General Motors Corp.
See Fig. 2. Fig. 1: Aligning Camshaft & Crankshaft Timing Marks
210 GEO
1.6L & 1.8L 4-Cylinder DOHC, Storm (Cont.)
Fig. 2: Timing Belt Installation

GEO/CHEVROLET 211
1.0L 3-Cylinder
Belt tamination. Ensure tensioner rotates freely. Replace dam-
Labor Component Part aged components.
1.0L 3-Cyl. CAUTION: Ensure concave side of timing belt guide faces oil
pump. Flat side of timing belt guide goes against crankshaft
Firefly (Canadian) sprocket.
1985-88 .......... 1 2.2 Hrs. .............................. T095
1989-91 .......... 1 2.2 Hrs. .............................. T166 CAUTION: Ensure tensioner plate moves when tensioner is moved
1994-95 .......... 1 2.2 Hrs. .............................. T241 toward timing belt. If tensioner plate does not move, ensure lug
1996-00 .......... 1 1.8 Hrs. .... TCK194A ........ T194 is engaged in hole on tensioner.
Metro
Installation:
1989-92 .......... 1 2.2 Hrs. .............................. T166 If tensioner was removed, install tensioner plate on
1993 ............... 1 2.2 Hrs. ............................ 2 T166 tensioner. Ensure tensioner plate lug engages hole on rear
1993 ............... 1 2.2 Hrs. ............................ 3 T241 of tensioner. Install tensioner assembly on cylinder block.
1994-95 .......... 1 2.2 Hrs. .............................. T241 Tighten tensioner bolt finger tight to allow movement of
1996-97 .......... 1 2.2 Hrs. .... TCK194A ........ T194 tensioner.
1996-00 .......... 1 1.8 Hrs. .... TCK194A ........ T194 Ensure all timing marks align. See Fig. 2 or 5. If timing
marks are not aligned, rotate camshaft or crankshaft to
Sprint (Includes Canadian) align timing marks. DO NOT rotate camshaft or crankshaft
1985-88 .......... 1 2.2 Hrs. .............................. T095 so timing mark moves more than 90 degrees or engine
1989-91 .......... 1 2.2 Hrs. .............................. T166 damage may occur. See Fig. 3.
1
- With Air Cond. add .4 hours. CAUTION: Install timing belt so arrow on timing belt, or mark
2
Four bolt sprocket. made during removal, points in direction of crankshaft rotation.
3
Five bolt sprocket. Crankshaft rotates clockwise.
NOTE: A timing belt component kit is available for Install tensioner spring and spring damper, push tensioner
plate upward and tighten tensioner bolt. Install timing belt
this application. See page I for information on component so arrow on timing belt, or mark made during removal,
kits. points in direction of crankshaft rotation. Ensure no slack
exists on drive side of timing belt. Loosen tensioner bolt
MANUFACTURERS SUGGESTED and allow spring tension to remove slack in timing belt.
Tighten tensioner bolt.
belt be replaced at 60,000 mile intervals. For 1998-00 model
years, the manufacturer recommends the belt be inspected at
60,000 miles and replaced at 100,000 miles.

TIMING BELT
Removal:
Disconnect negative battery cable. Remove air cleaner. Re-
move A/C suction pipe bracket (if equipped). Raise and
support vehicle. Remove lower right engine undercover.
Remove lower generator cover plate. Remove all acces-
sory drive belts.
Remove outer bolts retaining crankshaft pulley. Remove
crankshaft pulley. DO NOT remove crankshaft pulley center
bolt. Remove wire harness from timing belt cover.
Remove timing belt cover and seal. See Fig. 1 or 4. Rotate
crankshaft and align timing marks. See Fig. 2 or 5. Remove
tensioner spring and tensioner stud. Loosen, but DO NOT
remove, tensioner bolt.
If reusing timing belt, mark rotation direction. Remove belt
tensioner, tensioner plate, tensioner spring, spring damper
and timing belt.
CAUTION: DO NOT rotate crankshaft or camshaft when timing

belt is removed or piston damage may result. Note direction of
timing belt guide for installation. Ensure concave side of timing Courtesy of General Motors Corp.
belt guide faces away from timing belt.
212 GEO/CHEVROLET
Fig. 2: Aligning Timing Marks (1985-97)
Fig. 3: Rotating Camshaft & Crankshaft

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 Courtesy of General Motors Corp.
timing marks are aligned. To install remaining components, Fig. 5: Aligning Timing Marks (1998-00)
reverse removal procedure. Adjust drive belts to proper ten-
A/C Compressor Mounting Bolt
12 mm ...................................................................... 21 (29)
14 mm ........................................................................ 33 (45)
Crankshaft Pulley-To-Crankshaft Bolt ......................... 12 (16)
Tensioner Bolt ............................................................ 20 (27)
INCH Lbs. (N.m)
Timing Belt Tensioner Stud ........................................ 97 (11)
Valve Cover Bolt ............................................................ 44 (5)
Water Pump Bolt (1998-00) .......................................... 115 (13)
Water Pump Bolt (1995-97) ......................................... 97 (11)
GEO/CHEVROLET 213
1.3L 4-Cylinder
TIMING BELT APPLICATION Turn crankshaft pulley bolt clockwise until punch mark on
sprocket aligns with arrow mark on oil pump case. See
Belt Fig. 3.
Labor Component Part Install timing belt on sprockets with drive-side of belt free of
Application Time Kit No. No. any slack when tensioner plate is pushed up with fingers.
1.3L 4-Cyl. Loosen tensioner bolt and allow tensioner to remove slack
Firefly (Canadian) in timing belt. Skip the next step to continue.
1995-97 .......... 1 2.6 Hrs. .............................. T272 NOTE: On 1998-01 models, camshaft sprocket is marked with
1998-00 .......... 1 2.6 Hrs. .... TCK194A ........ T194 a raised E for a timing mark.
Metro
1992-93 .......... 1 2.6 Hrs. .............................. T095
On 1998-01 models, ensure camshaft and crankshaft tim-
ing marks are still aligned. See Fig. 6. If timing marks are
1994 ............... 1 2.6 Hrs. .............................. T243 not aligned, rotate camshaft or crankshaft to align timing
1995-97 .......... 1 2.6 Hrs. .............................. T272 marks. DO NOT rotate camshaft or crankshaft more than
1998-01 .......... 1 2.6 Hrs. .... TCK194A ........ T194 90 degrees or engine damage may result. Install timing
belt. Ensure no slack exists on drive-side of timing belt.
1
- With Air Cond. add .4 hours. Loosen tensioner bolt and allow tensioner to remove slack
in timing belt. Go to next step.
NOTE: A timing belt component kit is available for Turn crankshaft 2 rotations clockwise to take up slack. En-
sure timing marks are still aligned. Tighten tensioner ad-
this application. See page I for information on component justment stud nut and tensioner bolt. Ensure seal is be-
kits. tween water pump and oil pump case. See Fig. 5. Install
timing belt outside cover.
belt be replaced at 60,000 mile intervals. For 1998-01 model
years, the manufacturer recommends the belt be inspected at
60,000 miles and replaced at 100,000 miles.

TIMING BELT
Removal:
hicle. Remove right side fender apron extension. Do not
push center pin in too far as it may fall into fender.
Remove alternator/water pump drive belt and water pump
pulley. Lock flywheel and loosen crankshaft pulley outer
bolts. See Figs. 1 and 2. It is NOT necessary to remove
crankshaft pulley center bolt. Remove crankshaft pulley.
Remove timing belt outside cover. Rotate crankshaft to align Fig. 1: Using Screwdriver To Lock Flywheel
camshaft and crankshaft timing marks. See Figs. 3 and 6.
Loosen tensioner bolt and stud. Push tensioner plate fully
upward and temporarily tighten tensioner bolt. Remove tim-
ing belt from sprockets.
Inspection:
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:
Ensure that tensioner rotates smoothly. Install tensioner
plate on tensioner. Lug of tensioner plate must fit in hole of
tensioner. Install tensioner assembly. Hand tighten
tensioner bolt. Plate movement in upward direction should
Fig. 2: Locking Flywheel In Position
cause tensioner to move in same direction.
On 1992-97 models only, remove air cleaner and valve cover,
then completely loosen all valve screws and lock nuts on
intake and exhaust rocker arms. Turn camshaft pulley clock-
wise until timing mark on pulley aligns with V mark on belt
inside cover. See Fig. 3.
214 GEO/CHEVROLET
Fig. 4: Adjusting Valve Lash

Fig. 3: Identifying Timing Marks (Up To 1997)
Fig. 5: Locating Oil Case Seal
On 1992-97 models, rotate crankshaft to position camshaft
lobe and rocker arm to adjust valve lash. See Fig. 4. En-
sure clearance is .010" ( .25 mm) at intake valves and .011"
(.28 mm) at exhaust valves. To adjust clearance, turn ad-
justing screw until correct clearance is obtained. Tighten
lock nut to 11-13.5 ft. lbs. (15-18 N.m).
On all models, to complete installation, reverse removal
procedure. Adjust drive belts to proper tension. See page
Crankshaft Pulley Bolt (1998-01) ................................ 12 (16)
Crankshaft Sprocket Bolt (1992-97) ......................... 79 (110)
Crankshaft Sprocket Bolt (1998-01) ......................... 96 (130)
Valve Adjustment Lock Nut ................................ 11-13 (15-18)
INCH Lbs. (N.m)
Crankshaft Pulley Bolt (1992-97) ................................ 97 (11)
Tensioner Stud ........................................................... 97 (11)
Timing Belt Cover Nut/Bolts ....................................... 97 (11)
Valve Cover Nuts .......................................................... 44 (5)
Fig. 6: Identifying Timing Marks (1998-01)

GEO/CHEVROLET 215
1.6L 4-Cylinder Tracker, 8-Valve

TIMING BELT APPLICATION Install tensioner spring to tensioner plate and tensioner
screw. Finger tighten tensioner stud. Rotate crankshaft 2
Application Labor Time Belt Part No. revolutions clockwise to ensure all slack is removed from
1.6L 4-Cyl. SOHC, VIN U timing belt.
Tracker & Sunrunner (Asuna & Pontiac, Canada) Ensure camshaft and crankshaft timing marks are still
1989-95 ................ 1 3.6 Hours .................. 2 T164 aligned. Tighten tensioner stud to specification. Tighten
1989-95 ................ 1 3.6 Hours .................. 3 T212 tensioner bolt to specification. See TORQUE SPECIFICA-
TIONS. Ensure all timing marks align.
1
- With Air Cond. add .4 hours. Adjust valve lash between rocker arm adjusting screw and
2
Except California. valve stem. See VALVE LASH SPECIFICATIONS. Turn crank-
3
California. shaft so No. 1 piston is at TDC of compression stroke.
Ensure camshaft timing mark is aligned with V timing
mark on rear timing belt cover.
MANUFACTURERS SUGGESTED Adjust valve lash on No. 1 and No. 2 intake valves. Adjust
SCHEDULED MAINTENANCE valve lash on No. 1 and No. 3 exhaust valves. Rotate crank-
Although the manufacturer does not recommend a specific shaft one full revolution (360 degrees). Adjust remaining
scheduled maintenance interval, belt manufacturers suggest intake and exhaust valves.
the belt be replaced at 60,000 mile intervals. Install timing belt cover. Install crankshaft pulley. To com-
plete installation, reverse removal procedures. Adjust drive
REMOVAL & INSTALLATION belts to proper tension. See page A-60 for belt tension
ranges.
TIMING BELT VALVE LASH SPECIFICATIONS
Removal:
Clearance Clearance
Disconnect negative battery cable. Remove accessory drive Valve Cold, In. (mm) Hot, In. (mm)
belts. Remove cooling fan, fan shroud and water pump
Intake ................... .051-.067 (.13-.17) ......... .009-.011 (.23-.27)
pulley. Remove outer bolts retaining crankshaft pulley.
Exhaust .............. .0063-.0075 (.15-.19) .. .0102-.0114 (.25-.29)
Remove 5 crankshaft pulley-to-sprocket bolts. Remove
crankshaft pulley. DO NOT remove center bolt from crank-
shaft pulley. The center bolt holds crankshaft sprocket to
crankshaft.
Remove timing belt cover and seal. See Fig. 1. Loosen
tensioner stud and remove tensioner spring from tensioner
plate and tensioner screw.
If reusing timing belt, mark timing belt with arrow to indi-
cate rotation direction. Remove timing belt.
Inspection:
Inspect timing belt for damaged teeth or cracking. Ensure
for freedom of rotation. Replace components if damaged.
Installation:
If tensioner was removed, install tensioner plate on
tensioner. Ensure lug of tensioner plate engages in hole
on rear of tensioner. Install tensioner, tensioner plate and
tensioner spring on engine block. Tighten tensioner bolt
finger tight to allow movement of tensioner.
CAUTION: Ensure tensioner plate moves when tensioner is moved

toward timing belt. If tensioner plate does not move, ensure lug
engages in tensioner bolt.
Remove valve cover. Loosen all valve adjusting screws fully
before installing timing belt. Ensure camshaft rotates freely
during belt tension adjustment. Rotate camshaft clockwise,
and align timing mark on camshaft sprocket with V timing
mark on timing belt inside cover. See Fig. 3.
Rotate crankshaft clockwise, and align timing mark on crank-
shaft sprocket with timing mark on oil pump housing. See
Fig. 3. Install timing belt on engine. If installing old belt,
ensure arrow on timing belt aligns with direction of crank-
shaft rotation. Ensure no slack exists on side of timing belt Fig. 1: Exploded View Of Timing Belt & Components
opposite tensioner.
216 GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 8-Valve (Cont.)
Fig. 2: Locking Camshaft During Sprocket Removal

A/C Compressor
8 mm Bolt ................................................................. 21 (29)
10 mm Bolt ............................................................... 33 (45)
Crankshaft Pulley-To-Sprocket Bolts .......................... 12 (16)
Power Steering Pump Mounting Bolt .......................... 21 (29)
Valve Adjusting Screw Locknut ....................................... 13 (17) Fig. 3: Aligning Timing Marks
INCH Lbs. (N.m)
Fan Clutch Nuts ......................................................... 97 (11)
Tensioner Stud ........................................................... 97 (11)
Valve Cover Bolt ............................................................ 44 (5)
Water Pump Bolt ...................................................... 106 (12)
GEO/CHEVROLET 217
1.6L 4-Cylinder Tracker, 16-Valve

If tensioner was removed, install tensioner plate, spring,
Application Labor Time Belt Part No. and tensioner pulley on engine. Tighten tensioner bolt and
1.6L 4-Cyl. SOHC, VIN 6 stud nut finger tight to allow movement of tensioner.
Tracker & Sunrunner (Canadian) Ensure camshaft and crankshaft timing marks are still
1994-98 ................ 1 4.0 Hours .................. 2 T164 aligned. Install timing belt. If reusing old belt, ensure it is
1994-98 ................ 1 4.0 Hours .................. 3 T212 installed in original rotation direction.
1999-01 ................ 1 4.0 Hours ................... T212 Loosen timing belt tensioner bolt and nut so it places ten-
sion on belt. Rotate crankshaft clockwise 2 revolutions.
1
- With Air Cond. add .4 hours. Ensure timing marks still align. See Fig. 2.
2
Except California. Tighten tensioner stud nut and tensioner pulley bolt to speci-
3
California. fication. See TORQUE SPECIFICATIONS. Install timing belt
cover.
To complete installation, reverse removal procedures. Ad-
MANUFACTURERS SUGGESTED just drive belts to proper tension. See page A-60 for belt
SCHEDULED MAINTENANCE tension ranges. If cooling system was drained, refill and
bleed air from system.
mile intervals. TORQUE SPECIFICATIONS
REMOVAL & INSTALLATION Camshaft Sprocket Bolt .............................................. 44 (60)
TIMING BELT Crankshaft Pulley Center Bolt ..................................... 81 (110)
Crankshaft Pulley-To-Crankshaft Bolt ......................... 12 (16)
Removal: Front Skid Plate Bolt ...................................................... 40 (55)
Disconnect negative battery cable. Remove cooling fan nuts Power Steering Pump Mounting Bolt .......................... 21 (29)
and fan shroud fasterners. Remove accessory drive belts. Timing Belt Tensioner Pulley Bolt ............................... 20 (27)
Raise and support vehicle. Remove front skid plate (if INCH Lbs. (N.m)
equipped). Remove 2 lower radiator shroud bolts. Remove Cooling Fan-To-Pulley Nut .......................................... 97 (11)
5 outer bolts retaining crankshaft pulley to crankshaft. Re- Timing Belt Cover Bolt .................................................. 89 (10)
move crankshaft pulley. DO NOT remove center bolt from Timing Belt Tensioner Stud Nut ................................... 97 (11)
crankshaft pulley. The center bolt holds crankshaft sprocket
to crankshaft.
Lower vehicle. On models with air conditioning, remove A/
C suction line bracket bolts from radiator support. On all
models, remove upper radiator shroud bolts and remove
radiator shroud with cooling fan and water pump pulley.
NOTE: It may be necessary to drain cooling system and disconnect

upper radiator hose to remove fan shroud.
Disconnect wiring harness from timing belt cover. Remove
timing belt cover. See Fig. 1.
Rotate crankshaft clockwise to align crankshaft and cam-
shaft timing marks. Stamped E on camshaft sprocket must
face up and align with mark on rear cover. See Fig. 2.
Loosen timing belt tensioner pulley center bolt and stud
nut. Remove tensioner spring. Push tensioner plate up-
ward to relieve tension on timing belt.
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
for freedom of rotation. Replace components if damaged.

218 GEO/CHEVROLET
1.6L 4-Cylinder Tracker, 16-Valve (Cont.)
Fig. 3: Timing Belt Tensioner Assembly

GEO & ISUZU 219
*1.5L 4-Cylinder
TIMING BELT APPLICATION Check timing marks. Loosen tensioner bolt and remove
slack from timing belt. There must be no slack in the belt
Belt Part No. after it has been installed.
1.5L 4-Cyl. To complete installation, reverse removal procedure. Ad-
I-Mark just drive belts to proper tension. See page A-60 for belt
1985-87 tension ranges.
Thru 6/30/86 ....... 1.5 Hours ..................... T118 TORQUE SPECIFICATIONS
From 7/1/86 ......... 1.5 Hours ..................... T162 Application Ft. Lbs. (N.m)
1988-89 ................. 1.5 Hours ..................... T162 Crankshaft Pulley Bolt ............................................ 108 (147)
Spectrum (Chevrolet & Geo) Timing Belt Tensioner Bolt ......................................... 37 (50)
1985-87 Water Pump Bolts ...................................................... 17 (24)
Thru 4/30/87 ....... 1.5 Hours ..................... T118 INCH Lbs. (N.m)
From 5/1/87 ........ 1.5 Hours ..................... T162 Timing Cover Bolts ..................................................... 86 (10)
1988-89 ................. 1.5 Hours ..................... T162
Sunburst (Canada)
1985-88 ................. 1.5 Hours ..................... T118
1
60,000 miles.


TIMING BELT & SPROCKETS
Removal:
Disconnect negative battery cable. Drain cooling system.
Place small piece of wood on jack under oil pan and care-
fully raise motor. Remove rear side torque rod and right
engine mount. Remove body side and engine side mounts.
Remove drive belts, crank pulley and timing belt cover. En- Fig. 1: Crankshaft Sprocket Timing Marks
sure timing marks are aligned with TDC. Use Crank Holder
(J-37376) or equivalent, to remove timing belt crankshaft
pulley. Confirm crankshaft is at TDC before removing belt.
See Fig. 1. Rotate crankshaft so camshaft pulley dowel is at
12 oclock and alignment mark aligns with edge of cylinder
head. See Fig. 2.
NOTE: The rear of timing belt crankshaft pulley has a small indent
which aligns with small triangle on engine block at 12 oclock.
Loosen belt tensioner attaching bolt. Insert Allen wrench
into pulley tensioner attaching bolt. Loosen timing belt
tensioner by rotating pulley clockwise. Remove timing belt.
Installation:
Ensure camshaft pulley mark is aligned with upper surface
of head and dowel pin is at 12 oclock position. Ensure
Woodruff key of crankshaft is in 12 oclock position. Install
timing belt. Tighten tensioner bolt, and rotate crankshaft 2
revolutions.

220 GEO & ISUZU

GENERAL MOTORS 221

TIMING BELT APPLICATION TIMING BELT ADJUSTMENT SPECIFICATIONS
Belt Part No. Belt Size Operating Range Specification
1.4L 4-Cyl. 3/4" (19 mm) ......... 50-80 Ibs. .......................... 63-77 Ibs.
Acadian, Chevette (110-176 kg) (140-160 kg)
1976 ...................... 1.4 Hours ..................... T037
1977 ...................... 1.4 Hours ..................... T039
1.6L 4-Cyl.
Acadian, Chevette, T-1000, 1000
1976 ...................... 1.4 Hours ..................... T037
1977-78 ................. 1.4 Hours ..................... T039
1979-87 ................. 1.4 Hours ..................... T061
1

TIMING BELT
Removal:
Disconnect negative battery cable. Remove radiator upper
mounting panel. On A/C equipped vehicles, remove upper
half of fan shroud. Remove drive belts and engine fan. Re-
move front cover retaining screws and nuts. Remove cover.
Rotate crankshaft until timing mark on pulley is at zero de-
grees (No. 1 cylinder at TDC). Remove A/C compressor
and brackets if necessary.
Insert 1/8" drill bit or rod through hole in upper rear cover
and through hole in camshaft drive sprocket. This is pro-
vided to verify camshaft timing. Remove timing belt front Fig. 1: Sprocket Timing Marks
and lower cover. Loosen idler pulley and allow pulley to
rotate clockwise. See Fig. 2. Remove timing belt from sprock- TORQUE SPECIFICATIONS
ets.
Installation: Application Ft. Lbs. (N.m)
With No. 1 piston at TDC, install belt on sprockets and use 1/ Camshaft Sprocket Bolts .......................................... 75 (101)
4" Allen wrench to move idler pulley counterclockwise until all Crankshaft Pulley Bolt ............................................ 100 (135)
slack is removed from belt. Tighten idler pulley bolt. Rotate Idler Pulley Bolts ......................................................... 15 (20)
crankshaft clockwise a minimum of one revolution. Stop with Water Pump Bolts ...................................................... 15 (20)
No. 1 piston at TDC. DO NOT let timing belt back up. INCH Lbs. (N.m)
Use belt tension gauge between camshaft sprocket and Front Cover (Nuts & Bolts) ............................................ 70 (8)
idler pulley. See Fig. 3. Be sure gauge finger is engaged in
slot between teeth of timing belt. Use 1/4" Allen wrench on
idler pulley to obtain correct tension. Reverse removal pro-
cedure to complete installation. Adjust drive belts to proper
222 GENERAL MOTORS
Fig. 2: Timing Belt Idler Pulley Courtesy of General Motors Corp.

GENERAL MOTORS 223
*1.6L 4-Cylinder LeMans

1.6L 4-Cyl.
Le Mans
1988-89 ................. 2.0 Hours ..................... T148
1990
With Tensioner
Pulley................. 2.0 Hours ..................... T203
Without Tensioner
Pulley................. 2.0 Hours ..................... T148
1991-93 ................. 2.0 Hours ..................... T203
1
*NOTE: For 1990-93 models, this application is an

interference engine. See page A-59 for interference
engine cautions.

TIMING BELT
Removal:
drive belts. Remove power steering pump and lines. Re-
move crankshaft pulley. Remove timing belt covers starting
with upper cover.
Rotate engine to align timing marks on crankshaft and cam-
shaft sprockets with reference mark on lower timing belt
cover. See Fig. 1. Loosen water pump bolt to release belt
tension. Remove timing belt.
CAUTION: Rotate engine and align reference mark on crankshaft

and camshaft sprockets with reference mark on lower timing
belt cover before removing belt. Use proper reference mark. Reference
marks may be difficult to locate.
Installation:
Install timing belt. Align all timing marks. Carefully rotate
water pump to remove slack from timing belt. Tighten water
pump bolts.
Using Belt Tension Gauge (J-26486-B) or equivalent, mea-
sure belt tension between water pump and camshaft
sprocket. Adjust belt tension to 35 Ibs. (16 kg). To install
remaining components, reverse removal procedure.
INCH Lbs. (N.m)
Timing Belt Cover Bolt (Front & Rear) ......................... 88 (10)
Water Pump Bolt .......................................................... 71 (8)

Fig. 1: Timing Belt & Pulley Alignment
224 GENERAL MOTORS
1.6L 4-Cylinder Nova
Belt
1.6L 4-Cyl.
Nova
SOHC
1985-88 ........ 3.1 Hours .. TCK070 ........... T070
DOHC
1988 ............. 3.1 Hours ............................. T112
1
With Cruise Control add .2 hours.

kits.

TIMING BELT
Removal:
Disconnect negative battery cable. Drain cooling system. Re-
move fan shroud on models with power steering. On models
with air conditioning, loosen idler pulley nut, adjusting bolt and
remove drive belt. On DOHC models, raise and support vehicle
and remove right front wheel and right side engine undercover.
Remove radiator and air cleaner assembly. If equipped with cruise Fig. 2: Timing Belt & Pulley Alignment
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).
Fig. 1: Camshaft Sprocket Alignment (DOHC) Fig. 3: Timing Belt Deflection Points
GENERAL MOTORS 225
1.6L 4-Cylinder Nova (Cont.)

Using puller, remove crankshaft pulley. Remove upper and If installing new belt, align camshaft(s) timing marks and
lower engine front cover mount bolts, gasket and covers. crankshaft timing marks. See Fig. 1 and Fig. 2. Install tim-
Mark timing belt location. Loosen idler pulley mount bolt, ing belt. Release idler pulley and place tension on belt.
position pulley at far left and retighten mount bolt. Remove After installing new or used belt, slowly turn crankshaft 2
timing belt. revolutions clockwise. Recheck timing marks. Adjust belt
Installation: tension and deflection. See Fig. 3. Belt tension should be
Loosen timing belt idler pulley mount bolt, move pulley as 4.4 Ibs. (2 kg), with a deflection of .24-.28" (6-7 mm) on 8-
far left as possible and retighten bolt. If reusing old belt, valve engines and .16" (4 mm) on 16-valve engines. To
align marks made during removal. Install belt with arrow complete installation, reverse removal procedure. Adjust
pointing in direction of rotation. DO NOT bend or twist belt. drive belts to proper tension. See page A-60 for belt tension
Release idler pulley and place tension on belt. ranges.
8-Valve .................................................................... 87 (117)
16-Valve ................................................................ 137 (186)
Timing Belt Idler Mount Bolt .............................. 26-36 (36-49)
226 GENERAL MOTORS
TIMING BELT APPLICATION Remove damper pulley and install belt holder in position away
from timing bolt. Install by-pass hose, dust covers, and damper
Belt Part No. pulley. Install cooling fan, belt and pulley. Install fan shroud.
1.8L 4-Cyl. Diesel Refill system with coolant and connect battery. Adjust drive
Acadian (Canadian) belts to proper tension. See page A-60 for belt tension ranges.
1981-85 ................. 3.1 Hours ..................... T076 TORQUE SPECIFICATIONS
Chevette Application Ft. Lbs. (N.m)
1981-86 ................. 3.1 Hours ..................... T076 Camshaft Pulley Bolt .................................................. 55 (75)
1
- With Air Cond. add .4 hours. Damper Pulley Bolt ..................................................... 12 (20)
With Pwr. Strng. add .4 hours. Tension Pulley
Center Bolt ................................................................ 54 (73)
Side Bolts ................................................................. 15 (20)
MANUFACTURERS SUGGESTED Water Pump Bolts ...................................................... 15 (20)


TIMING BELT
Removal:
Remove fan shroud, V-belt and pulley. Remove upper dust
cover. Disconnect by-pass hose.
With No. 1 piston at TDC of compression stroke, check that
timing mark on injection pump pulley is in alignment with
front plate pointer. Align injector gear by inserting 8 mm x 1.25
mm bolt through gear alignment hole and front flange plate.
See Fig. 1.
Remove valve cover. Attach Fixing Plate (J-29761) or equiva- 96E14856 Courtesy Of General Motors Corp.
lent, to slot in rear of camshaft. This will prevent camshaft Fig. 1: Injection Pump Alignment Marks & Lock Bolt
from rotating. Remove damper pulley and timing belt holder.
Recheck to be sure No. 1 cylinder is at TDC.
Remove lower dust cover and timing belt holder. Remove tension
spring from behind front plate, next to injection pump. Loosen
tension pulley and plate bolts. Remove timing belt.
Installation:
Remove bolt attaching camshaft gear. Using Gear Puller
(J-22888) or equivalent, remove cam gear. Reinstall cam
gear loosely so it can be turned by hand. Install timing belt
in proper sequence. See Fig. 2.
Belt should be properly tensioned between pulleys. Cogs
on belt and pulley should engage properly. Crankshaft
should not be turned. Concentrate belt looseness on ten-
sion pulley. Depress tension pulley with finger and install
tension spring.
Finger tighten tensioner bolts in sequence to prevent move-
ment of tensioner pulley. See Fig. 3. Tighten camshaft pulley
bolt. Remove injection pump gear lock bolt. Remove fixing Courtesy Of General Motors Corp.
plate on end of camshaft. Fig. 2: Timing Belt Installation Sequence
Install damper pulley on hub and check that No. 1 cylinder
is at TDC. DO NOT turn crankshaft if adjustment is needed.
Be sure mark on injection pump pulley aligns with mark on
plate. See Fig. 1. Fixing plate should fit smoothly into slot at
rear of camshaft. Remove fixing plate.
Loosen tensioner pulley and plate bolts. Concentrate belt loose-
ness on tensioner and tighten bolts in sequence. See Fig. 3. Belt
tension should be checked at point between camshaft gear
and injection pump gear using Belt Tension Gauge (J-29771)
or equivalent. Belt tension should be 46-63 lbs (20-28 kg).
GENERAL MOTORS 227
*1.8L 4-Cylinder Diesel (Cont)
Courtesy Of General Motors Corp.
Fig. 3: Locating/Tightening Tensioner Bolts

228 GENERAL MOTORS
1.8L 4-Cylinder
TIMING BELT APPLICATION If belt tension is incorrect, loosen water pump bolts and
rotate pump until correct tension is obtained. Hot timing
Belt Part No. belt tension specification is 30 lbs. (13 kg).
1.8L 4-Cyl. OHC DO NOT leave tension gauge on belt during retightening or
J2000, 2000, 2000 Sunbird reading will be inaccurate. Tighten water pump bolts. Re-
1982-84 ................. 2.7 Hours ..................... T081 verse removal procedure to complete installation. Adjust
Firenza drive belts to proper tension. See page A-60 for belt tension
ranges.
1982-86 ................. 2.7 Hours ..................... T081
Skyhawk TORQUE SPECIFICATIONS
1982-86 ................. 2.7 Hours ..................... T081 Application Ft. Lbs. (N.m)
Sunbird Camshaft Sprocket Bolt .............................................. 34 (45)
1985-86 ................. 2.7 Hours ..................... T081 Crankshaft Pulley-To-Sprocket Bolt ............................ 20 (27)
Crankshaft Sprocket Retaining Bolt ........................ 115 (156)
1
- With Air Cond. add .4 hours. Timing Belt Rear Cover Bolt ....................................... 19 (25)
With Pwr. Strng. add .4 hours. Water Pump Retaining Bolts ...................................... 19 (25)
INCH Lbs. (N.m)
MANUFACTURERS SUGGESTED Camshaft Thrust Plate Bolt .......................................... 72 (8)
SCHEDULED MAINTENANCE Timing Belt Front Cover Bolt ......................................... 60 (7)


TIMING BELT
Removal:
Disconnect negative battery cable. Remove belts, brackets
and shields necessary to gain access to crankshaft pulley.
Remove timing belt front cover.
Rotate crankshaft so timing mark on crankshaft pulley lines
up with 10 BTDC mark on indicator scale. Mark on cam-
shaft sprocket must align with mark on camshaft carrier.
Remove timing probe holder. Verify timing marks are aligned
and loosen water pump retaining bolts to remove timing
belt.
Installation:
Install new timing belt on sprockets. Install crankshaft pul-
ley and check for alignment of timing marks. Using Ad-
juster (J-33039) or equivalent , rotate water pump clock-
wise until slack is removed from timing belt. Tighten water
pump bolts. See Fig. 1.
NOTE: If new timing belt has been installed, check final ten-
sion with engine at operating temperature. If new head gasket
is installed, cylinder head must be retightened AFTER initial
warm up. Timing belt tension MUST then be rechecked.
Using Cam Drive Belt Tension Gauge (J-26486-A) or
equivalent, check belt tension between water pump and
camshaft sprocket. Initial new belt tension should be 38
lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16
kg). Fig. 1: Timing Belt Tension Adjustment
Reassemble components and run engine to operating tem-
perature (thermostat open). As new belt takes a set posi-
tion, substantial tension loss will occur. After belt has been
run, recheck tension with gauge on belt.
GENERAL MOTORS 229
2.0L 4-Cylinder
Belt
Application Time1 Kit No. No.
2.0L 4-Cyl. OHC
Firenza
1987-88 ............ 2.7 Hrs. .............................. T081
Grand Am
1987-88 ............ 2.7 Hrs. .............................. T081
1989 ................. 2.7 Hrs. ..... TCK163 ......... T163
Le Mans
1989
1st Design ..... 2.7 Hrs. .............................. T081
2nd Design ... 2.7 Hrs. ..... TCK163 ......... T163
1990 ................. 2.7 Hrs. ..... TCK163 ......... T163
Skyhawk
1987-88 ............ 2.7 Hrs. .............................. T081
Sunbird
1987-88 ............ 2.7 Hrs. .............................. T081
1989-94 ............ 2.7 Hrs. ..... TCK163 ......... T163
1

kits.
SCHEDULED MAINTENANCE Fig. 1: Timing Belt Tension Adjustment
Although the manufacturer does not recommend a specific Using Cam Drive Belt Tension Gauge (J-26486-A) or
scheduled maintenance interval, belt manufacturers suggest equivalent, check belt tension between water pump and
the belt be replaced at 60,000 mile intervals. camshaft sprocket. Initial new belt tension should be 38
lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16
REMOVAL & INSTALLATION kg).
TIMING BELT & SPROCKETS
Reassemble components and run engine to operating tem-
perature (thermostat open). As new belt takes a set posi-
Removal (1987-88): tion, substantial tension loss will occur. After belt has been
Disconnect negative battery cable. Remove belts, brackets run, recheck tension withgauge on belt.
and shields necessary to gain access to crankshaft pulley. If belt tension is incorrect, loosen water pump bolts and
Remove timing belt front cover. rotate pump until correct tension is obtained. Hot timing
Rotate crankshaft so timing mark on crankshaft pulley lines belt tension specification is 30 lbs. (13 kg).
up with 10 degrees BTDC mark on indicator scale. Mark on DO NOT leave tension gauge on belt during retightening or
camshaft sprocket must align with mark on camshaft car- reading will be inaccurate. Tighten water pump bolts. Re-
rier. Remove crankshaft pulley. verse removal procedure to complete installation. Adjust
Remove timing probe holder. Verify timing marks are aligned drive belts to proper tension. See page A-60 for belt tension
and loosen water pump retaining bolts to remove timing ranges.
belt. Removal (1989-94):
Installation (1987-88): Disconnect negative battery cable. Remove serpentine belt,
Install new timing belt on sprockets. Install crankshaft pulley brackets, and shields necessary to gain access to crank-
and check for alignment of timing marks. Using Adjuster (J- shaft pulley. Remove front timing belt cover. See Fig. 2.
33039) or equivalent, rotate water pump clockwise until slack Remove crankshaft pulley. Loosen water pump retaining
is removed from timing belt. Tighten water pump bolts. See bolts. Using Timing Belt Adjuster (J-33039-A) or equiva-
Fig. 1. lent, rotate water pump to release timing belt tension. Re-
move timing belt.
NOTE: If new timing belt has been installed, check final ten- Installation (1989-94):
sion with engine at operating temperature. If new head gasket
is installed, cylinder head must be retightened AFTER initial
To install camshaft and crankshaft sprockets (if removed),
reverse removal procedure. Tighten retaining bolts to speci-
warm up. Timing belt tension MUST then be rechecked.
fication. See TORQUE SPECIFICATIONS.
230 GENERAL MOTORS
Rotate crankshaft and camshaft clockwise to align timing
marks on sprockets with marks on rear cover. Install new
timing belt on sprockets. Ensure belt has tension on it be-
tween the camshaft sprocket and crankshaft sprocket.
NOTE: Adjust timing belt with engine coolant temperature at

68F (20C).
Using timing belt tension adjuster, rotate water pump clock-
wise until tensioner contacts the high torque stop. See Fig.
3. Slightly tighten water pump retaining bolts.
Using crankshaft sprocket bolt, rotate engine clockwise 2 revo-
lutions to fully seat timing belt. Rotate water pump eccentric
counterclockwise until hole in tensioner arm aligns with hole
in base.
Tighten water pump bolts to specification. See TORQUE
SPECIFICATIONS. Ensure tensioner holes remain in align-
ment as stated. Ensure all timing marks are properly
aligned. To install remaining components, reverse removal
procedure. Adjust drive belts to proper tension. See page
A-60 for belt tension ranges. Fig. 3: Timing Belt Tensioner (1989-94)
Camshaft Pulley-To-Sprocket Bolt
1987-88 .................................................................... 20 (27)
1989-92 .................................................................... 15 (20)
Serpentine Belt Tensioner Bolt ................................... 35 (47)
Water Pump Bolt ........................................................ 18 (24)
INCH Lbs. (N.m)
Camshaft Carrier Cover Bolt ...................................... 84 (10)

GENERAL MOTORS 231
*3.0L V6 DOHC, Catera

3.0L V6 DOHC
Catera
1997-01 ................. 2.6 Hours ..................... T285
The manufacturer recommends the belt be replaced at
100,000 mile intervals.
Using scan tool, check cold start counter (also called a heavy
duty register). If there were any cold starts below -20F (-28C),
visually inspect timing belt for cracks. If there are cracks
present, DO NOT reuse the belt. Replace belt. If belt is okay
and reused, DO NOT clear the cold start counter.


TIMING BELT Courtesy of General Motors Corp.
Precautions: Fig. 1: Timing Belt Front Cover

When servicing timing belt, always turn crankshaft in nor-
mal direction of rotation (clockwise).
Install timing belt with engine at room temperature.
Never remove timing belt without first setting camshaft gears
and crankshaft drive gear to TDC and locking them in place.
Guide marks on timing belt are to aid in timing belt installa-
tion. If guide marks cannot be identified, a new belt must
be installed.
Removal:
Disconnect negative battery cable. Remove air intake reso-
nator and ducting from throttle body.
Raise and support vehicle. Remove lower front splash
shield. Remove AIR injection crossover pipe clamps and
bushing nut from front cover. See Fig. 1. Separate air injec-
tion crossover pipe from hoses and front cover.
Lower vehicle. Remove air injection crossover pipe from
front cover.
Loosen, but do not remove water pump pulley bolts. Courtesy of General Motors Corp.
Loosen, but do not remove, power steering pump pulley Fig. 2: Positioning Crankshaft At 60 Degrees BTDC
bolts. Remove A/C compressor hose strap from AIR injec-
tion crossover bracket. Remove accessory drive serpen-
tine belt.
Release plastic retaining tabs, and remove wiring harness
channel cover from front of engine. Move wiring harness
out of way.
Remove water pump pulley bolts and pulley. Remove power
steering pump pulley bolts and pulley. Remove accessory
drive serpentine belt tensioner.
Remove front timing belt cover. Remove 6 harmonic bal-
ancer-to-crankshaft bolts. Remove harmonic balancer. It is
NOT necessary to remove crankshaft center bolt.
Rotate crankshaft clockwise to 60 degrees before TDC.
See Fig. 2. Ensure timing marks are not 180 degrees from
TDC.
Install Crankshaft Holder (J-42069-10) and rotate crank-
shaft clockwise until holder contacts water pump. See Fig.
3. Secure moveable lever of tool to water pump pulley flange.
Camshaft timing marks should be aligned with marks on Fig. 3: Installing Crankshaft Holder
rear cover. See Figs. 4 and 5. If not aligned, crankshaft 180
degrees (one half turn) off.
232 GENERAL MOTORS
*3.0L V6 DOHC, Catera (Cont.)

Fig. 6: Installing Camshaft Gear Holders
NOTE: Install timing belt at room temperature. NEW timing belts

are marked with direction of rotation arrow and mating marks.
Courtesy of General Motors Corp. Make sure belt is installed with arrows pointing in correct direction
Fig. 4: Aligning Timing Belt Marks With Rear Cover Marks or rotation.
(Up To 1999 Early Design) Installation:
To install timing belt, remove crankshaft holder. Raise and
support vehicle. Start installation of belt at crankshaft pul-
ley. Install timing belt with double dash marks aligned with
oil pump and drive gear marks. See Fig. 7. Install Timing
Belt Holder (J42069-30) or equivalent plastic wedge to hold
belt against crankshaft sprocket.
NOTE: Timing belt configuration changed in mid-1999 model

year. For both designs, use the marks on each side of the direction
of rotation arrows to line up the left (drivers side) camshaft sprockets.
For early design (up to mid-1999), use the remaining 3 White
marks on the Gates timing belt. For later design (mid-1999 to
present), use the remaining 3 Yellow marks on the Gates timing
belt. Correct belt application MUST be used on each engine design.
Lower vehicle. Route timing belt around tensioner, right
bank (passengers side) camshaft gears, idler pulley, and
left bank (drivers side) camshaft pulleys. Ensure timing
belt marks are aligned with marks on camshaft sprockets
and notches on rear timing belt cover. Keep timing belt
taught between idler pulley and left bank camshaft pulleys.
See Figs. 4 and 5.

Fig. 5: Aligning Timing Belt Marks With Rear Cover Marks
(From 1999 Late Design)
To lock camshafts in place, install Camshaft Gear Holders
(J42069-1 and J-42069-2). See Fig. 6. It may be necessary
to loosen timing belt idler pulley and turn eccentric until
holder can be inserted.
Loosen timing belt tensioner and idler pulley bolts. If reus-
ing timing belt, mark belt with arrow to indicate original
CAUTION: Do not move camshafts with belt removed. Do not remove

Camshaft Holders (J-42069) with timing belt removed.
Inspection: Courtesy of General Motors Corp.
Check timing belt for excessive wear, cracks, or missing Fig. 7: Aligning Timing Belt Marks On Crankshaft Pulley
teeth. Inspect timing belt tensioner and idler pulleys for
worn bearings. Replace as necessary.
GENERAL MOTORS 233
Fig. 8: Measuring Timing Belt Deflection
Ensure timing belt tension is taught (no slack). Measure

timing belt deflection midway between left bank camshafts
(viewed from rear of engine) and left side idler pulley (viewed
from rear of engine). See Fig. 8. Deflection should be no
more than 0.40 (10 mm). If initial timing belt deflection is
okay, go to TIMING BELT TENSION ADJUSTMENT. If timing
belt deflection is not correct, go to TIMING BELT DEFLEC-
TION ADJUSTMENT.
Timing Belt Deflection Adjustment:
If timing belt deflection adjustment is necessary, loosen
left (drivers) side idler pulley bolt. (This is NOT the idler Courtesy of General Motors Corp.
pulley positioned between camshaft sprockets in top, cen-
Fig. 9: Adjusting Timing Belt Tension (New Design Engine
ter of engine). Turn left idler pulley counterclockwise until
Shown; Early Design Engine Tensioner Is The Same)
high point of eccentric nut is in about 12 oclock position.
See Fig 5. Snug idler pulley bolt while holding eccentric so Ensure crankshaft timing mark aligns with mark on oil pump
it does not move. Go to next step. housing. Ensure camshaft timing marks align with notches
Apply additional tension to timing belt by loosening bolt for on rear cover.
idler pulley located between camshaft sprockets (top, cen- Use Checking Gauge (J42069-20) to inspect alignment of
ter of engine). Rotate high point of eccentric to 9 oclock left bank and right bank camshaft gears. See Fig. 10. The
position. Tighten idler pulley bolt while holding eccentric reference marks on both sets of camshaft sprockets must
so it does not rotate. Go to TIMING BELT TENSION AD- match exactly with marks on Checking Gauge (J42069-
JUSTMENT. 20).
Timing Belt Tension Adjustment: If timing belt readjustment is NOT necessary, go to FINAL
Loosen timing belt tensioner lock nut. Turn tensioner ec- TIMING BELT TENSIONING & INSTALLATION. If timing belt
centric counterclockwise to full stop. Turn eccentric back readjustment IS necessary, go to TIMING BELT READJUST-
until reference mark is .039 (1 mm) from belt tension set- MENT.
ting flange. See Fig 9. Tighten timing belt tensioner lock nut
until snug. Lock nut will be final tightened after final adjust- NOTE: When readjusting timing belt tension, Crankshaft Holder
ments are made. Go to CHECKING CAMSHAFT (J42069-10) must be in position on engine.
SPROCKET ALIGNMENT.
Checking Camshaft Sprocket Alignment: Timing Belt Readjustment (Left Bank Camshafts):
Ensure timing belt alignment marks are still aligned with If timing belt readjustment is required, always start with left
reference points on camshaft sprockets and rear timing bank (drivers side) camshafts first. Install Checking Gauge
belt cover. Remove all locking tools from camshafts and (J42069-20) to left bank camshafts.
timing belt. Loosen idler pulley on drivers side of engine. This is idler
Rotate crankshaft clockwise 2 revolutions, stopping at 60 pulley below camshaft sprockets. Using Wrench (J42069-
degrees before TDC mark. See Fig. 2. Install Crankshaft 40) or equivalent, turn idler pulley eccentric COUNTER-
Holder (J42069-10) to crankshaft flange. Secure moveable CLOCKWISE until timing marks on camshaft sprockets
lever of tool to water pump pulley flange. and checking gauge are in alignment. High point of idler
pulley eccentric should be in about the 12 oclock position.
NOTE: Alignment marks on timing belt will no longer align with Tighten idler pulley bolt while holding eccentric from turn-
camshaft sprocket marks after one or more crankshaft revo- ing.
lutions.
234 GENERAL MOTORS
If timing belt idler pulley bolts were loosened, final tighten
them to specification. See TORQUE SPECIFICATIONS. In-
spect high points of timing belt tensioner eccentrics. Left
Timing Belt side idler pulley (viewed from rear of engine) eccentric high
point should be in about the 12 oclock position. Top center
idler pulley eccentric high point should be in about the 9
oclock position. See Fig. 5.
Remove crankshaft holding tool. Rotate crankshaft clock-
wise 2 revolutions, stopping at 60 degrees before TDC
mark. Install Crankshaft Holder (J-42069-10) to crankshaft
drive gear.
Turn crankshaft clockwise until lever of holder firmly con-
tacts water pump pulley flange. Secure moveable lever of
tool to water pump pulley flange.
Ensure camshaft timing marks align with notches on rear
cover and crankshaft timing mark align with mark on oil
pump housing. Use Checking Gauge (J42069-20) to in-
spect alignment of left bank and right bank camshaft gears.
Courtesy of General Motors Corp. Adjust timing belt position, if necessary. Ensure all tools
Fig. 10: Installing Checking Gauge on Camshaft Sprockets are removed from engine. Install timing belt front cover.
Install crankshaft harmonic balancer. Tighten bolt to speci-
Remove checking gauge and crankshaft holder. Rotate fication.
crankshaft clockwise 2 revolutions, stopping at 60 degree Install timing belt cover. Install accessory drive belt tensioner.
BTDC. Install Crankshaft Holder (J42069-10) to crankshaft
Install water pump and power steering pump pulleys. In-
drive gear. Rotate crankshaft to secure lever of holder to stall serpentine drive belt.
water pump flange. Install Checking Gauge (J42069-20) to Install air injection crossover pipe to front of engine. Install
left bank camshafts. If camshaft sprockets are now prop-
air intake resonator and ducting. Install engine splash
erly aligned, go to FINAL TIMING BELT TENSIONING & IN- shield.
STALLATION. If not, repeat readjustment procedure.
Timing Belt Readjustment (Right Bank Camshafts) TORQUE SPECIFICATIONS
If timing belt readjustment is required, always start with left Application Ft. Lbs. (N.m)
bank (drivers side) camshafts first. Install Checking Gauge Camshaft Sprocket Bolt
(J42069-20) to right bank (passengers side) camshafts. Step 1 ........................................................................... 37 (50)
Loosen bolt on idler pulley that is located the center and Step 2 ................................................... Additional 60 Degrees
below the left bank and right bank camshafts. Step 3 ................................................... Additional 15 Degrees
Using Wrench (J42069-40) or equivalent, turn idler pulley Crankshaft Harmonic Balancer Bolt ............................... 15 (20)
eccentric COUNTERCLOCKWISE until timing marks on Crankshaft Sprocket Center Bolt
camshaft sprockets and checking gauge are in alignment. Step 1 ....................................................................... 184 (250)
High point of idler pulley eccentric should be in about the 9 Step 2 ................................................... Additional 45 Degrees
oclock position. Tighten idler pulley bolt while holding ec- Step 3 ................................................... Additional 15 Degrees
centric from turning. Generator Bolt ............................................................... 30 (40)
Remove checking gauge and crankshaft holder. Rotate Power Steering Pump Pulley Bolt .................................. 15 (20)
crankshaft clockwise 2 revolutions, stopping at 60 degree Serpentine Drive Belt Tensioner Bolt ............................ 30 (40)
BTDC. Install Crankshaft Holder (J42069-10) to crankshaft Timing Belt Idler Pulley Bolt ........................................... 30 (40)
drive gear. Rotate crankshaft to secure lever of holder to Timing Belt Tensioner Bracket Bolt ................................ 30 (40)
water pump flange. Install Checking Gauge (J42069-20) to Timing Belt Tensioner Eccentric
right bank camshafts. If camshaft sprockets are now prop- Lock Nut ....................................................................... 15 (20)
erly aligned, go to FINAL TIMING BELT TENSIONING & IN- INCH Lbs. (N.m)
STALLATION. If not, repeat readjustment procedure. Timing Belt Front Cover Bolt ............................................. 71 (8)
Final Timing Belt Tensioning & Installation Water Pump Pulley Bolt ................................................ 71 (8)
To set final timing belt tension, loosen timing belt tensioner
eccentric lock nut. Turn timing belt eccentric counterclock-
wise to full stop. Turn tensioner back until reference mark
is .079-.157 (2-4 mm) ABOVE reference mark on flange.
See Fig. 9. Tighten tensioner eccentric lock nut to specifi-
cation.
GENERAL MOTORS 235
*3.0L V6 DOHC, Saturn

3.0L V6 DOHC
Saturn L Series
2000-01 ................. 4.0 Hours ..................... T285

REMOVAL & INSTALLATION Fig. 1: Positioning Crankshaft At 60 Degrees BTDC
TIMING BELT
Removal:
sembly.
Raise and support vehicle. Remove right front wheel. Re-
move lower front splash shield.
NOTE: Right engine mount must be removed before accessory

drive belt can be removed from vehicle.
Lower vehicle. Loosen, but do not remove water pump pul-
ley bolts. Loosen, but do not remove power steering pump
pulley bolts. Rotate accessory serpentine belt tensioner
clockwise, and remove accessory serpentine belt from
pulleys.
Support weight of engine from above or below with floor Courtesy of General Motors Corp.
jack. Remove front engine mount (timing belt end of en- Fig. 2: Installing Crankshaft Holder
gine) from engine and frame. Remove engine mount bracket
from engine block.
NOTE: Install timing belt at room temperature.
Remove water pump pulley bolts and pulley. Remove power
steering pump pulley bolts and pulley. Remove accessory Inspection:
drive belt tensioner front engine block. Check timing belt for excessive wear, cracks, or missing
Remove 6 harmonic balancer-to-crankshaft bolts. Remove teeth. Inspect timing belt tensioner and idler pulleys for
harmonic balancer. It is NOT necessary to remove crank- grease leaks or worn bearings. Replace as necessary.
shaft center bolt.
Remove wiring harness channel from front timing belt cover NOTE: Upper timing belt idler pulley uses a narrow .20 (5 mm)
and secure away from engine. Remove front timing belt thick spacer and a Black bolt. The lower timing belt idler pulley
cover. Inspect sealing strip on outer edge of cover for cracks uses a .40 (11 mm) thick spacer and a Silver bolt.
or tears. Replace, if necessary. Installation:
Rotate crankshaft clockwise to 60 degrees before TDC. To install timing belt, remove crankshaft holder. Using a felt
See Fig. 1. Ensure timing marks are not 180 degrees from pen, mark the face of the upper and lower timing belt idler
TDC. Camshaft timing marks should be aligned with marks pulleys. The mark should line up with point farthest away
on rear cover. See Fig. 5. from the Torx head mounting bolt. See Fig. 7. The idler
Install Crankshaft Holder (J-42069-10) and rotate crank- pulleys provide adjustment by rotating on an eccentric circle
shaft clockwise until holder contacts the water pump. See around the mounting bolt.
Fig. 2. Secure moveable lever of tool to water pump pulley Loosen lower idler pulley mounting bolt just enough so
flange. that pulley will rotate with slight resistance. Remove upper
To lock camshafts in place, install Camshaft Gear Holders timing belt pulley.
(J42069-1 and J-42069-2). See Fig. 3. It may be necessary
to loosen timing belt idler pulley and turn eccentric until NOTE: Use the marks on each side of the direction of rotation
holder can be inserted. arrows to line up the left (drivers side) camshaft sprockets. For
Loosen timing belt tensioner and idler pulley bolts. If reus- this design (idler pulley located above crankshaft) engine, use
ing timing belt, mark belt with arrow to indicate original the remaining 3 White marks on the Gates timing belt. Correct
direction of rotation. Remove timing belt. belt marks MUST be used.
NOTE: DO NOT move camshafts with belt removed. DO NOT remove

Camshaft Holders (J-42069) with timing belt removed.
236 GENERAL MOTORS
*3.0L V6 DOHC, Saturn (Cont.)

Fig. 3: Installing Camshaft Gear Holders
Fig. 5: Aligning Timing Belt Marks With Rear Cover Marks

Fig. 4: Aligning Timing Belt Marks On Crankshaft Pulley
Install timing belt onto left hand camshafts (as viewed from Courtesy of General Motors Corp.
rear of engine), matching marks on timing belt with corre- Fig. 6: Setting Timing Belt Tension Setting
sponding marks on camshaft sprockets. See Fig. 5. Keep-
ing slack out of belt, route timing belt around lower idler Remove camshaft holders from camshaft sprockets. In-
pulley and around crankshaft sprocket. Ensure mark on stall Checking Gauge (J42069-20) to left hand (drivers side)
timing belt mates with mark on crankshaft sprocket face. camshafts. See Fig. 8. Pull timing belt between timing belt
Hold timing belt in place against crankshaft sprocket using tensioner and crankshaft sprocket to take up slack between
Plastic Wedge (J-42069-30). Route timing belt around right left hand camshaft sprocket and lower idler pulley.
hand camshaft pulleys (as viewed from rear of engine). Ensure left hand camshaft timing marks are about 1 mm
Ensure timing belt dash marks are aligned with marks on (about the width of the timing marks on the sprockets) on
right hand camshaft sprockets. the retard side. See Fig. 8. If they are not, turn lower idler
Install upper idler pulley. Tighten mounting bolt just enough pulley clockwise to allow retard of left hand camshafts. Pull
so that the pulley will rotate with slight resistance. Install timing belt between timing belt tensioner and crankshaft
Timing Belt Holder (J42069-30) or equivalent to crankshaft. sprocket to take up slack between left hand camshaft
Tighten lever arm to water pump pulley flange. sprocket and lower idler pulley.
Ensure timing belt tension is taught (no slack). Loosen
timing belt tensioner lock nut. Turn tensioner eccentric until CAUTION: If TDC is passed while rotating crankshaft, DO NOT
center alignment mark is about .118 (3 mm) above align- turn crankshaft counterclockwise. This will take out correct timing
ment mark on spring loaded idler pulley. See Fig. 6. Re- belt tension between timing belt tensioner and crankshaft sprocket.
move plastic wedge holding timing belt against crankshaft To correct for this, rotate crankshaft 2 additional turns.
sprocket. Tighten timing belt tensioner lock nut until snug. Remove Crankshaft Holder (J42069-10). Rotate crankshaft
Lock nut will be final tightened after final adjustments are clockwise 1 3/4 revolutions. Install Crankshaft Holder
made. (J42069-10) to crankshaft flange, and then stop at TDC.
Adjust upper timing belt idler pulley so that the largest part Tighten lever arm to water pump pulley flange.
of the eccentric is above and to the left of the mounting Torx
bolt. Temporarily tighten Torx mounting bolt. See Fig. 7. NOTE: Alignment marks on timing belt will no longer align with
Adjust lower idler pulley so that the largest part of the ec- camshaft sprocket marks after one or more crankshaft revo-
centric is above and to the left of the mounting Torx bolt. lutions. Timing marks on timing belt are used for initial installation
Temporarily tighten Torx mounting bolt. See Fig. 7. only.
GENERAL MOTORS 237
*3.0L V6 DOHC, Saturn (Cont.)

CAUTION: If TDC is passed while rotating crankshaft, do NOT
turn crankshaft counterclockwise. This will take out correct timing
belt tension between timing belt tensioner and crankshaft sprocket.
To correct for this, rotate crankshaft 2 additional turns.
Remove Camshaft Gear Holder (J42069-2, Green) from
left hand camshaft sprockets. Remove Crankshaft Holder
(J42069-10) from crankshaft. Rotate crankshaft clockwise
1 3/4 revolutions. Install Crankshaft Holder (J42069-10) to
crankshaft flange, and then stop at TDC. Tighten lever arm
to water pump pulley flange.
Recheck both camshaft timing marks on both banks with
Checking Gauge (J42069-20). If timing marks are NOT
aligned, readjust timing belt. It is NOT necessary to remove
timing belt. If camshaft timing marks are aligned, final tighten
upper and lower timing belt idler pulley Torx mounting bolts
to 30 ft. lbs. (40 N.m).
Courtesy of General Motors Corp. Adjust timing belt tensioner so that the center alignment
Fig. 7: Positioning Timing Belt Idler Pulleys mark is about 3 mm above alignment mark on spring loaded
idler. See Fig. 6. Tighten timing belt tensioner pulley nut.
Verify all timing marks are still aligned.
Remove Crankshaft Holder (J42069-10). Remove Check-
ing Gauge (J42069-20). Install timing belt front cover. In-
stall crankshaft harmonic balancer. Tighten bolts to speci-
fication.
Install water pump and power steering pump pulleys. In-
stall accessory drive belt tensioner. Install accessory drive
belt. Install engine mount. Connect negative battery cable.
Raise vehicle. Install splash shield. Install wheel. Lower
vehicle and install air cleaner assembly.
Step 1 ........................................................................... 37 (50)
Step 2 ................................................... Additional 60 Degrees
Step 3 ................................................... Additional 15 Degrees
Crankshaft Harmonic Balancer Bolt ............................... 15 (20)
Fig. 8: Positioning Timing Belt On Left Hand Camshafts Step 1 ....................................................................... 184 (250)
Rotate lower timing belt idler pulley counterclockwise until Step 2 ................................................... Additional 45 Degrees
the left hand camshaft timing marks on the sprockets are Step 3 ................................................... Additional 15 Degrees
lined up with marks on the Checking Gauge (J42069-20). Engine Mount-To-Bracket Bolt ........................................ 41 (55)
While holding lower idler pulley in this position, tighten lower Engine Mount Bracket-To-Engine Bolt ............................ 41 (55)
idler pulley Torx mounting bolt to 15 ft. lbs. (20 N.m). Generator Bolt ............................................................... 30 (40)
Remove Crankshaft Holder (J42069-10). Rotate crankshaft Power Steering Pump Pulley Bolt .................................. 15 (20)
1 3/4 turns clockwise. DO NOT rotate crankshaft counter- Serpentine Drive Belt Tensioner Unit Bolt ..................... 30 (40)
clockwise. Install Crankshaft Holder (J42069-10) to crank- Timing Belt Idler Pulley Torx Bolt ................................... 30 (40)
shaft flange, and then stop at TDC. Tighten lever arm to Timing Belt Tensioner Bracket Bolt ................................ 30 (40)
water pump pulley flange. Timing Belt Tensioner Eccentric
Inspect left hand camshaft timing marks for alignment. Lock Nut ....................................................................... 15 (20)
Sprocket timing marks should align with marks on rear Water Pump Bolt ............................................................ 18 (25)
cover. Realign, if necessary. Wheel Lug Nut ............................................................. 92 (125)
Remove Checking Gauge (J42069-20) from left hand cam- INCH Lbs. (N.m)
shaft sprockets. Install checking gauge on right hand Timing Belt Front Cover Bolt ............................................. 71 (8)
sprockets (passenger side). Install Camshaft Gear Holder Water Pump Pulley Bolt ................................................ 71 (8)
(J42069-2, Green) between left hand camshaft sprockets.
Turn upper timing belt idler pulley counterclockwise until
the right hand camshaft sprocket timing marks are aligned
with marks on Checking Gauge (J42069-20). While hold-
ing idler pulley eccentric in this position, tighten upper idler
pulley Torx mounting bolt to 15 ft. lbs. (20 N.m).
238 GENERAL MOTORS
*3.4L V6
3.4L V6 DOHC
Cutlass Supreme & Grand Prix
1991-95 ............ 1 4.5 Hours ........................ T192
1996 ................. 1 4.5 Hours ........................ T273
Lumina
1991-95 ............ 1 4.5 Hours ........................ T192
1997-96 ............ 1 4.5 Hours ........................ T273
Monte Carlo
1995 ................. 1 4.5 Hours ........................ T192
1996-97 ............ 1 4.5 Hours ........................ T273
1
With Air. Cond. add .4 hours.
mile intervals.


TIMING BELT Fig. 1: Timing Belt Assembly
NOTE: Revised repair procedure are from GM technical service

bulletin 47-61-34; December, 1994.
Removal:
Disconnect negative battery cable. Remove air cleaner and
duct assembly. Drain engine coolant.
Remove accelerator and cruise control cables from throttle
body. Remove fuel rail cover. Relieve fuel pressure. Re-
move fuel lines from fuel rail. Remove fuel mounting
bracket.
Remove heater hose and bracket from lower intake mani-
fold. Remove PCV valve and vacuum line from throttle body.
Remove electrical connectors from EGR valve, canister
purge solenoid and MAP sensor. Remove vacuum lines Fig. 2: Measuring Timing Belt Tensioner Actuator Length
from upper intake manifold tee.
Remove wiring loom bracket for rear spark plug wires. Re-
move upper intake manifold. Remove coolant recovery tank.
Remove serpentine drive belt and drive belt tensioner.
Siphon fluid from power steering pump. Disconnect power
steering lines and remove power steering pump.
On 1993-91 vehicles only, reposition PCM out of way. Re-
move PCM mounting bracket. On 1995-94 vehicles only,
disconnect PCM connectors and secure out of way.
On all vehicles, note position for reassembly reference and
remove spark plug wires from spark plugs. Remove wiring
harness cover at right side (passenger) strut tower. Re-
move fuel line bracket. Fig. 3: Reworking Paper Clip
Remove timing belt covers. Remove breather hose from Remove side plate bolts securing timing belt tensioner
rear camshaft cover and crankcase vent from breather mani-
actuator. Rotate actuator assembly from tensioner pulley
fold. Remove camshaft carrier covers.
socket and out of mounting base. Remove timing belt
NOTE: Actuator assembly uses a tapered bushing between the tensioner pulley. See Fig. 1.
actuator and mounting base. DO NOT lose or damage the bushing Position timing belt tensioner actuator in vise with rod tip
when removing the actuator assembly. (rubber boot end) pointing down.
GENERAL MOTORS 239
*3.4L V6 (Cont.)
CAUTION: Allow oil to flow towards boot end of actuator for at
least 5 minutes prior to refilling.
NOTE: Tensioner actuator is oil filled. Removal of plug may allow

oil to escape. DO NOT remove vent plug.
Straighten out a standard paper clip (.032 with no serra-
tions) and form a loop at one end. See Fig. 3. Remove
rubber end plug from rear of tensioner actuator. Push pa-
per clip through end of vent plug and into pilot hole. Insert a
small screwdriver into the screw slot inside actuator, be-
hind rubber end plug.
Retract actuator plunger by rotating screw in a clockwise
direction, until it is fully retracted. Push on paper clip and
slowly rotate screw counterclockwise until paper clip en-
gages. Remove timing belt. Courtesy of General Motors Corp.
Fig. 5: Identifying Camshaft Sprocket Designs

NOTE: Remove timing marks from camshaft and intermediate
shaft sprockets. is 3.2-3.7 (80.5-94.0 mm) for a used belt, the belt is in
Rotate crankshaft so that No. 1 cylinder is at TDC of com- acceptable range. Replace belt is measurement is more
pression stroke. Mark the timing indicator with White paint than 3.7 (94 mm).
or equivalent on the crankshaft balancer and front cover. Inspect belt teeth and back side of belt for cracks, tears or
Position camshafts so that flat spots are UP for installa- other damage. Inspect components for excessive wear or
tion of Camshaft Hold-Down Tools (J 38613-A). Install Cam- unusual conditions. Note any evidence of oil or other fluid
shaft Hold-Down Tools (J 38613-A) on both camshaft carri- intrusion.
ers. See Fig. 4. Installation:
Remove camshaft sprocket center bolts. Note difference Install camshaft sprockets with bolts and locks. Tighten
between early and late designs. See Fig. 5. Lightly tap on bolts finger tight. Install timing belt onto camshaft sprock-
rear of sprockets to remove from camshaft. ets in a counterclockwise direction. Continue installing tim-
Inspection: ing belt, making sure timing belt teeth are fully engaged
To determine if timing belt length is within specifications, with all sprockets.
measure tensioner actuator from centerline of tensioner Install timing belt tensioner pulley. Tighten timing belt
actuator to end of rubber boot. See Fig. 2. If measurement tensioner pulley bolt to 37 ft. lbs. (50 N.m).

Fig. 4: Installing Camshaft Hold-Down Tools (J 38613-A)
240 GENERAL MOTORS
*3.4L V6 (Cont.)
NOTE: If tensioner oil has been lost, fill tensioner with Mobil
Rotate engine clockwise (as viewed from front) 2 times to
seat belt and verify correct valve timing. DO NOT reverse
1 SAE 5W-30 synthetic engine oii through plug hole. Fill to bottom
rotation. Make sure both camshaft flat spots are up on one
of plug hole only when plunger is fully retracted and pin is installed.
bank and down on opposing bank.
Install rubber end plug in rear of tensioner assembly until Install camshaft carrier covers. Install breather hose and
flush. Ensure plug is sealed against case. crankcase vent onto rear cover. Install timing belt covers.
Continue installation in reverse of removal procedure. Re-
NOTE: Ensure actuator bushings and appropriate holes in side fill cooling system with 50/50 mix of water and coolant.
plate are clean. DO NOT lubricate bushings. Open air bleed valve on thermostat housing while filling
Install actuator bushing into side plate. Install timing belt cooling system. Adjust drive belts to proper tension. See
actuator and actuator side plate. Tighten side plate bolt to page A-60 for belt tension ranges.
20 ft. lbs. (27 N.m). TORQUE SPECIFICATIONS
Rotate pulley assembly into timing belt a maximum of 11 ft. Application Ft. Lbs. (N.m)
lbs. (15 N.m) to allow engagement of actuator shaft into Camshaft Sprocket Bolt ............................................ 96 (130)
pulley pocket arm socket. Pull the paper clip from the ac- Crankshaft Balancer Bolt .......................................... 79 (107)
tuator. Retighten pulley assembly counterclockwise to seat Crankshaft Pulley Bolt ................................................ 37 (50)
pulley into belt. EGR Valve Bolts ............................................................. 18 (25)
Tighten both right hand camshaft sprockets (bank closest Front Cover Bolts
to firewall) to 96 ft. lbs. (130 N.m). Remove camshaft hold- Large Bolts ............................................................... 35 (47)
down from right hand camshaft carrier. Small Bolts ............................................................... 18 (25)
Rotate crankshaft one full turn (360 degrees) clockwise, Intermediate Shaft Belt Sprocket Bolt ........................ 96 (130)
as viewed from front of engine. Align crankshaft reference Serpentine Belt Tensioner Bolt ....................................... 33 (45)
marks. Make sure both right hand camshaft flat spots are Timing Belt Actuator Side Plate Bolt ............................... 20 (27)
down. Tighten both left hand camshaft sprockets (bank Timing Belt Tensioner Pulley Bolt ................................... 37 (50)
closest to radiator) to 96 ft. lbs. (130 N.m). Remove cam- Timing Chain Tensioner Bolt ...................................... 18 (24)
shaft hold-down from left hand camshaft carrier. 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)
HONDA 241
*1.2L 4-Cylinder
1.2L 4-Cyl.
Civic
1973-79 ................. 1.5 Hours ..................... T028
1


TIMING BELT
Removal:
Disconnect negative battery cable. Remove wheelwell
splash shield. Remove air conditioning compressor ad-
justment pulley complete with bracket drive belt. Remove
remaining accessory drive belt(s). Remove valve cover. Re-
move water pump pulley and crankshaft pulley. See Fig. 1.
Ensure that cylinder No. 1 is at TDC of compression stroke
and camshaft is aligned with mark. See Fig. 3.
Remove upper timing belt cover from cylinder head. Re-
move lower timing belt cover from engine block. Loosen
(do not remove) timing belt adjusting and pivot bolts. Slide
belt off pulleys.
Installation:
To install, reverse removal procedure using care not to ex-
cessively bend or twist timing belt. Do not expose belt to
engine oil as this will cause belt rubber to swell. Install belt
in same direction of rotation to prevent premature wear or
failure. Adjust drive belts to proper tension. See page A-60
Application Ft. lbs (N.m)
A/C Pulley Bolt ............................................................ 17 (23)
Alternator
Through-Bolt ............................................................. 33 (45)
Adjustment Bolt ........................................................ 17 (23)
Engine Support Bolts/Nut ........................................... 40 (55)
Side Bracket ............................................................... 33 (45)
INCH Lbs. (N.m)
Timing Belt Cover ...................................................... 84 (9.7)
Valve Cover ................................................................ 84 (9.7)
242 HONDA
Fig. 2: Aligning Camshaft Marks

HONDA 243
*1.3L 4-Cylinder
TIMING BELT APPLICATION CAUTION: Belt tension must be adjusted when engine temperature
Belt is cold.
Labor Component Part Install washer on crankshaft bolt with flat side toward the
Application Time Kit No. No. pulley. See Figs. 2 and 4.Tighten retaining bolt to specifica-
1.3L 4-Cyl. tion. Reverse removal procedure to complete installation.
Civic Tighten all bolts to specification. On specified Civic mod-
els, valve cover bolts must be tightened in proper sequence.
1980-83
See Fig. 3. Adjust drive belts to proper tension. See page A-
Canada ........ 22.0 Hrs. ............................... T028 60 for belt tension ranges.
US ............... 22.0 Hrs. ............................... T073
1984-85 .......... 22.0 Hrs. ............................... T099
1986-87 .......... 22.0 Hrs. ..... TCK161 .......... T161 Application Ft. Lbs. (N.m)
Civic CRX Alternator Adjustment Bolt .......................................... 17 (23)
Alternator Bracket Bolt ................................................ 33 (45)
1984 ............... 22.0 Hrs. ............................... T099 Camshaft Pulley Bolt .................................................. 27 (37)
1
- With Air Cond. add .9 hours. Crankshaft Pulley Bolt
2
- With Air Cond. add .4 hours. 1980-83 .................................................................... 61 (81)
1984-87 .................................................................. 83 (112)
NOTE: A timing belt component kit is available for Timing Belt Adjuster Bolt ............................................. 35 (48)
INCH Lbs. (N.m)
this application. See page I for information on component Timing Belt Cover Bolt .................................................. 84 (9)
kits. Valve Cover Bolt ........................................................ 108 (12)
Valve Cover Nut ............................................................ 84 (9)
MANUFACTURERS SUGGESTED Water Pump Bolt ...................................................... 108 (12)


TIMING BELT
Removal:
Disconnect negative battery cable. Remove wheelwell
splash shield. Remove A/C compressor or adjusting pul-
ley and bracket. Remove A/C belt. Remove accessory drive
belts. Remove engine support bolts and nut. Remove side
mount rubber. Rotate crankshaft counterclockwise to posi-
tion No. 1 cylinder to TDC of compression stroke.
See Figs. 2 and 4. Ensure camshaft timing marks are
aligned with valve cover surface and UP or ROUND mark
is upward. See Figs. 1 and 5.
Remove crankshaft pulley. Remove lower timing belt cover
from engine block. Loosen timing belt tensioner to relieve
timing belt tension.
If timing belt is being reused, mark direction of belt rotation
before removing. Remove timing belt from camshaft and
crankshaft gears.
Inspection:
Inspect timing belt for wear on rounded edges of drive teeth.
Inspect belt for signs of oil contamination. Replace belt if
damaged or contaminated. Inspect all drive gears for wear
in drive belt area. Replace as necessary.
Installation :
Ensure No. 1 piston is at TDC of compression stroke. Ensure
camshaft timing marks are aligned with valve cover surface
and UP or ROUND mark is upward. See Figs. 1 and 4.
Install timing belt. Use care not to excessively bend or twist Courtesy of American Honda Motor Co.
belt. Ensure belt is installed in original direction of rotation. Fig. 1: Aligning Timing Marks (1980-83)
Belt tension must be adjusted. Rotate crankshaft counter-
clockwise 3 teeth on camshaft pulley to create tension on
belt. Tighten tensioner adjustment bolt to specification.
244 HONDA
Fig. 3: Valve Cover Tightening Sequence

HONDA 245

246 HONDA
*1.5L 4-Cylinder
Belt
1.5L 4-Cyl.
Civic CVCC
1975 ............... 2.0 Hrs. ...... TCK036 .......... T036
1976-79 .......... 2.0 Hrs. ................................ T041
Civic
1980-83 .......... 2.0 Hrs. ................................ T041
1984-85 .......... 2.0 Hrs. ................................ T099
1986-87 .......... 2.0 Hrs. ...... TCK161 .......... T161
1988-95 .......... 2.0 Hrs. ...... TCK143 .......... T143
Civic VX
1992-95 .......... 2.0 Hrs. ................................ T223
Civic CRX
1984-85 .......... 2.0 Hrs. ................................ T099
1986-87 .......... 2.0 Hrs. ...... TCK161 .......... T161
Civic Del Sol
1993-95
Exc. VX ........ 2.0 Hrs. ...... TCK143 .......... T143
VX ................ 2.0 Hrs. ................................ T223
1

kits.
scheduled maintenance interval for 1975-89 models, belt Installation (1975-79):
manufacturers suggest the belt be replaced at 60,000 mile Ensure camshaft and crankshaft timing marks are still
intervals. On 1990-94 models, the manufacturer recommends aligned. See Figs. 1 and 5. Reverse removal procedure
the belt be replaced at 90,000 mile intervals. For 1995 mod- using care not to excessively twist or bend belt. Adjust drive
els, the manufacturer recommends the belt be replaced at belts to proper tension. See page A-60 for belt tension
90,000 mile intervals for normal service and 60,000 miles for ranges.
severe service. Removal (1980-95):
* NOTE: This application is an interference engine. terclockwise until No. 1 cylinder is at TDC of compression
See page A-59 for interference engine cautions. stroke. Remove splash shield. Remove power steering
pump, leaving hoses attached. Remove A/C belt idler pul-
REMOVAL & INSTALLATION ley bracket and belt. Remove alternator belt. Remove power
steering pump bracket.
TIMING BELT Remove cruise control actuator (if equipped). Remove
Removal (1975-79): power steering reservoir bracket. Remove engine mount
nuts. Loosen engine mount bolt. Pivot side engine mount
Disconnect negative battery cable. Remove wheelwell cushion aside.
splash shield. Remove A/C compressor adjusting pulley
together with bracket and A/C belt. Remove alternator Remove valve cover. Remove upper timing belt cover. Re-
move crankshaft pulley. Loosen timing belt tension adjuster
bracket and belt. Remove engine support bolts and nut.
bolt 180 degrees. Push tensioner to release belt tension.
Remove rubber mount. Remove valve cover. Remove crank-
shaft pulley. Remove upper timing belt cover from cylinder Retighten tension adjuster bolt. Disengage timing belt from
pulleys. See Figs. 1, 2 and 3.
head and remove lower timing belt cover from engine block.
Installation (1980-95):
Ensure that No. 1 cylinder is at TDC on compression stroke
with camshaft aligned with marks. Remove timing belt. 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 tim-
HONDA 247
ing mark aligns with pointer on lower timing belt cover. See TIMING BELT ADJUSTMENT
Figs. 5, 6, 7, 8 or 9.
Adjust timing belt tension. See TIMING BELT ADJUSTMENT. CAUTION: Always adjust timing belt tension with engine cold.
Before installing valve cover gasket, apply non-hardening
sealant to rounded surfaces of front and rear camshaft Remove cylinder head cover. Remove upper timing belt
caps. To complete installation, reverse removal procedure. cover. Rotate crankshaft counterclockwise until No. 1 cylin-
Tighten bolts to specification. See TORQUE SPECIFICA- der is at TDC of compression stroke. Loosen but do not
TIONS. Adjust drive belts to proper tension. See page A-60 remove, timing belt adjuster bolt. See Fig. 4.
for belt tension ranges. Rotate crankshaft 3 teeth counterclockwise on camshaft
sprocket to create tension on timing belt. Tighten adjuster
bolt to specification. Retighten crankshaft pulley bolt to
specification if it loosened during crankshaft rotation. See
248 HONDA

A/C Compressor Bracket Bolt .................................... 33 (45)
SOHC
1975-79 ................................................................. 22 (30)
1980-95 ................................................................. 28 (33)
SOHC ................................................................... 134 (185)
Power Steering Pump Bracket Bolt ............................. 33 (45)
Timing Belt Adjuster Bolt ............................................. 33 (45)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 89 (10)
Water Pump Bolt ...................................................... 108 (12)
1
- Lubricate bolt threads. Do not lubricate washer or washer
mating surface of bolt.

HONDA 249

Courtesy of American Honda Motor Co. (1988-91: Dual Point Injection)

Fig. 8: Aligning Timing Marks (1988-91 Civic Si & 4WD
Civic Wagon; Multipoint Injection)

250 HONDA

HONDA 251

Application Labor Time Belt Part No. Timing belt drive pulley TDC mark must align with pointer
1.6L 4-Cyl. DOHC on oil pump housing. See Fig. 2. Set intake and exhaust
Civic Del Sol camshaft pulleys to TDC. The TDC marks should align
1994-97 ................ 1 2.0 Hours .................... T227 with each other with UP marks pointing up. See Fig. 2.
Install timing belt in this sequence: timing belt drive pulley,
1
- With Air Cond. add .4 hours. tension adjusting pulley, water pump pulley, intake cam-
With Cruise Control add .3 hours. shaft pulley, and exhaust camshaft pulley. See Fig. 4. DO
NOT bend or twist belt excessively. Ensure arrow on used
MANUFACTURERS SUGGESTED belt points in original rotation direction. Ensure crankshaft
and camshaft pulleys remained aligned with TDC marks.
SCHEDULED MAINTENANCE Loosen and retighten adjusting bolt to tension timing belt.
For 1994 vehicles, the manufacturer recommends the belt be Install lower and middle covers. Install crankshaft pulley.
replaced at 90,000 miles. For 1995-96 vehicles, the manufac- Tighten pulley bolt to specification. See TORQUE SPECIFI-
turer recommends the belt be replaced at 90,000 miles for CATIONS. Rotate crankshaft pulley 5-6 turns counterclock-
normal service and 60,000 miles for severe service. wise so timing belt seats on pulleys.
For 1997 vehicles, normal replacement interval is at 105,000
miles or 84 months. Replace at 60,000 miles if car is regularly CAUTION: Always adjust timing belt tension with engine cold.
driven in extreme temperatures (over 110 degrees F, or under To adjust timing belt tension, set No. 1 piston at TDC (White
-20 degrees F). TDC mark on crankshaft pulley aligned with pointer on
cover). See Fig. 1. Loosen adjusting bolt 180 degrees.
*NOTE: This application is an interference engine. Rotate crankshaft counterclockwise 3 teeth on camshaft
See page A-59 for interference engine cautions. pulley. Tighten adjusting bolt. If necessary, retorque crank-
shaft pulley bolt.
REMOVAL & INSTALLATION Ensure crankshaft and camshaft pulleys are still aligned at
TIMING BELT tioned. To complete installation, reverse removal proce-
Removal: dure. When installing valve cover gasket, apply liquid gas-
If the radio has a theft protection circuit, be sure to get the ket to 8 corners where gasket meets camshafts. Tighten
customers code before disconnecting battery. Disconnect fasteners to specification. See TORQUE SPECIFICATIONS.
negative battery cable. Remove engine lower splash shield. Adjust drive belts to proper tension. See page A-60 for belt
Remove power steering, alternator, and A/C compressor tension ranges.
drive belts. Remove power steering pump and hang out of
way, leaving hoses connected. Rotate crankshaft counter-
clockwise to TDC of compression stroke. See Fig. 1.
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.
Remove valve cover. Remove middle and lower covers.
See Fig. 3. Loosen timing belt tension adjusting bolt 180
degrees. Push tensioner to release belt tension. Retighten
tension adjusting bolt. Mark rotation direction of timing belt
if it is to be reused. Remove timing belt from pulleys.

Fig. 2: Aligning Crankshaft & Camshaft TDC Marks
Fig. 1: Setting Crankshaft Pulley To TDC
252 HONDA
Camshaft Pulley Center Bolt .......................................... 41 (56)
Crankshaft Pulley Bolt 1 ............................................ 130 (177)
Engine Mount Bracket Nuts ............................................ 54 (74)
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)
Valve Cover Nuts 2 ..................................................................................................... 89 (10)
Water Pump Bolt (6 x 1.0 mm) .................................. 106 (12)
1
- Lubricate bolt threads and bottom shoulder of bolt head. Courtesy of American Honda Motor Co. , Inc.
2
- Tighten nuts in 2-3 steps, starting from center outward. Fig. 4: Timing Belt Installation Sequence

HONDA 253
*1.6L 4-Cylinder SOHC, 1976-95

TIMING BELT APPLICATION Install timing belt onto crankshaft pulley, tension adjuster
pulley, water pump pulley, and camshaft sprocket. DO NOT
Belt Part No. bend or twist belt excessively. Ensure arrow on used belt
1.6L 4-Cyl. points in original rotation direction. Ensure crankshaft and
Accord (Includes Canadian) camshaft timing marks are still aligned.
1976-78 ................. 2.0 Hours ..................... T041 Adjust timing belt tension. See TIMING BELT ADJUSTMENT.
1980-83 ................. 2.0 Hours ..................... T041 Before installing valve cover gasket, apply non-hardening
sealant to rounded surfaces of front and rear camshaft
Civic & Civic del Sol caps. To complete installation,reverse removal procedure.
1988-91 ................. 2.1 Hours ..................... T145 Tighten bolts to specification. See TORQUE SPECIFICA-
1992 TIONS. Adjust drive belts to proper tension. See page A-60
(Except Si) ......... 2.1 Hours ..................... T145 for belt tension ranges.
(Si) ...................... 2.0 Hours ..................... T224
1993-95 ................. 2.1 Hours ..................... T224 TIMING BELT ADJUSTMENT
Civic CRX
1988-91 ................. 2.1 Hours ..................... T145
Prelude (Canadian) Remove valve cover. Remove upper timing belt cover. Ro-
1980-82 ................. 2.1 Hours ..................... T041 tate crankshaft counterclockwise until cylinder No. 1 is at
TDC of compression stroke. Loosen but do not remove,
1
- With Air Cond. add .4 hours. timing belt adjuster bolt. See Fig. 2.
Rotate crankshaft 3 teeth counterclockwise on camshaft
MANUFACTURERS SUGGESTED sprocket to create tension on timing belt. Tighten adjuster
SCHEDULED MAINTENANCE bolt. Retighten crankshaft pulley bolt to specification if it loos-
ened during crankshaft rotation. See TORQUE SPECIFICA-
Although the manufacturer does not recommend a specific TIONS.
scheduled maintenance interval for 1975-89 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 replace-
ment interval is 90,000 for normal service and 60,000 for se-
vere service.


TIMING BELT
Removal:
Disconnect battery negative cable. Rotate crankshaft coun-
terclockwise until No. 1 cylinder is at TDC of compression
stroke. Remove wheelwell splash shield. Remove power
steering pump, leaving hoses attached.
Remove A/C belt idler pulley bracket, and belt. Remove
alternator belt. Remove power steering pump bracket. Re-
move cruise control actuator (if equipped).
Remove power steering reservoir bracket. Use jack to sup-
port engine and then remove engine mount nuts. Loosen
engine mount bolt. Pivot side engine mount-cushion aside.
Remove valve cover. Remove upper timing belt cover. Re-
move crankshaft pulley. Remove crankshaft position sen-
sor from oil pump (if equipped). Loosen timing belt tension
adjuster bolt 180 degrees. See Fig. 2. Push tensioner to
release belt tension. Retighten tension adjuster bolt. Mark
rotation direction of timing belt if it is to be reused. Remove
timing belt from pulleys. See Figs. 1 and 5.
Installation: Fig. 1: Exploded View Of Timing Belt Components (Accord
Ensure No. 1 cylinder is at TDC of compression stroke. & Prelude)
Crankshaft keyway will be at 12 oclock position, and
sprocket groove or mark will align with pointer on oil pump
housing.
254 HONDA
*1.6L 4-Cylinder SOHC, 1976-95 (Cont.)

(Accord, 1976-82)
DOHC ....................................................................... 38 (51)
SOHC ....................................................................... 28 (38)
SOHC ................................................................... 130 (180)
SOHC ................................................................... 134 (185)
Timing Belt Adjuster Bolt
DOHC ....................................................................... 41 (55)
SOHC ....................................................................... 33 (45)
INCH Lbs. (N.m)
Courtesy of American Honda Motor Co., Inc. Valve Cover Nut .......................................................... 89 (10)
Fig. 3: Aligning Crankshaft & Camshaft Timing Marks Water Pump Bolt ...................................................... 108 (12)
(Prelude, 1980-82) 1
- Lubricate bolt threads but do not lubricate washer or mat
ing surface of bolt.
HONDA 255

Fig. 5: Exploded View Of Timing Belt Components (1992-95 Civic)
256 HONDA
Fig. 6: Aligning Timing Belt Marks (Civic, 1988-95)

HONDA 257
*1.6L 4-Cylinder SOHC, 1996-2000

1.6L 4-Cyl. SOHC NOTE: If the radio has a coded theft protection circuit, be sure
Civic
1996-00 ................ 1 2.0 Hours .................... T224 TIMING BELT
Civic Del Sol Removal:
1996-97 ................ `1 2.0 Hours ................... T224 Disconnect negative battery cable. Remove engine lower
1
- With Air Cond. add .4 hours. splash shield. Remove power steering, alternator, and A/C
With Cruise Control add .3 hours. compressor drive belts. Rotate crankshaft counterclock-
wise to TDC of compression stroke. See Fig. 3.
MANUFACTURERS SUGGESTED Remove engine oil dipstick. Remove power steering pump
and set aside with hoses attached. Remove timing belt
SCHEDULED MAINTENANCE upper cover and A/C drive belt idler pulley bracket.
For 1996 vehicles, manufacturer recommends replacing belt Use jack to support engine. Working from front of engine,
at 90,000 miles for normal service and 60,000 miles for se- remove engine mount bracket nuts. Remove crankshaft
vere service. For 1997-00 vehicles, normal replacement inter- pulley. Remove lower cover and dipstick tube.
val is at 105,000 miles or 84 months. Replace at 60,000 miles Remove Crankshaft Speed Fluctuation (CKF) sensor from
if car is regularly driven in extreme temperatures (over 110 oil pump. Loosen the timing belt tension adjusting bolt 180
degrees F, or under -20 degrees F). degrees. Push tensioner to release belt tension. Retighten
tension adjusting bolt. Mark rotation direction of timing belt
*NOTE: This application is an interference engine. if it is to be reused. Remove timing belt from pulleys. See
Fig. 1.

258 HONDA
Installation:
on oil pump housing. See Fig. 2.
top surface of cylinder head. See Fig. 3.
tension adjusting pulley, water pump pulley, and camshaft
pulley. See Fig. 4. DO NOT bend or twist belt excessively.
Ensure arrow on used belt points in original rotation direc-
tion. Ensure crankshaft and camshaft pulley timing mark
are aligned with TDC marks.
Loosen and retighten adjusting bolt to tension timing belt.
Install lower cover. Install crankshaft pulley. Tighten pulley
bolt to specification. See TORQUE SPECIFICATIONS. Ro-
tate crankshaft pulley 5-6 turns counterclockwise so timing
belt seats on pulleys.
Fig. 2: Aligning Crankshaft TDC Mark & Oil Pump Mark CAUTION: Always adjust timing belt tension with engine cold.
NOTE: The following revised timing belt tensioner information TDC mark on crankshaft pulley aligned with pointer on
is from Honda technical service bulletin 96-057; August 4, 1998. cover). Loosen adjusting bolt 180 degrees. See Fig. 5. Ro-
tate crankshaft counterclockwise 3 teeth on camshaft pul-
Inspection:
ley. Tighten adjusting bolt. If necessary, retorque crankshaft
Inspect timing belt tensioner pulley for worn bearing. Re- pulley bolt.
place as necessary.
If there was a customer complaint of a whine or chirping Ensure crankshaft and camshaft pulleys are still aligned at
noise from the front of the engine at idle, or just above idle,
tioned. To complete installation, reverse removal proce-
this may be caused by a timing belt that is tensioned too
tight. A revised timing belt tensioner and spring are avail-
FICATIONS. Adjust drive belts to proper tension. See page
able for all 1996, 1997 and some 1998 engines.
The timing belt tensioner kit is available under part number
14520-P2A-305.

HONDA 259
Alternator Mount Bolt ................................................... 33 (45) Courtesy of American Honda Motor Co. , Inc.
Camshaft Pulley Center Bolt .......................................... 27 (37) Fig. 5: Locating Timing Belt Adjuster Bolt
Step 1 ....................................................................... 14 (20)
Step 2 ...................................... Plus 90 Degrees Clockwise
Power Steering Pump Lock Bolt ................................ 17 (24)
Timing Belt Tensioner Adjusting Bolt ........................... 33 (45)
INCH Lbs. (N.m)
CKF Sensor Bolt ....................................................... 106 (12)
Engine Lower Splash Shield .......................................... 89 (10)
Water Pump Bolt ...................................................... 106 (12)
1
260 HONDA
1.7L 4-Cyl. SOHC NOTE: If the radio has a coded theft protection circuit, be sure
Civic
2001 ..................... 1 2.7 Hours .................... T312 TIMING BELT
1
- With Air Cond. add .2 hours. Removal:
Disconnect negative battery cable. Remove engine lower
splash shield. Rotate crankshaft counterclockwise to TDC
MANUFACTURERS SUGGESTED of compression stroke. See Fig. 2. Remove front wheels.
SCHEDULED MAINTENANCE Remove splash shield. Remove power steering adjusting
For 2001 vehicles, normal replacement interval is at 110,000 plate mounting bolt, then remove power steering pump
miles or 84 months. Replace at 60,000 miles if car is regularly belt and pump without disconnecting hoses. Remove al-
driven in extreme temperatures (over 110 degrees F, or under ternator.
-20 degrees F). Remove four (4) ignition coils, throttle cable clamps and
harness holder from cylinder head cover. Remove cylinder
head cover. See Fig. 1.

HONDA 261

Fig. 5: Removing CKP Sensor From Oil Pump
Fig. 2: Aligning Crankshaft Pulley TDC Marks

Fig. 6: Removing Tension From Timing Belt
Fig. 3: Removing Crankshaft Pulley

Fig. 7: Aligning Crankshaft TDC Mark & Oil Pump Mark
Hold crankshaft pulley with Holder Handle (07JAB-
001020A), Holder Attachment (07JAA-001020A) and use a
heavy duty 19 mm socket and breaker bar to remove pulley
Courtesy of American Honda Motor Co. , Inc. bolt. See Fig. 3. Support engine with a jack and wood block
Fig. 4: Removing Timing Belt Covers under oil pan. Remove upper engine bracket from timing
belt end of engine.
Remove grommet from upper timing belt cover and dis-
connect TDC sensor connector. Remove both upper and
lower timing belt covers. See Fig. 4.
262 HONDA
1.7L 4-Cylinder SOHC, (Cont.)
tensioner pulley, water pump pulley, and camshaft pulley.
See Fig. 9. DO NOT bend or twist belt excessively. Ensure
arrow on used belt points in original rotation direction. En-
sure crankshaft and camshaft pulley timing marks are
aligned with TDC marks.
Install CKP sensor, side engine mount bracket, lower tim-
ing belt cover, and crankshaft pulley. Tighten bolts to speci-
fication. See TORQUE SPECIFICATIONS. Rotate crankshaft
pulley 5-6 turns counterclockwise so timing belt positions
on pulley.

Turn crankshaft pulley so No. 1 piston is at TDC (White
TDC mark on crankshaft pulley aligns with pointer on
cover). See Fig. 2.
Courtesy of American Honda Motor Co. , Inc. Ensure camshaft pulley marks are aligned at TDC. See
Fig. 8. If not, timing belt will need to be removed and repo-
Fig. 8: Aligning Camshaft TDC Marks sitioned. To complete installation, reverse removal proce-
dure. Tighten all nuts and bolts to specification. See
Auto Tensioner Mounting Bolt ..................................... 33 (44)
Step 1 ....................................................................... 14 (20)
Step 2 ...................................... Plus 90 Degrees Clockwise
Engine Side Mount Bracket Nuts .................................... 33 (44)
Engine Upper Bracket Nuts ............................................ 40 (54)
INCH Lbs. (N.m)
CKP Sensor Bolt ...................................................... 106 (12)
Courtesy of American Honda Motor Co. , Inc. Engine Lower Splash Shield .......................................... 89 (10)
Fig. 9: Locating Timing Belt Adjuster Bolt Harness Holder & Cable Clamps .................................. 89 (10)
Remove side engine mount bracket. Remove CKP sensor Water Pump Bolt ...................................................... 106 (12)
from oil pump without disconnecting connector. See Fig. 5. 1
Move auto tensioner to remove tension from timing belt
and remove timing belt. See Fig. 6.
Installation:
on oil pump housing. See Fig. 7.
top surface of cylinder head. See Fig. 8
HONDA 263
*1.8L 4-Cylinder
Belt
1.8L 4-Cyl.
Accord
1979-83 .......... 12.0 Hrs. ............................... T041
1984-85 .......... 12.0 Hrs. ..... TCK160 .......... T094
Prelude
1979-82 .......... 12.0 Hrs. ............................... T041
1983-85 .......... 12.0 Hrs. ..... TCK160 .......... T094
1986-87 .......... 12.0 Hrs. ..... TCK160 .......... T160
1

kits.
Although the manufacturers does not recommend a specific


TIMING BELT
Removal (1979-81):
Disconnect negative battery cable. Remove engine sup-
port bolts and nuts. Remove side rubber mount. Remove
side mount bracket. Remove cruise control actuator. Re- Fig. 1: Exploded View Of Timing Belt & Components
(Accord & Prelude, 1979-83)
move engine splash guard. Remove water pump drive belt,
water pump pulley and crankshaft pulley. Remove alterna-
tor, belt, A/C compressor and belt.
Remove valve cover. Ensure cylinder No. 1 is at TDC of
compression stroke and camshaft is aligned to mark. Re-
move upper timing belt cover from cylinder head and re-
move lower timing belt cover from engine block. Loosen,
do not remove, timing belt adjusting and pivot bolts. If reus-
ing belt, mark direction of belt rotation. Slide belt off pulleys.
To install, reverse removal procedure using care not to ex-
cessively bend or twist belt. If re-installing old belt, install
belt so same direction of rotation will be maintained. Ad-
just drive belts to proper tension.
Removal (1982-87):
Disconnect negative battery cable. Remove engine sup-
port bolts and nuts. Remove side rubber mount. Remove
side mount bracket. Remove cruise control actuator. Re-
move engine splash guard. Remove water pump drive belt,
water pump pulley. Remove alternator, belt, A/C compres-
sor and belt. Rotate crankshaft counterclockwise to posi-
tion No. 1 cylinder to TDC of compression stroke. Remove
all drive belts.
Ensure camshaft timing marks are aligned with valve cover
surface and UP or ROUND mark is upward. See Fig. 2, Fig. 2: Aligning Crankshaft & Camshaft Timing Marks
Fig. 3 or Fig. 4. (Accord, 1984-85)
264 HONDA

(Accord, 1979-83)
Remove crankshaft pulley. Remove lower timing belt cover (Prelude, 1984-87)
from engine block. Loosen timing belt tensioner to relieve Install washer on crankshaft bolt with flat side toward the
timing belt tension. pulley. Tighten retaining bolt to specification. Reverse re-
If timing belt is being reused, mark direction of belt rotation moval procedure to complete installation. Tighten all bolts
before removing. Remove timing belt from camshaft and to specification. Apply non-hardening sealant to rounded
crankshaft gears. surfaces of front and rear camshaft caps before installing
Inspection (1982-87): valve cover gasket. Adjust drive belts to proper tension. See
Inspect timing belt for wear or rounded edges of drive teeth. page A-60 for belt tension ranges.
Inspect belt for signs of oil contamination. Replace belt if dam-
aged or contaminated. Inspect all drive gears for wear in drive TORQUE SPECIFICATIONS
belt area. Replace as necessary. Application Ft. Lbs. (N.m)
Installation (1982-87): A/C Compressor Bracket Bolts ................................... 35 (47)
Ensure cylinder No. 1 is at TDC of compression stroke. Alternator Adjustment Bolt ........................................... 17 (23)
Ensure camshaft timing marks are aligned with valve cover Alternator Bracket Bolt ................................................. 33 (45)
surface and UP or ROUND mark is upward. See Fig. 2, Camshaft Pulley Bolt
Fig. 3 or Fig. 4. 1983-87 ..................................................................... 27 (37)
Install timing belt. Use care not to excessively bend or twist 1979-82 ..................................................................... 22 (30)
belt. Ensure belt is installed in original direction of rotation. Crankshaft Pulley Bolt ............................................... 83 (112)
Belt tension must be adjusted. Rotate crankshaft counter- Timing Belt Adjuster Bolt .............................................. 32 (44)
clockwise 3 teeth on camshaft pulley to create tension on INCH Lbs. (N.m)
belt. Tighten tensioner adjustment bolt to specification. Timing Belt Cover Bolt ................................................... 84 (9)
Valve Cover Bolt ......................................................... 108 (12)
CAUTION: Belt tension must be adjusted when engine temperature Valve Cover Nut ............................................................. 84 (9)
is cold.
Water Pump Bolt ....................................................... 108 (12)
HONDA 265

Fig. 5: Exploded View Of Timing Belt & Components (Accord, 1984-85 & Prelude, 1984-87)
266 HONDA
*2.0L 4-Cylinder CR-V
Application Labor Time Belt Part No. Timing belt drive pulley TDC mark must align with pointer
2.0L 4-Cyl. on oil pump housing. See Fig. 2.
CR-V Set intake and exhaust camshaft pulleys to TDC. The TDC
1997-01 .............. 1 3.0 Hours .................... T184 marks should align with cylinder head surface with UP
marks pointing up. See Fig. 2.
1
- With Cruise Control add .3 hours. Install timing belt in this sequence: timing belt drive pulley,
tension adjusting pulley, water pump pulley, exhaust cam-
MANUFACTURERS SUGGESTED shaft pulley, and intake camshaft pulley. See Fig. 4. DO
NOT bend or twist belt excessively. Ensure arrow on used
SCHEDULED MAINTENANCE belt points in original rotation direction. Check that crank-
Normal replacement interval is at 105,000 miles or 84 months. shaft and camshaft pulleys remained aligned with TDC
Replace at 60,000 miles if car is regularly driven in extreme marks.
temperatures (over 110 degrees F, or under -20 degrees F). Loosen and retighten adjusting bolt to tension timing belt.
Install lower and middle covers. Install crankshaft pulley.
*NOTE: This application is an interference engine. Tighten pulley bolt to specification. See TORQUE SPECIFI-
See page A-59 for interference engine cautions. CATIONS. Rotate crankshaft pulley 5-6 turns counterclock-
wise so timing belt positions on pulley.
REMOVAL & INSTALLATION CAUTION: Always adjust timing belt tension with engine cold.

TDC mark on crankshaft pulley aligned with pointer on
cover). See Fig. 1. Loosen adjusting bolt 180 degrees.
TIMING BELT Rotate crankshaft counterclockwise 3 teeth on camshaft
Removal:
Disconnect battery negative cable. Remove engine guard
bar and lower splash shield. Remove power steering, al-
ternator, and A/C compressor drive belts. Remove cruise
control actuator and vacuum tank from left side fenderwell
(if equipped) and hang out of way. Rotate crankshaft coun-
terclockwise to TDC of compression stroke. See Fig. 1.
Use jack to support engine. Working from front of engine,
remove engine mount bracket nuts and bracket. Remove
the crankshaft pulley.
Remove cylinder head cover. Remove middle and lower
covers. See Fig. 3. Loosen timing belt tension adjusting
bolt 180 degrees. Push tensioner to release belt tension.
Retighten tension adjusting bolt. Mark rotation direction of
timing belt if it is to be reused. Remove timing belt from
pulleys.
Courtesy of American Honda Motor Co. , Inc. Courtesy of American Honda Motor Co. , Inc.
Fig. 1: Setting Crankshaft Pulley To TDC Fig. 2: Aligning Crankshaft & Camshaft TDC Marks
HONDA 267
*2.0L 4-Cylinder CR-V (Cont.)

pulley. Tighten adjusting bolt. If necessary, retorque crank-
shaft pulley bolt.
Ensure crankshaft and camshaft pulleys are still aligned at
tioned.
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 fasterners to specification. See


268 HONDA
*2.0L 4-Cylinder CR-V (Cont.)
Alternator Adjusting Lock Nut ......................................... 17 (24)
Crankshaft Pulley Bolt 1 ............................................ 130 (177)
Engine Underguard Bar Bolts ........................................ 17 (24)
Power Steering Pump-To-Bracket Bolts ......................... 17 (24)
Timing Belt Adjusting Bolt ............................................. 40 (54)
INCH Lbs. (N.m)
Cylinder Head Cover Nuts 2 .......................................... 89 (10)
Water Pump Bolt ...................................................... 106 (12)
1
- Lubricate bolt threads and bottom shoulder of bolt head.
2
- Tighten nuts in 2-3 steps, starting from center outward.
HONDA 269
*2.0L 4-Cylinder SOHC, Accord & Prelude

Belt
2.0L 4-Cyl. SOHC
Accord
1986-89 .......... 1 2.7 Hrs. .... TCK160 .......... T160
Prelude
1985 ............... 1 2.7 Hrs. .... TCK160 .......... T094
1986-87 .......... 1 2.7 Hrs. .... TCK160 .......... T160
1988-90 .......... 1 2.7 Hrs. .............................. T144
1
kits.
For 1985-89 vehicles, although the manufacturer does not
recommend a specific scheduled maintenance interval, belt
manufacturers suggest the belt be replaced every 60,000
miles. For 1990 vehicles, the manufacturer recommends the
belt be replaced at 90,000 miles.

See page A-59 for interference engine cautions. (Except 1988-90 Prelude)

TIMING BELT
Removal (Except 1988-90 Prelude):
stroke. Remove drive belts. Remove left engine mount bolts/
nuts, engine mount and bracket. Remove cruise control
actuator (if equipped). See Fig. 1.
Remove splash shield. Remove power steering adjusting
pulley. Remove power steering pump with hoses attached
and set aside. Remove alternator. Remove A/C compres-
sor (if equipped). Remove engine valve cover and upper
timing belt cover. Ensure timing marks align and UP mark
is facing upward. See Fig. 3.
Remove crankshaft pulley. Remove lower timing belt cover.
If timing belt is going to be reused, mark belt rotation direc- Courtesy of American Honda Motor Co., Inc.
tion before removing. Loosen timing belt tensioner adjust- Fig. 2: Timing Belt Installed Position
ment bolt. Push tensioner to release belt tension, retighten (1988-90 Prelude)
adjustment bolt. Remove timing belt.
Inspection: shaft pulley to create tension on timing belt. Tighten adjust-
Inspect timing belt for wear and for signs of oil contamina- ment bolt to specification. See TORQUE SPECIFICATIONS.
tion. Replace belt if damaged or contaminated. Inspect all Apply non-hardening sealant to rounded surfaces of front
drive gears for wear. Inspect water pump for excessive bear- and rear camshaft caps before installing valve cover gas-
ing play or coolant leakage. Replace as necessary. ket. To complete installation, reverse removal procedure.
Installation (Except 1988-90 Prelude): Tighten bolts to specification. See TORQUE SPECIFICA-
Ensure cylinder No. 1 is still at TDC. Install timing belt on TIONS. Adjust drive belts to proper tension.
sprockets. DO NOT excessively bend or twist belt. Ensure Removal (1988-90 Prelude):
arrow on used belt points in original rotation direction. Turn crankshaft counterclockwise (as viewed from timing
Adjust timing belt tension by rotating crankshaft counter- belt end of engine) so that No. 1 cylinder is at TDC of com-
clockwise until cylinder No. 1 is at TDC of compression pression stroke. TDC mark (White paint) is at rear of en-
stroke. Loosen, but do not remove timing belt adjustment gine on transaxle mating flange. See Fig. 3.
bolt. Rotate crankshaft counterclockwise 3 teeth on cam-
270 HONDA
*2.0L 4-Cylinder SOHC, Accord & Prelude (Cont.)
Remove engine lower splash shield. Support weight of
engine from above or with floor jack. Remove engine mount
from timing belt end of engine. Remove cruise control ac-
tuator (if equipped).
Remove accessory drive belts. Remove generator and set
aside. Remove power steering pump with hoses attached
and set aside. Remove A/C compressor (if equipped) with
hoses attached and set aside.
Remove valve cover. Remove crankshaft pulley center bolt.
Remove crankshaft pulley. Remove upper and lower tim-
ing belt covers. Noting installed position for reassembly
reference, remove timing belt guide plate from crankshaft.
Loosen timing belt tensioner bolt and remove timing belt.
Inspection:
Inspect timing belt for wear and for signs of oil contamina-
tion. Replace belt if damaged or contaminated. Inspect all
drive gears for wear. Inspect water pump for excessive
bearing play or coolant leakage. Replace as necessary.
Installation (1988-90 Prelude):
Ensure crankshaft is still at TDC. Ensure camshaft sprocket
is correctly aligned. See Fig. 3. UP mark on camshaft
should be facing straight up and grooves on sprocket
should align with top surface of cylinder head.
Install timing belt on engine. Move tensioner toward belt
and temporarily tighten tensioner bolt. Without moving
crankshaft, install timing belt guide plate (concave side
faces away from engine). Install lower timing belt cover.
Install crankshaft pulley. Apply engine oil to bolt threads
and install crankshaft pulley bolt and washer. Tighten to
Loosen, but DO NOT remove, timing belt adjusting bolt
through access hole in timing belt cover. See Fig. 4. Rotate
crankshaft counterclockwise 3 teeth on camshaft pulley to
tension timing belt. Tighten adjusting bolt to 31 ft. lbs. (43
Fig. 3: Aligning Crankshaft & Camshaft Timing Marks N.m). Install upper timing belt cover. Install valve cover.
(1985-87 Prelude, Others Similar) Install generator, power steering pump and A/C compres-
sor. Install accessory drive belts and adjust to proper ten-
sion. Install engine mount and cruise control actuator.
TORQUE SPECIFICATIONS (EXCEPT 1988-90 PRELUDE)
Alternator Bracket Adjustment Bolt .............................. 51 (69)
INCH Lbs. (N.m)
Valve Cover Nut ............................................................ 84 (9)
Water Pump Bolt ...................................................... 106 (12)
TORQUE SPECIFICATIONS (1988-90 PRELUDE)

A/C Compressor Mounting Bolt .................................. 18 (25)
Engine Mount-To-Engine Nut ......................................... 47 (65)
Generator Lower Mount Bolt ....................................... 33 (45)
Generator Upper Mount Bolt ....................................... 20 (27)
Courtesy of American Honda Motor Co., Inc. Power Steering Pump Upper Mount Bolt ........................ 20 (27)
Fig. 4: Adjusting Timing Belt Tension Timing Belt Adjuster Bolt ............................................. 31 (42)
(1988-90 Prelude) INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 89 (10)
Water Pump Bolt ...................................................... 106 (12)
HONDA 271
*2.0L & 2.1L 4-Cylinder DOHC, Prelude

TIMING BELT APPLICATION Remove engine splash shield. Remove power steering
adjusting pulley. Remove power steering pump with hoses
Application Labor Time Belt Part No. attached and set aside. Remove alternator.
2.0L 4-Cyl. DOHC Remove A/C compressor (if equipped). Remove engine
Prelude valve cover and upper timing belt cover. See Fig. 2. Ensure
1988-91 ................ 1 3.3 Hours .................... T142 timing marks align, and UP marks on camshaft sprockets
2.1L 4-Cyl. DOHC are positioned at the top. See Fig. 1.
Prelude Remove crankshaft pulley. Remove lower timing belt cover.
If reusing timing belt, mark belt rotation direction before
1990-91 ................ 1 3.3 Hours .................... T142 removing. Loosen timing belt tensioner adjustment bolt
1
- With Air Cond. add .5 hours. and push tensioner to release belt tension. Tighten adjust-
ment bolt and remove timing belt.
MANUFACTURERS SUGGESTED Inspection:
SCHEDULED MAINTENANCE Inspect timing belt for wear and for signs of oil contamina-
tion. Replace belt if damaged or contaminated. Inspect all
Although the manufacturer does not recommend a specific drive gears for wear in drive belt area. Inspect water pump
scheduled maintenance interval for 1989 models, belt manu- for excessive bearing play or coolant leakage. Replace if
facturers suggest the belt be replaced at 60,000 mile inter- necessary.
vals. On 1990-91 models, the manufacturer recommends belt Installation:
be replaced every 90,000 miles. Ensure cylinder No. 1 is still at TDC. Install timing belt on
sprockets. DO NOT bend or twist belt excessively. Ensure
*NOTE: This application is an interference engine. arrow on used belt points in original rotation direction.
See page A-59 for interference engine cautions. Adjust timing belt tension by rotating crankshaft counter-
clockwise until cylinder No. 1 is at TDC of compression
REMOVAL & INSTALLATION stroke. Loosen, but do not remove timing belt adjustment
TIMING BELT shaft pulley to create tension on timing belt. Tighten adjust-
Removal: ment bolt to specification. See TORQUE SPECIFICATIONS.
Disconnect negative battery cable. Rotate crankshaft coun- To complete installation, reverse removal procedure. Apply
terclockwise until cylinder No. 1 is at TDC of compression non-hardening sealant to rounded surfaces of front and
stroke. Remove drive belts. Remove left engine mount bolts/ rear camshaft caps before installing valve cover gasket.
nuts, engine mount and bracket. Remove cruise control Tighten bolts to specification. See TORQUE SPECIFICA-
actuator (if equipped). TIONS. Adjust drive belts to proper tension. See page A-60
Alternator Bracket Adjustment Bolt .............................. 20 (27)
Power Steering Adjustment Nut .................................. 31 (42)
Timing Belt Adjustment Bolt ....................................... 31 (42)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 90 (10)
Water Pump Bolt ...................................................... 108 (12)

272 HONDA
*2.0L & 2.1L 4-Cylinder DOHC, Prelude (Cont.)

HONDA 273
*2.2L 4-Cylinder DOHC, Prelude

Remove balancer belt drive pulley. Ensure crankshaft drive
Belt pulley TDC (White) mark is aligned with pointer on oil pump
Labor Component Part housing. See Fig. 3. Align camshaft pulleys at TDC posi-
Application Time Kit No. No. tion. See Fig. 1.
2.2L 4-Cyl. DOHC, H22A Remove the auto-tensioner from front of engine. Place auto-
Prelude tensioner in soft-jawed vise with maintenace bolt facing
up. See Fig. 4. DO NOT grip housing.
1993-01 ......... 1 3.3 Hrs. .... TCK186 ........ 2 T226 Remove maintenace bolt from top of auto-tensioner. Use a
1993-01 .............................. TCK186 ........ 3 T186 flat blade screwdriver to compress auto-tensioner to bot-
1
- Balancer shaft belt included in camshaft belt tomed out position. Place stopper on auto-tensioner. Refill
labor time. any oil that may have spilled out, and install maintenance
bolt with new gasket.
With Air Cond. add .5 hours. Install auto-tensioner on engine with stopper in place. In-
2
Camshaft timing belt. stall timing belt around crankshaft drive pulley, adjusting
3
Balancer shaft belt. pulley, water pump, exhaust camshaft pulley, then intake
camshaft pulley. Ensure crankshaft and camshaft pulleys
NOTE: A timing belt component kit is available for remain aligned at TDC.
this application. See page I for information on component Remove the auto-tensioner stopper. Install balancer belt
drive pulley. Temporarily install lower cover, crankshaft pul-
kits. ley, and crankshaft pulley bolt. Tighten bolt.
Rotate crankshaft about 5-6 times counterclockwise so that
MANUFACTURERS SUGGESTED timing belt positions on the pulleys. Place crankshaft and
camshaft pulleys at TDC positions. If either crankshaft or
SCHEDULED MAINTENANCE camshaft pulley is not positioned at TDC, timing belt will
For 1993-94 vehicle, the manufacturer recommends camshaft have to be repositioned.
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).


TIMING & BALANCER SHAFT BELTS

Removal:
Disconnect the negative battery cable. Rotate crankshaft
counterclockwise so that cylinder No. 1 is at TDC of com-
pression stroke. Timing marks are viewed through window
on transaxle-to-engine mating flange. See Fig. 1.
Remove engine lower splash shield. Remove power steer-
ing pump and alternator drive belts. Remove alternator ter-
minal and connector. If equippped, disconnect cruise con-
trol actuator electrical connector. Move cruise control actua-
tor out of way with cable attached.
Support engine with floor jack. Remove engine side mount
and bracket from front of engine. Remove dipstick tube
from front of engine. Remove cylinder head cover.
Remove middle timing belt cover. Remove crankshaft pul-
ley. Loosen belt tension adjusting nut. Push belt tensioner
to release tension from balancer belt. Tighten adjusting
nut. Remove balancer shaft and camshaft timing belts.
Inspection:
With belt or belt covers removed, inspect belts for wear,
cracks, or oil soaking. Inspect belt teeth for wear. Replace Courtesy of American Honda Motor Co., Inc.
belt if worn, oil soaked, or cracked. Inspect water pump for Fig. 1: Identifying Camshaft & Crankshaft TDC Marks
leaks.
274 HONDA
*2.2L 4-Cylinder DOHC, Prelude (Cont.)

Remove crankshaft pulley and lower cover. Loosen belt Install lower cover and crankshaft pulley. Lubricate crank-
tension adjusting nut about 1 turn. Verify balancer belt ad- shaft pulley bolt and underside of bolt shoulder. Install and
juster moves freely. Retighten tension adjusting nut. tighten bolt to specification.
Remove sealing bolt from maintenance hole in side of en- Turn crankshaft pulley about 1 turn counterclockwise.
gine block. See Fig. 5. Insert a 6x100 mm bolt into mainte- Tighten belt tension adjusting nut. Install rubber seal around
nance hole to lock rear balancer shaft in place. Ensure bolt adjusting nut. Install accessory drive belts and adjust ten-
inserts at least 2.9 (74 mm). Align groove on front balancer sion.
shaft with pointer on oil pump housing. See Fig. 6. Install middle cover. When installing cylinder head cover
Install balancer belt. Loosen adjusting nut to tension bal- gasket, apply liquid gasket (Part No. 08718-001 or -0003)
ancer belt. Remove 6 x 100 mm bolt from side of engine to 8 corners where gasket meets camshafts. Reverse re-
block. Install sealing bolt. moval procedure to complete installation.
HONDA 275
*2.2L 4-Cylinder DOHC, Prelude (Cont.)
Fig. 3: Aligning Timing Belt Drive Pulley With TDC Mark

Fig. 5: Aligning & Locking Balancer Shaft
Fig. 4: Compressing Auto-Tensioner
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)
Water Pump Bolt ...................................................... 106 (12)
1
- Lubricate bolt threads and underside of bolt shoulder.

Fig. 6: Aligning Balancer Shaft Pulley
276 HONDA
*2.2L 4-Cylinder SOHC, Odyssey
Belt
2.2L 4-Cyl. RA1
Odyssey
1997-95
Balance Shaft ..................... TCK186....... T186
Camshaft ........ 1 2.7 Hrs. ... TCK186...... T187
1
- Balance shaft belt included in camshaft belt
labor time.

kits.
1995-96 vehicles, the manufacturer recommends the belt be
replaced at 90,000 miles for normal service or 60,000 miles
for severe service.
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).
96H14628 Courtesy of American Honda Motor Co., Inc.
*NOTE: This application is an interference engine. Fig. 1: Timing Belt, Balance Belt & Related Components

TIMING BELT
Removal:
signs of seal leakage. Remove accessory drive belts. Re-
move alternator terminal and connector. Raise and sup-
port vehicle. Remove wheelwell splash shield. Use a jack,
with cushion between oil pan and jack, to support engine.
Remove side engine mount.
Remove cylinder head cover. Remove crankshaft pulley.
Remove upper and lower timing belt covers. Loosen tim-
ing belt tensioner adjuster bolt 145-180 degrees. Push
tensioner to release belt tension from timing belt and bal-
ancer belt. Retighten tensioner adjuster bolt. Mark rotation
direction of timing belt if it is to be reused. Remove timing
belt from pulleys.
96I14629 Courtesy of American Honda Motor Co., Inc.
Installation:
Ensure cylinder No. 1 is at TDC of compression stroke. Fig. 2: Removing/Installing Timing Belt Covers
Install timing belt in sequence shown. See Fig. 6. Tighten
bolts to specification. See TORQUE SPECIFICATIONS. To
complete installation, reverse removal procedure. Adjust
ranges.
HONDA 277
*2.2L 4-Cylinder SOHC, Odyssey (Cont.)
96D14632 Courtesy of American Honda Motor Co., Inc.

Fig. 5: Aligning Camshaft Pulley TDC Marks
96B14630 Courtesy of American Honda Motor Co., Inc.

Fig. 3: Loosening Tensioner Adjusting Nut

96C14631 Courtesy of American Honda Motor Co., Inc.
Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
Power Steering Pump Mounting Nut ........................... 16 (22)
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................. 86-104 (7.2-8.7)
Valve Cover Nut ......................................................... 86 (9.8)
278 HONDA
*2.2L & 2.3L 4-Cylinder DOHC & SOHC
Belt
Labor Component Part NOTE: If the radio has a coded theft protection circuit, be sure
2.2L 4-CYL. SOHC TIMING & BALANCE SHAFT BELTS
Accord Removal:
1990-93 Disconnect negative battery cable. Position crankshaft with
Balance Shaft ..................... TCK186...... T186 cylinder No. 1 at TDC of compression stroke. See Figs. 1, 2,
Camshaft ........... 1 3.1 Hrs. .. TCK186....... T187 or 3. Disconnect battery negative cable. Remove splash
1994-95 shield. Remove cruise control actuator, leaving cable con-
EX Model nected. Remove power steering pump, leaving hoses con-
nected.
Balance Shaft .......................................... T186 Disconnect alternator wiring. Remove wiring harness from
Camshaft .......... 1 3.1 Hrs. ........................ T244 valve cover. Remove alternator and A/C belts (if equipped).
Except EX Model Remove valve cover and upper timing belt cover. Remove
Balance Shaft .................... TCK186....... T186 side engine mount. Remove engine oil dipstick and tube.
Camshaft .......... 1 3.1 Hrs. .. TCK186....... T187 Remove crankshaft pulley.
1996-97 Support engine. Remove 2 rear bolts from engine center
support beam. Lower engine enough to permit removal of
w/VTEC lower timing belt cover. Remove rubber seal from belt ten-
Balance Shaft .......................................... T186 sion adjuster nut. Remove lower timing belt cover.
Camshaft .......... 1 3.1 Hrs. ........................ T244 Lock timing belt adjuster arm into position by installing one
w/o VTEC lower cover retaining bolt. Loosen belt tension adjuster
Balance Shaft .................... TCK186....... T186 bolt. Push belt tensioner to release tension from belt.
Camshaft .......... 1 3.1 Hrs. .. TCK186....... T187 Tighten adjuster bolt. Remove balance shaft and camshaft
Prelude timing belts.
1992-96
Balance Shaft ..................... TCK186....... T186
Camshaft ........... 1 3.1 Hrs. .. TCK186....... T187
2.3L 4-Cyl. DOHC
Prelude
1992-96
Balance Shaft .......................................... T186
Camshaft ........... 1 3.3 Hrs. ........................ T216
1
labor time. With Air Cond. add .5 hours.

kits.
For 1990-94 vehicle, the manufacturer recommends camshaft
and balance shaft belts be replaced at 90,000 miles. For 1995-
96 vehicles, the manufacturer recommends the belt be re-
placed at 90,000 miles for normal service or 60,000 miles for
severe service.
miles or 84 months. Replace at 60,000 miles if car is regularly
driven in extreme temperatures (over 110 degrees F, or under
-20 degrees F).
*NOTE: This application is an interference engine. Fig. 1: Positioning Camshaft Sprocket For Valve
See page A-59 for interference engine cautions. Adjustment (Prelude 2.2L SOHC)
HONDA 279
*2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)

CAUTION: DO NOT rotate crankshaft or camshaft when removing
timing belts.
Inspection:
With belt or belt covers removed, inspect belts for wear,
cracks, or oil soaking. Inspect belt teeth for wear. Replace
belt if worn, oil soaked, or cracked.
Installation:
Align White mark on flywheel or drive plate (flexplate) with
pointer on block. Ensure camshaft(s) is at TDC for No. 1
cylinder. See Figs. 1, 2, or 3. Install camshaft timing belt.
See Fig. 4. Align rear timing balance shaft belt pulley by
inserting a 6X100 mm bolt 2.9 inches (74 mm) into align-
ment access hole. Align groove on front balance shaft pul-
ley with pointer on oil pump body.
Adjust timing belt tension by rotating crankshaft counter-
clockwise until No. 1 piston is at TDC of compression
stroke. Loosen, but do not remove timing belt adjustment
shaft pulley to create tension on timing belt. Tighten adjust-
ment bolt to specification. See TORQUE SPECIFICATIONS.
Reverse removal procedure to complete installation.
Tighten crankshaft pulley bolt to specification. See TORQUE
Fig. 2: Positioning Camshaft Sprocket For Valve

Adjustment (Accord 2.2L SOHC)
Fig. 3: Positioning Camshaft Sprockets For Valve Adjustment (Prelude 2.3L DOHC)
280 HONDA
Fig. 4: Removing/Installing Timing & Balance Shaft Belts
Alternator Bracket Adjuster Bolt ................................... 16 (22)
Balance Shaft Pulley Bolt ............................................ 22 (30)
Camshaft Pulley Bolt
2.2L DOHC ............................................................... 37 (51)
2.2L SOHC & 2.3L .................................................... 27 (37)
Power Steering Belt Adjuster Nut ................................ 11 (15)
Power Steering Pump Mounting Bolt .......................... 16 (22)
Shift Cable Bracket Bolt .............................................. 16 (22)
Timing Belt Tension Adjuster ...................................... 33 (45)
INCH Lbs. (N.m)
Valve Cover Nut .......................................................... 90 (10)
Water Pump Bolt ...................................................... 108 (12)
Fig. 5: Locating Timing Belt Adjuster Nut (Typical)

HONDA 281
Fig. 6: Installing Crankshaft Pulley (Typical)
Fig. 7: Aligning Balancer Belt Driven Pulley

282 HONDA
2.3L 4-Cyl. F23A, SOHC
Accord
1998-01
Balance Shaft .......................................... T186
Camshaft ........... 1 3.6 Hours ................... T244
Odyssey
1998
Balance Shaft .......................................... T186
Camshaft ........... 1 4.0 Hours ................... T244
1
labor time.
Normal replacement interval is at 105,000 miles or 84 months.
Replace at 60,000 miles if vehicle is regularly driven in ex-
treme temperatures (over 110 degrees F, or under -20 de-
grees F).


TIMING & BALANCER SHAFT BELTS 96H14628 Courtesy of American Honda Motor Co., Inc.
Removal:
Fig. 1: Timing Belt, Balancer Belt & Related Components
signs of seal leakage. Raise and support vehicle. Remove
engine lower splash shield.
Remove accessory drive belts. Remove alternator terminal
and connector. Remove alternator and alternator bracket.
Use a jack, with cushion between oil pan and jack, to sup-
port engine. Remove side engine mount from front of en-
gine. Remove dipstick tube from front of engine.
Remove upper and lower timing belt covers. See Fig. 1 and
2.
Insert a 6 mm timing cover bolt through the hole in the end
of the timing belt adjuster arm. This will temporarily lock
the arm in place.
Loosen belt tensioner adjusting nut about 1 turn. See Fig.
3. Push outer balancer shaft belt tensioner pulley up to
take tension off of the balancer belt. Retighten belt tensioner
adjusting nut. Remove balancer shaft belt.
Loosen belt tensioner adjusting nut about 1 turn. See Fig.
3. Push camshaft timing belt tensioner pulley down to take
tension off of camshaft timing belt. Retighten belt tensioner
adjusting nut. Remove camshaft timing belt.
Installation:
Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by 96I14629 Courtesy of American Honda Motor Co., Inc.
aligning dimple on timing belt drive pulley with pointer on
oil pump housing. See Fig. 4. Ensure camshaft pulley TDC Fig. 2: Removing/Installing Timing Belt Covers
marks are aligned. See Fig. 5.
HONDA 283


Rotate crankshaft so that crankshaft and camshaft pulleys
are at TDC position. Ensure camshaft UP mark is facing
Install camshaft timing belt in sequence shown. See Fig. up. If they are not, timing belt will have to be repositioned.
6. Loosen and retighten tensioner adjusting nut to tension Remove crankshaft pulley and lower cover. Set timing belt
camshaft timing belt. Install balancer belt drive pulley and drive pulley to TDC position.
lower cover. Install crankshaft pulley. Install bolt. Lock camshaft timing belt adjuster arm in place by install-
Rotate crankshaft pulley COUNTERCLOCKWISE about 5- ing a 6x10 mm timing cover bolt. Loosen belt tensioner
6 turns so timing belt positions on pulley. Set No. 1 piston adjusting nut about 1 turn. See Fig. 3. Verify balancer belt
at TDC of compression stroke. Loosen belt tensioner ad- tensioner pulley moves freely. Push balancer belt tensioner
justing nut about 1 turn. Rotate crankshaft counterclock- up then retighten belt tensioner adjusting nut.
wise 3 teeth on camshaft pulley. Tighten belt tensioner ad- Remove sealing bolt from maintenance hole on side of
justing nut to specification. See TORQUE SPECIFICA- engine block. See Fig. 7. Scribe a line 2.9 (74 mm) from
TIONS. end of of 6x100 mm bolt. Install 6x100 mm bolt into sealing
bolt hole to lock balancer shaft in place.
284 HONDA
Align front balancer shaft pulley groove with pointer on oil
pump housing. See Fig. 8. Install balancer belt. Loosen
tensioner adjusting nut about 1 turn to tension balancer
shaft belt. Remove 6x100 mm bolt from rear of balancer
shaft. Install sealing bolt with new washer.
Temporarily install crankshaft pulley and bolt. Turn crank-
shaft pulley about 1 turn counterclockwise, then tighten
tensioner adjusting nut. Remove the 6x10 mm bolt that
locked camshaft timing belt adjuster arm in place.
Remove crankshaft pulley. Install lower cover with new gas-
ket or liquid gasket. Install rubber seal around belt
tensioner adjusting nut. DO NOT loosen nut. Install crank-
shaft pulley. Lubricate crankshaft pulley bolt and underside
of bolt shoulder. Install and tighten crankshaft pulley bolt to
specification.
Install dipstick tube with new O ring. When installing cyl-
inder head cover gasket, apply liquid gasket (Part No. 08718-
0001 or -0003) to 4 corners where gasket meets cam-
shafts.
Install alternator and harness. Install accessory drive belts.
Install engine mount bracket to engine and frame. Connect
negative battery cable. Adjust drive belts to proper tension.
See page A-60 for belt tension ranges.
Alternator Adjusting Lock Nut ......................................... 16 (22) Fig. 8: Aligning Balancer Belt Drive Pulley
Engine Block Sealing Bolt .............................................. 22 (29)
Engine Bracket-To-Engine Side Mount Nut/Bolt
Accord .......................................................................... 40 (54)
Engine Side Mount Through-Bolt
Odyssey ....................................................................... 47 (64)
Engine Side Mount-To-Bracket Nut/Bolt
Odyssey ....................................................................... 47 (64)
Timing Belt Tensioner Adjusting Nut .......................... 33 (44)
INCH Lbs. (N.m)
Cylinder Head Cover Nut ........................................... 86 (9.8)
Dipstick Tube Bolt ........................................................ 106 (12)
Water Pump Bolts ........................................................ 106 (12)

Fig. 7: Locking Balancer Shaft In Place
HONDA 285
*2.6L 4-Cylinder
TIMING BELT APPLICATION CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft
Application Labor Time1 Part No. or damage may result.
2.6L 4-Cyl. Inspection:
Passport Handle timing belt carefully. Avoid twisting or kinking belt.
1994-96 Do not allow belt to become contaminated by water, oil, dirt
M/T ..................... 1.6 Hours ................... T147 or other contaminates. Inspect belt for cracks or damage.
Replace, if necessary.
A/T ..................... 1.9 Hours ................... T147
Measure tensioner pulley spring length and force. Spring
1
- With Air Cond. add .4 hours. length should not exceed 2.76" (70.2 mm) and spring force
With Pwr. Strng. add .3 hours. should not be less than 197-343 lbs. (27-48 kg).
Replace tensioner pulley spring if not within specification.
MANUFACTURERS SUGGESTED TIMING SPROCKET SPECIFICATIONS
SCHEDULED MAINTENANCE Application Standard Limit
The manufacturer recommends the belt be replaced every In. (mm) In. (mm)
60,000 miles. Camshaft ....................... 5.202 ................................ 5.198
(132.03) ......................... (131.93)
* NOTE: This application is an interference engine. Crankshaft ...................... 2.574 ................................ 2.570
See page A-59 for interference engine cautions. (65.33) ............................. (65.23)
Oil Pump ........................ 4.485 ................................ 4.481
(113.84) ......................... (113.74)
Installation:
TIMING BELT Pull tensioner fully toward water pump side and tempo-
rarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC
NOTE: Some procedures may differ slightly due to engine construction. on compression stroke by rotating crankshaft until keyway
aligns with mark on front crankshaft seal housing (12
Removal: oclock).
Disconnect negative battery cable. Remove all necessary Rotate camshaft until timing mark on cam gear (arrow) aligns
air ducts. Position No. 1 cylinder at TDC of compression with mark on upper camshaft cover (notch). See Fig. 1.
stroke. Align timing marks. See Fig. 3. Remove fan and fan Position timing belt over crankshaft sprocket, oil pump
shroud. Remove accessory drive belts. Remove water pump sprocket, camshaft sprocket and tensioner in that order.
pulley. If necessary, remove radiator and splash guard. Ensure belt is positioned in sequence given and without
Prevent engine from rotating and remove crankshaft timing slack between sprockets. Loosen tensioner pulley adjust-
pulley. Remove upper and lower timing belt covers. See ing bolt allowing spring tension to tighten belt. Tighten ad-
Fig. 2. Remove spring from tension pulley. Loosen adjust- justing bolt temporarily.
ing bolt and move pulley toward water pump. Remove tim- Temporarily install crankshaft pulley bolt and rotate crank-
ing belt. shaft 2 complete revolutions in opposite direction of en-
gine rotation, until marks on crankshaft and front oil seal
retainer are aligned again. See Fig. 1. Loosen tensioner
lock bolt, allowing tensioner spring to fully adjust tension.
Tighten tensioner lock bolt.
Install timing belt covers. To complete installation, reverse
removal procedures. Tighten all bolts to specification. See
Front Cover ................................................................. 14 (19)
Tensioner Pulley
Bolts ......................................................................... 18 (24)
Nut ............................................................................ 10 (14)
Water Pump Bolt .......................................................... 14 (19)
INCH Lbs. (N.m)

286
HONDA
Fig 3: Installing Belt Guide

HONDA 287
*2.7L V6
TIMING BELT APPLICATION If timing belt is being reused, mark direction of belt rotation
before removing. Rotate crankshaft clockwise until No. 1
Belt Part No. piston is at TDC of compression stroke. See Fig. 1.
2.7L V6 Loosen timing belt adjusting bolt 180 degrees and push
Accord tensioner to remove tension from timing belt. Retighten
1996-97 .................. 4.0 Hours ..................... T263 adjusting bolt and remove timing belt. Inspect camshaft
and crankshaft seals, replace if leaking.
1
- With Air Cond. add .3 hours. Inspection:
Inspect timing belt for wear or rounded edges of drive teeth.
MANUFACTURERS SUGGESTED Inspect belt for signs of oil contamination. Replace belt if
SCHEDULED MAINTENANCE damaged or contaminated.
Installation:
1996 vehicles, the manufacturer recommends the belt be re- Clean timing belt covers and ensure No. 1 piston is at TDC
placed at 90,000 miles for normal service or 60,000 miles for of compression stroke. Ensure crankshaft and camshaft
severe service. pulleys are at TDC and install timing belt in sequence
For 1997 vehicles, normal replacement interval is at 105,000 shown. See Fig. 1.
miles or 84 months. Replace at 60,000 miles if car is regularly To adjust timing belt, rotate crankshaft clockwise 5-6 revo-
driven in extreme temperatures (over 110 degrees F, or under lutions to seat belt and then rotate crankshaft until No. 1
-20 degrees F). piston is at TDC of compression stroke. Loosen adjusting
bolt 180 degrees then retighten adjusting bolt. See Fig. 1.
* NOTE: This application is an interference engine. Adjust drive belts to proper tension. See page A-60 for belt
See page A-59 for interference engine cautions. tension ranges.
REMOVAL & INSTALLATION Application Ft. Lbs. (N.m)
TIMING BELT A/C Compressor Bracket Bolt
8 mm Bolts ............................................................... 16 (22)
Removal:
10 mm Bolts ............................................................. 33 (44)
Disconnect negative battery cable. Remove front wheels A/C Idler Pulley Center Nut ......................................... 33 (44)
and splash shield. Support engine with cushioned jack.
Alternator Bracket Bolts
Remove 3 bolts attaching side engine mount to engine,
8 mm Bolts ............................................................... 16 (22)
then loosen mount center bolt and pivot mount out of way.
10 mm Bolts ............................................................. 33 (44)
Remove A/C, P/S and alternator belt. Remove dipstick and Camshaft Pulley Bolts ................................................ 23 (31)
pipe. Remove crankshaft pulley. Remove timing belt covers.
See Fig. 2.
Engine Mount Bolts .................................................... 43 (59)
Idler Pulley Center Nut ................................................ 33 (44)
INCH Lbs. (N.m)
Dipstick Bracket Bolts .................................................. 84 (9)
Fig. 2: Identifying Lower & Upper Timing Belt Covers
Fig. 1: Identifying TDC Marks, Timing Belt Adjusting Bolt

& Installation Sequence
288 HONDA
*3.0L & 3.5L V6
Application Labor Time Belt Part No. TIMING BELT
3.0L V6 (J30A1) Removal:
Accord Disconnect negative battery cable. Turn crankshaft pulley
1998-01 ................. 4.7 Hours ..................... T286 so that No. 1 piston is at TDC on compression stroke.
3.5L V6 (J35A1) White mark on crankshaft pulley should align with pointer
Odyssey on front cover. Remove lower engine splash shield. Re-
1999-01 .................. 4.0 Hours ..................... T286 move the generator and power steering pump drive belts.
Remove dipstick tube from front of engine. Support engine
with a jack, and remove engine side mount from front of
MANUFACTURERS SUGGESTED engine. Remove crankshaft pulley.
SCHEDULED MAINTENANCE Remove upper and lower timing belt covers. See Fig. 1. If
reusing timing belt, mark direction of belt rotation for instal-
lation reference.
Replace at 60,000 miles if car is regularly driven in extreme
temperatures (over 110 degrees F, or under -20 degrees F).
Remove one of the battery clamp bolts from battery tray.
Grind threaded end of bolt to a partial point (about 45 de-
*NOTE: The 3.0L is an interference engine. See page gree chamfer). Thread battery bolt into rear cover to hold
timing belt adjuster in installed position. Hand tighten ONLY.
A-59 for interference engine cautions. See Fig. 2.

HONDA 289
*3.0L & 3.5L V6 (Cont.)

Remove side engine mount bracket from front of engine
(above water pump pulley). Loosen timing belt idler pulley
bolt 5-6 turns. Remove timing belt.
Installation:
Ensure that engine is at TDC. Align dimple on timing belt
drive pulley with pointer on oil pump. See Fig. 3. Align cam-
shaft pulleys with pointers on back covers.
CAUTION: Handle auto-tensioner carefully so oil does not spill

or leak out. Replace any oil that may leak out.
Remove battery clamp bolt from back cover. Remove the
timing belt auto-tensioner.
For auto-tensioner with removeable bolt, hold auto-
tensioner with maintenance bolt pointing up. Remove main-
tenance bolt. See Fig. 4. Clamp auto-tensioner in soft-jawed
vise. DO NOT grip auto-tensioner housing. Insert flat blade
screwdriver into maintenance hole. Place stopper on auto-
tensioner while turning screwdriver clockwise to compress Fig. 2: Installing Battery Clamp Bolt On Auto-Tensioner
tensioner to bottom.
Replace any oil that may have spilled out of auto-tensioner.
Reinstall maintenance bolt with NEW gasket. Ensure no
oil is leaking around maintenance bolt, then reinstall auto-
tensioner onto engine with stopper in place.
On 2000-01 models with sealed auto-tensioner, place
tensioner in press. SLOWLY compress tensioner until pin
can be inserted through tensioner body and insert pin. See
Fig. 5. Install auto-tensioner onto engine.
On all models, install timing belt in following sequence:
Crankshaft pulley, idler pulley, front camshaft pulley, water
pump pulley, rear camshaft pulley and tension adjust pul-
ley. See Fig. 6. Ensure crankshaft and camshaft pulleys
remained aligned with marks on back cover. Tighten idler
pulley bolt.
Remove stopper or pin from auto-tensioner. Install engine
side mount bracket to the front of engine (above water pump
pulley). Install upper and lower covers. Install crankshaft
pulley. Lubricate crankshaft pulley bolt threads and install
bolt. Tighten crankshaft pulley bolt to specification. See
Rotate crankshaft about 5-6 turns clockwise to position
timing belt on pulleys. Ensure crankshaft and camshaft
pulleys are aligned at TDC. Crankshaft pulley White mark
should be aligned with pointer on front cover. Remove rub-
ber plugs from upper covers to check camshaft pulley posi-
tions.
If either camshaft is not at TDC, remove timing belt and
readjust position. To complete installation, reverse removal
procedure. Tighten all fasteners to specification. See
Camshaft Sprocket Center Bolt ...................................... 67 (90)
Engine Side Mount Bracket-To-Mount Through-Bolt
Accord & Odyssey ......................................................... 40 (54)
Engine Side Mount-To-Engine Bolts .............................. 33 (44)
Power Steering Pump Lock Nut ..................................... 17 (24)
Power Steering Pump Mount Bolt ................................... 17 (24)
INCH Lbs. (N.m)
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) Fig. 3: Aligning Crankshaft & Camshaft Timing Marks
Water Pump Bolts .................................................... 106 (12)
290 HONDA
*3.0L & 3.5L V6 (Cont.)

Fig. 4: Compressing Auto-Tensioner
(Accord; 1999 Odyssey) Fig. 6: Installing Timing Belt
Fig. 5: Compressing Auto-Tensioner (2000-01 Odyssey)

HONDA 291
3.2L V6 DOHC
3.2L V6
Passport
1998-01 ................. 2.8 Hours ..................... T303
Normal replacement interval is at 75,000 miles for 1998-99
model years. For 2000-01 model year vehicles, recommended
replacement interval is 105,000 miles.

TIMING BELT
Removal: NOTE: For correct timing belt installation, lettering on belt must
Disconnect negative battery cable. Remove air cleaner as- be able to be read as viewed from the front of the vehicle. Also,
note arrow on belt which indicates direction of rotation.
sembly. Remove upper fan shroud. Remove serpentine
drive belt. Installation:
Remove cooling fan and drive pulley. Remove serpentine Align grove on crankshaft sprocket with mark on oil pump.
drive belt idler pulley assembly. Remove serpentine drive See Fig. 2. Install timing belt on crankshaft pulley, aligning
belt tensioner assembly. White dotted line on belt with timing mark on crankshaft
Remove power steering pump with hoses attached, and pulley. Secure belt to sprocket with spring clip.
set aside. Remove crankshaft pulley bolt. Using Puller (J- Align timing mark on right hand (passenger side) cam-
8614-01) or equivalent, remove crankshaft pulley. shaft sprocket with alignment mark on valve cover. See Fig.
Remove timing belt covers. Rotate crankshaft to align tim- 3. Install timing belt on right hand camshaft sprocket, align-
ing marks. See Figs. 1 and 2. When timing marks are ing the White alignment mark on timing belt with camshaft
aligned, No. 2 piston will be at TDC. sprocket mark. If reusing old timing belt, align mating marks
If reusing timing belt, mark belt with arrow to indicate origi- on belt and camshaft sprocket that were made during re-
nal rotation direction. Also place mating marks on timing moval. Secure belt with spring clip.
belt and camshaft sprockets for reassembly reference. Re- Align timing mark on left hand (driver side) camshaft
move timing belt tensioner, and set aside with push rod sprocket with alignment mark on valve cover. See Fig. 4.
facing up. Remove timing belt. Route timing belt around water pump pulley and install on
other left hand camshaft sprocket, aligning the White align-
CAUTION: To prevent air from entering timing belt tensioner, ment mark on timing belt with camshaft sprocket mark.
tensioner rod must always face up. Install pinch clip to hold belt on sprocket. Ensure there is
no slack in belt between camshaft pulleys.
Install timing belt around idler pulley and tensioner pulley.
Temporarily install crankshaft pulley. Turn pulley clockwise
slightly to give some belt slack between the crankshaft
sprocket and right hand camshaft sprocket.
tensioner rod.
Holding tensioner upright, SLOWLY compress timing belt
tensioner rod until hole in top of rod and holes in housing
are aligned. Install a locking pin through the holes. See
Fig. 5.
Install tensioner on engine with locking pin in place. Tighten
Remove locking pin from timing belt tensioner. Remove
clips from camshaft and crankshaft sprockets.
Rotate crankshaft 2 turns clockwise. Ensure timing marks
are still aligned.
Fig. 1: Aligning Camshaft Timing Marks Remove crankshaft pulley and install timing belt covers.
belt cover bolts. See Fig. 6.
292 HONDA
3.2L V6 DOHC (Cont.)

Fig. 3: Installing Timing Belt On Right Hand Camshaft Courtesy of American Honda Motor Co.
Sprocket Fig. 5: Installing Locking Pin In Timing Belt Tensioner

Fig. 4: Installing Timing Belt On Left Hand Camshaft
Sprocket
Install crankshaft pulley. Tighten center bolt to specifica-

tion. Install cooling fan pulley. Install power steering pump.
Install cooling fan. Install serpentine drive belt idler pulley
and tensioner assemblies. Install radiator fan shroud. Con-
nect battery.
Cooling Fan Pulley Bolt .............................................. 16 (22)
M8 Bolt ......................................................................... 16 (22)
M10 Bolt ...................................................................... 34 (46)
Timing Belt Tensioner Pulley Pivot Bolt ...................... 31 (42)
Water Pump Bolt ......................................................... 18 (25)
HYUNDAI 293

TIMING BELT APPLICATION Remove timing belt covers and gaskets, noting bolt length
and location. Rotate crankshaft clockwise to align timing
Application Labor Time Belt Part No. marks on crankshaft and camshaft sprockets. See Fig. 1.
1.5L 4-Cyl. If reusing old belt, place mark on belt to indicate direction of
Accent belt rotation. Loosen timing belt tensioner bolts, and move
1995-97 ................ 1 2.2 Hours .................... T282 tensioner inward toward water pump. Temporarily tighten
bolt in slotted side of tensioner. Remove timing belt.
1
- With Air Cond. add .2 hours. Inspection:
Check timing belt for cracks, cracked or missing teeth, and
MANUFACTURERS SUGGESTED separating canvas. Inspect timing belt tensioner and idler
SCHEDULED MAINTENANCE pulley for worn bearing.
Installation:
For 1995-96 vehicles, the manufacturer recommends the belt Ensure camshaft and crankshaft timing marks are still
be replaced every 60,000 miles. aligned. See Fig. 1. Move timing belt tensioner toward wa-
For 1997 vehicles, the manufacturer recommends the belt be ter pump and tighten bolt. Install crankshaft sprocket (if
replaced every 60,000 miles, except in California. In Califor- removed) with chamfer (flange) toward engine.
nia, timing belt replacement is recommended, but not required Install timing belt on crankshaft and camshaft sprockets.
at 60,000 miles. Make sure there is no slack in belt. If reusing old belt, en-
sure belt is installed in original direction of rotation.
*NOTE: This application is an interference engine. Apply counterclockwise force on camshaft sprocket to ap-
See page A-59 for interference engine cautions. ply tension on tension side of belt. Ensure all timing marks
are aligned. See Fig. 1.
REMOVAL & INSTALLATION CAUTION: Slot-side timing belt tensioner bolt must be tightened
TIMING BELT before pivot-side to prevent belt tensioner from rotating, causing
belt to be over tightened.
Removal:
Loosen, but do not remove water pump pulley bolts. Re- Loosen timing belt tensioner bolts to place tension on tim-
move all accessory drive belts. Remove pulleys from crank- ing belt. See Fig. 2. Tighten timing belt tensioner bolts to
shaft and water pump. specification. See TORQUE SPECIFICATIONS.
Smoothly rotate crankshaft clockwise for one full revolu-
CAUTION: DO NOT rotate engine counterclockwise. If reusing tion. Realign crankshaft and camshaft timing marks.
timing belt, place reference mark on timing belt to indicate direction Loosen pivot-side bolt and then slot-side bolt. Tighten slot-
of rotation before removal. side bolt, and then pivot-side bolt to specification.
To check belt tension, hold belt tensioner and timing belt
together and apply slight thumb pressure at center point of
belt tensioner. This about 11 lbs. See Fig. 2.
Ensure belt cog will reach half the width of timing belt
tensioner bolt on slot-side of belt tensioner. Install crank-
shaft flange. Install timing belt cover. To install remaining
components, reverse removal procedure. Adjust drive belts
to proper tension. See page A-60 for belt tension ranges.
Camshaft Sprocket ......................................... 59-74 (80-100)
Crankshaft Pulley-To-Sprocket Bolt .......... 103-111 (140-150)
Crankshaft Sprocket Center Bolt ............... 103-111 (140-150)
Timing Belt Idler Pulley Bolt ................................. 32-41 (43-55)
INCH Lbs. (N.m)
Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Tlming Marks Fig. 2: Checking Tlming Belt Tension
294 HYUNDAI
Belt TIMING BELT
Labor Component Part Removal:
Application Time Kit No. No. Remove all accessory drive belts. Remove pulleys from
1.5L 4-Cyl. crankshaft and water pump.
Accent
1995-01 .......... 1 2.2 Hrs. .... TCK191 .......... T191 CAUTION: DO NOT rotate engine counterclockwise. If reusing
timing belt, place reference mark on timing belt to indicate direction
Excel of rotation before removal.
1986-89 .......... 1 2.2 Hrs. .............................. T073
1990-94 .......... 1 2.2 Hrs. .... TCK128 .......... T128 Remove timing belt covers and gaskets, noting bolt length
Scoupe marks on crankshaft and camshaft sprockets. See Fig. 1.
1991-93 .......... 1 2.2 Hrs. .... TCK128 .......... T128 If reusing old belt, place mark on belt to indicate direction of
1994-95 .......... 1 2.2 Hrs. .... TCK191 .......... T191 belt rotation. Move tensioner inward toward water pump,
1
- With Air Cond. add .2 hours. and temporarily tighten bolt in slotted side of tensioner.
Remove timing belt.
Inspection:
NOTE: A timing belt component kit is available for Check timing belt for cracks, cracked or missing teeth, and
this application. See page I for information on component separating canvas. Inspect timing belt tensioner for worn
kits. bearing.
Installation:
Ensure camshaft and crankshaft timing marks are still
MANUFACTURERS SUGGESTED aligned. See Fig. 1. Move timing belt tensioner toward wa-
SCHEDULED MAINTENANCE ter pump and tighten bolt.
Install timing belt on crankshaft and camshaft sprockets.
For 1986-96 vehicles, the manufacturer recommends the belt Make sure there is no slack in belt. If reusing old belt, en-
be replaced every 60,000 miles. sure belt is installed in original direction of rotation.
For 1997-01 vehicles, the manufacturer recommends the belt Apply counterclockwise force on camshaft sprocket to ap-
be replaced every 60,000 miles, except in California. In Cali- ply tension on tension side of belt. Ensure all timing marks
fornia, timing belt replacement is recommended, but not re- are aligned. See Fig. 1.
quired at 60,000 miles.

Courtesy of Hyundai Motor Co. Courtesy of Hyundai Motor Co.

Fig. 1: Aligning Timing Marks Fig. 3: Locating Camshaft & Crankshaft Sprocket Marks
HYUNDAI 295

CAUTION: Slot-side timing belt tensioner bolt must be tightened
before pivot-side to prevent belt tensioner from rotating, causing Application Ft. Lbs. (N.m)
belt to be over tightened. Camshaft Sprocket ......................................... 59-74 (80-100)
Loosen timing belt tensioner bolts to place tension on tim-
ing belt. See Fig. 2. Tighten timing belt tensioner bolts to
INCH Lbs. (N.m)
tion. Realign crankshaft and camshaft timing marks. Loosen
Water Pump Pulley Bolt ............................... 106-133 (12-15)
pivot-side bolt and then slot-side bolt. Tighten slot-side
bolt, and then pivot-side bolt to specification.
belt tensioner. This is about 11 lbs. (4.98 kg). See Fig. 2.
tensioner bolt on slot-side of belt tensioner. Install timing
belt cover. To install remaining components, reverse re-
296 HYUNDAI
TIMING BELT APPLICATION Remove timing belt covers and gaskets, noting bolt length
Application Labor Time Belt Part No. marks on crankshaft and camshaft sprockets. See Fig. 1.
1.6L 4-Cyl. If reusing old belt, place mark on belt to indicate direction of
Accent belt rotation. Loosen timing belt tensioner bolts, and move
2001 ..................... 1 2.0 Hours .................... T282 tensioner inward toward water pump. Temporarily tighten
1
- With Air Cond. add .2 hours. bolt in slotted side of tensioner. Remove timing belt.
Inspection:
1
- With Pwr. Strg. add .2 hours. Check timing belt for cracks, cracked or missing teeth, and
separating canvas. Inspect timing belt tensioner and idler
MANUFACTURERS SUGGESTED pulley for worn bearing.
For 2001 vehicles, the manufacturer recommends the belt be aligned. See Fig. 1. Move timing belt tensioner toward wa-
inspected every 30,000 miles. Manufacturer recommends the ter pump and tighten bolt. Install crankshaft sprocket (if
belt be replaced every 60,000 miles, except in California. In removed) with chamfer (flange) toward engine.
California, timing belt replacement is recommended, but not Install timing belt on crankshaft and camshaft sprockets.
required at 60,000 miles. Make sure there is no slack in belt. If reusing old belt, en-
sure belt is installed in original direction of rotation.
*NOTE: This application is an interference engine. Apply counterclockwise force on camshaft sprocket to ap-
See page A-59 for interference engine cautions. ply tension on tension side of belt. Ensure all timing marks
REMOVAL & INSTALLATION CAUTION: Slot-side timing belt tensioner bolt must be tightened
before pivot-side to prevent belt tensioner from rotating, causing
TIMING BELT belt to be over tightened.
Removal:
Loosen, but do not remove water pump pulley bolts. Re- Loosen timing belt tensioner bolts to place tension on tim-
move all accessory drive belts. Remove pulleys from crank- ing belt. See Fig. 2. Tighten timing belt tensioner bolts to
shaft and water pump. specification. See TORQUE SPECIFICATIONS.
CAUTION: DO NOT rotate engine counterclockwise. If reusing tion. Realign crankshaft and camshaft timing marks.
timing belt, place reference mark on timing belt to indicate direction Loosen pivot-side bolt and then slot-side bolt. Tighten slot-
of rotation before removal. side bolt, and then pivot-side bolt to specification.
belt tensioner. This about 11 lbs. See Fig. 2.
tensioner bolt on slot-side of belt tensioner. Install crank-
shaft flange. Install timing belt cover. To install remaining
components, reverse removal procedure. Adjust drive belts
Camshaft Sprocket ......................................... 59-74 (80-100)
Crankshaft Pulley-To-Sprocket Bolt .......... 103-111 (140-150)
Timing Belt Idler Pulley Bolt ................................. 32-41 (43-55)
INCH Lbs. (N.m)

Fig. 1: Aligning Tlming Marks Fig. 2: Checking Tlming Belt Tension
HYUNDAI 297
*1.6L & 1.8L 4-Cylinder DOHC

TIMING BELT APPLICATION Remove plug at left side of cylinder block. See Fig. 6. Insert
screwdriver to hold left balance shaft in place. Screwdriver
Belt should insert at least 2.4 (60 mm) into hole. If not, rotate oil
Labor Component Part pump sprocket one full turn and align timing mark. Ensure
Application Time 2 Kit No. No. screwdriver inserts correct amount.
1.6L 4-Cyl. DOHC Loosen balance belt tensioner bolt. Remove balance belt.
Elantra Inspection:
1992 ..................... 1 3.0 Hrs. ........................ T165 Check belt teeth for cracks, damage and oil contamination.
1993-95 and idler pulley for grease leakage and roughness in rota-
Balance Shaft ........................................... T168 tion. Replace components if damaged.
Camshaft ........... 1 3.0 Hrs. ........................ T165 Check end of automatic tensioner rod for wear. Measure
1.8L 4-Cyl. DOHC distance from end of automatic tensioner rod to top of auto-
Elantra matic tensioner housing. Distance should be .47" (12 mm).
1993-95 If out of specification, replace automatic tensioner.
Compressing Automatic Tensioner:
Balance Shaft ...................... TCK167...... T168 Check if plug at bottom of tensioner protrudes past
Camshaft ........... 1 3.0 Hrs. ... TCK167...... T167 tensioner housing. If plug protrudes past housing, place a
1
- With Air Cond. add .2 hours. washer over plug to prevent plug from contacting vise when
With Pwr. Strng. add .3 hours. pushing rod into tensioner housing. Place tensioner as-
sembly in a soft-faced vise.
2
- Balance shaft belt included in camshaft belt SLOWLY squeeze rod back into automatic tensioner. Re-
labor time. place tensioner if rod can be retracted easily into automatic
tensioner. Align holes in rod and automatic tensioner body.
NOTE: A timing belt component kit is available for See Fig. 3. Insert drill bit or pin through holes to retain rod in
retracted position.
kits. 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
MANUFACTURERS SUGGESTED of engine oil to spacer.
SCHEDULED MAINTENANCE SCHEDULE Installation (Balance Shaft Belt):
The manufacturer recommends the belt be replaced every Ensure crankshaft sprocket and right side balance shaft
60,000 miles. sprocket timing marks are aligned with marks on oil pump
housing. See Fig. 1. Install balance shaft belt. If removed,
*NOTE: This application is an interference engine. install balance shaft tensioner pulley and center bolt.
See page A-59 for interference engine cautions. Install balance shaft belt (timing belt B). No slack should
be present in belt. Lift tensioner toward belt so that large
REMOVAL & INSTALLATION part of center eccentric is to the left and above the center
bolt. See Fig. 2.
TIMING BELT While tightening balance shaft tensioner center bolt, en-
sure tensioner and sprockets DO NOT rotate. Ensure tim-
Removal:
ing marks are still aligned. Check belt tension by applying
Remove cover from under engine (if equipped). Support finger pressure to side of belt opposite tensioner. See Fig.
engine weight with floor jack. Remove engine mount lo-
2. Deflection should be .20-.28" (5-7 mm). If not, readjust
cated near timing belt cover. Remove all accessory drive
belt tension.
belts. Remove water pump pulley and crankshaft pulley.
Remove timing belt covers and gaskets, noting bolt lengths
Install crankshaft flange and outer sprocket. Install flange
in correct direction to prevent damage to timing belt. See
and locations.
Fig. 5.
CAUTION: DO NOT rotate engine counterclockwise (as viewed
from timing belt end of engine). If reusing timing belt, place reference
Rotate engine clockwise to align all timing marks so No. 1
cylinder is at TDC of compression stroke. See Fig. 7. Re-
move automatic tensioner. Place mark on timing belt to
indicate direction of belt rotation. Remove timing belt.
On models equipped with balance shaft, remove outer
crankshaft sprocket. Align oil pump sprocket timing mark
with mark on oil pump case. See Fig. 7.
CAUTION: Leave screwdriver inserted in block until timing belt

is installed. This will lock left side balance shaft in correct position.
Fig. 1: Aligning Crankshaft & Balance Shaft Sprockets

298 HYUNDAI
*1.6L & 1.8L 4-Cylinder DOHC (Cont.)
Fig. 2: Balance Shaft Tension Pulley Alignment
Fig. 3: Retracting Automatic Tensioner Rod

Fig. 4: Installing Flange & Crankshaft Sprocket
(Engines Without Balance Shaft Belt)
Fig. 8: Installing Tensioner Pulley
Fig. 5: Installing Flange & Crankshaft Sprocket

(Engines With Balance Shaft Belt)
Fig. 9: Removing Timing Belt Automatic Tensioner Lock

Wire
HYUNDAI 299

Fig. 10: Exploded View Of Timing Belt & Components (Engines Without Balance Shaft)
Installation (Camshaft Timing Belt): Rotate camshaft sprockets so dowel pins face up and tim-
If crankshaft sprocket was removed, ensure sprocket, ing marks on sprockets align. See Fig. 7. Inner marks on
spacer and flange are installed correctly. See Fig. 4. sprockets should be aligned with cylinder head surface.
Remove automatic tensioner from vise, and install onto When exhaust camshaft sprocket is released, camshaft
engine with wire in place. Install tensioner arm. Position will rotate one tooth in counterclockwise direction. When
tensioner pulley so that pin holes are left of center bolt. See installing timing belt, compensate for rotation.
Fig. 8. Temporarily tighten camshaft tension pulley center Rotate crankshaft and align timing marks on crankshaft
bolt. and oil pump sprockets. If installing old timing belt, ensure
it is installed in original direction of rotation.
CAUTION: The same camshaft sprocket is used on intake and Install timing belt on tensioner pulley and crankshaft
exhaust camshafts. Each has two timing marks. Both camshaft sprocket. Hold belt in place using left hand. Pull belt around
sprockets are positioned correctly when the center dowel pin oil pump sprocket using right hand. Pull belt around idler
holes face up (12 oclock position). pulley.
300 HYUNDAI
Install timing belt around intake camshaft sprocket. En-
sure exhaust timing mark on camshaft sprocket aligns with
cylinder head surface. See Fig. 7. Using both hands, install
timing belt around exhaust camshaft sprocket.
Rotate tensioner pulley in toward timing belt until belt does
not sag. Temporarily tighten center bolt on tensioner pulley.
Ensure all timing marks are still aligned.
To adjust camshaft belt tension, rotate crankshaft 1/4 turn
counterclockwise, and then rotate until No.1 cylinder is at
TDC. Loosen center bolt on camshaft belt tensioner pulley.
Install Socket Wrench (MD998752) into pin holes offset to
left center of pulley. See Fig. 12. Using INCH lb. torque
wrench and socket wrench, apply a clockwise torque of 23-
25 INCH Ibs. (2.6-2.8 N.m) on tensioner pulley. With torque
applied to tensioner pulley, tighten tensioner pulley center
bolt to 31-40 ft. Ibs. (42-54 N.m). DO NOT allow pulley to
rotate while tightening center bolt.
NOTE: If engine is in vehicle, it may be necessary during tensioner

pulley adjustment to jack up engine slightly for clearance.
Install Set Screw (09244-28000) or equivalent, in left en-
gine support bracket until screw end contacts tensioner
arm. See Fig. 9. Turn set screw further until wire can be Courtesy of Hyundai Motor Co.
removed from automatic tensioner. Remove set screw. Fig. 11: Installing Timing Belt Cover Bolts
Rotate crankshaft clockwise 2 complete revolutions, and
leave in this position for approximately 15 minutes. After 15
minutes, measure distance between bottom of tensioner
arm and top of automatic tensioner body (automatic
tensioner rod extension). Distance should be .15-.18" (3.8-
4.5 mm). See Fig. 13, Dimension A. Repeat timing belt
tensioning procedure until correct distance is obtained. If
correct distance can be measured, go to last step. If correct
distance CANNOT be measured, go to next step.
If engine is in vehicle or distance cannot be measured due
to lack of clearance, an alternate method can be used.
Install Set Screw (09244-28000) until it contacts tensioner
arm.
Turn set screw inward, counting number of turns until
tensioner arm contacts automatic tensioner housing. Set
screw should rotate 2 1/2 - 3 turns inward if belt tension is Fig. 12: Adjusting Camshaft Belt Tension
correct. Repeat timing belt tensioning procedure until cor-
rect distance is obtained. Remove set screw.
Install rubber plug in rear timing belt cover. To complete
installation, reverse removal procedure. Ensure timing belt
cover bolts are installed in proper location. See Fig. 11.
tension ranges.
Camshaft Sprocket Bolt .................................. 58-72 (80-100)
Crankshaft Sprocket Center Bolt ................... 80-94 (110-130)
Front Cover Bolt
8 x 30 mm Bolt ................................................ 20-26 (27-35) Courtesy of Hyundai Motor Co.
Except 8 x 30 mm Bolt .................................... 14-20 (19-27) Fig. 13: Measuring Timing Belt Tensioner Protrusion
Timing Belt Cover
Left Lower Rear .............................................. 22-30 (30-42)
Except Left Lower Rear ...................................................... 1
1
- Tighten to 89-106 INCH lbs. (10-12 N.m).
HYUNDAI 301
*1.8L & 2.0L 4-Cylinder Elantra & Tiburon

1.8L 4-Cyl. DOHC Camshaft Sprocket Bolt ............................... 77-89 (100-120)
Elantra Timing Belt Idler Bolt .......................................... 31-41 (43-55)
1996-98 ................ 1 2.4 Hours .................... T278 Timing Belt Tensioner Bolt .................................. 32-41 (43-55)
Tiburon INCH Lbs. (N.m)
1997 ..................... 1 2.4 Hours .................... T278 Timing Belt Cover Bolt ............................................ 71-86 (8-10)
2.0L 4-Cyl. DOHC
Elantra
1999-01 ................ 1 2.4 Hours .................... T284
Tiburon
1997-01 ................ 1 2.4 Hours .................... T284
1
SCHEDULED MAINTENANCE SCHEDULE
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.
*NOTE: This application is an interference engine. Courtesy of Hyundai Motor Co.

REMOVAL & INSTALLATION Adjust timing belt tension until .15-.24 (4-6 mm) deflection
is present midway between idler pulley and camshaft
TIMING BELT sprocket, with a force of 4.4 lbs. (2 kg) applied to belt.
Removal:
Rotate engine clockwise 2 revolutions. Ensure timing marks
are still aligned and proper belt tension still exists. Install
Remove all drive belts and drive pulleys from crankshaft timing belt covers. Install crankshaft pulley. To complete
and water pump. Remove crankshaft pulley and water pump installation, reverse removal procedure.
pulleys. Adjust drive belt tension. See page A-60 for belt tension
Remove timing belt covers and gaskets, noting bolt lengths ranges.
and locations. DO NOT rotate engine counterclockwise, as
viewed from timing belt side of engine. TECHNICAL SERVICE BULLETIN
Rotate engine clockwise to align all timing marks so No. 1
cylinder is at TDC of compression stroke. See Fig. 1. Move TIMING BELT NOISE: FRONT CASE
timing belt tensioner out of way to relieve belt tension. If Description: Some 1999-00 Elantras and Tiburons produced
reusing belt, place mark on timing belt to indicate direction before Sept. 22, 1999, may exhibit an unusual noise at the
of belt rotation. Remove timing belt. front of the engine. The noise may be caused by the timing
Inspection: belt rubbing against the front of the engine.
Check belt teeth for cracks, damage, and oil contamina- Some timing belt idler pulley mounting surfaces were ma-
tion. Inspect all sprockets for damage. Check tensioner chined incorrectly. This can cause the timing belt to ride off of
pulley and idler pulley for grease leakage and worn bear- the timing belt sprockets and into the front cover.
ings. Replace components if damaged. Service Procedure: If this condition exists, the forward edge
Installation: of the timing belt will shredded and the inside of the upper
Ensure camshaft and crankshaft timing marks are still timing belt cover will be worn. Replace the front case, idler
aligned. Outer marks on sprockets should be aligned with pulley, timing belt and any other damaged components.
rocker cover surface. Install timing belt. If reusing old belt,
ensure belt is installed in original direction of rotation. NOTE: This information is from the Hyundai technical service
Loosen timing belt tensioner bolt, allowing tensioner pul- bulletin 00-20-002-1; May, 2000.
ley to contact belt. Tighten timing belt tensioner pulley bolt.
Rotate crankshaft one turn clockwise. Realign camshaft
and crankshaft timing marks.
302 HYUNDAI
*2.0L 4-Cylinder Sonata
TIMING BELT APPLICATION Inspect automatic tensioner for leaks. Check rod end of
automatic tensioner for wear. Measure distance from
Belt tensioner rod end to tensioner housing. Distance should
Labor Component Part be .47" (12 mm). If not, replace automatic tensioner.
2.0L 4-Cyl. DOHC NOTE: If plug at bottom of tensioner protrudes past tensioner
housing, place a washer over plug to prevent contacting vise
Sonata when pushing rod into tensioner housing.
1992-98
Balance Shaft ................. TCK167 .......... T168 Retract rod into tensioner housing by placing automatic
tensioner assembly in a soft-faced vise. Close vise
Camshaft ..... 1 3.8 Hrs. .... TCK167 .......... T167 SLOWLY to push rod back into tensioner. See Fig. 4.
1
- Balance shaft belt included in camshaft belt Replace automatic tensioner assembly if rod can be easily
labor time. With Air Cond. add .4 hours. 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.
this application. See page I for information on component Align timing marks on balance shaft sprockets with timing
kits. marks on engine case. See Fig. 5. Install balance shaft
timing belt and crankshaft flange. Install crankshaft flange
in correct direction. See Fig. 6.
MANUFACTURERS SUGGESTED Position balance shaft tensioner so that the center of the
SCHEDULED MAINTENANCE pulley is to the left and above the tensioner bolt. See Fig.
5. Hold tensioner tightly against belt. Tighten tensioner
60,000 miles, except in California. In California, timing belt pulley bolt without letting tensioner rotate.
replacement is recommended, but not required at 60,000 To check balance shaft belt tension, depress belt with fin-
ger midway between sprockets (opposite tensioner pul-
miles.
ley). Deflection should be between .20-.29 (57 mm). If not,
*NOTE: This application is an interference engine. readjust belt tension.
Place crankshaft sprocket on crankshaft. Tighten bolt to
Ensure screwdriver is still installed through left side of cyl-
REMOVAL & INSTALLATION inder block to hold balance shaft in place. Install automatic
tensioner on engine block with rod locked in place.
TIMING BELT Rotate camshaft sprockets so dowel pins face upward and
Removal: timing marks on sprockets align. See Fig. 2. Outer marks
Remove all drive belts. Remove crankshaft pulley and wa- on sprockets should be aligned with cylinder head surface.
ter pump pulley. Remove upper and lower timing belt cov-
ers, noting bolt lengths and locations. NOTE: The same camshaft sprockets are installed on intake and
Turn crankshaft clockwise and align timing marks so No. 1 exhaust camshafts. Timing marks are correctly aligned when
cylinder is at TDC. Timing marks on camshaft sprockets dowel pin holes are facing straight up.
should be aligned at upper surface of cylinder head. See
Fig. 2. 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.
Remove timing belt automatic tensioner. See Fig. 1. Mark
timing belt to indicate original direction of rotation. Remove
timing belt.
Remove balance shaft access plug from cylinder block.
Insert Phillips screwdriver to block left balance shaft. See
Fig. 3. Balance shaft is correctly locked in place if screw-
driver can be inserted at least 2.36 (60 mm). If not, rotate
oil pump sprocket so screwdriver can be inserted to cor-
rect depth.
Loosen balance shaft belt tensioner bolt. Remove front
crankshaft sprocket and flange. Remove balance shaft tim-
ing belt.
Inspection:
Check belt teeth for damage and oil contamination. Inspect
belt is not cracked, separated or showing canvas fiber. Fig. 1: Exploded View Of Timing Belt & Related Components
and idler pulley for grease leakage and roughness in rota-
tion. Replace components if damaged.
HYUNDAI 303
*2.0L 4-Cylinder Sonata (Cont.)
Fig. 5: Aligning Balance Shaft Timing Marks

Fig. 3: Locking Balance Shaft In Place Fig. 6: Installing Crankshaft Flange
Courtesy of Hyundai Motor Co. Fig. 7: Tensioning Camshaft Timing Belt

304 HYUNDAI
*2.0L 4-Cylinder Sonata (Cont.)
Align crankshaft sprocket timing marks and oil pump
sprocket timing marks. See Fig. 2. Install timing belt around
tensioner pulley and crankshaft sprocket. Hold timing belt
on tensioner pulley using left hand. Pulling belt with right
hand, install belt around oil pump sprocket.
Install belt around idler pulley. Align timing mark on ex-
haust camshaft sprocket with top of cylinder head. Pulling
belt with both hands, install it around exhaust camshaft
sprocket.
Gently raise tensioner pulley so belt does not sag. Position
timing belt tensioner pin holes so that they face up. Tempo-
rarily tighten center bolt. See Fig. 7.
To adjust belt tension, rotate crankshaft 1/4 turn counter-
clockwise, and then rotate clockwise until No. 1 cylinder is
at TDC. Ensure all timing marks are aligned.
Loosen center bolt on tensioner pulley. Note location of pin
holes in tensioner pulley.
Using INCH lb. torque wrench and Socket Wrench (09224-
28100), apply a torque of 22-24 INCH Ibs. (2.6-2.8 N.m) on
tensioner pulley. With torque applied to tensioner pulley,
tighten tensioner pulley center bolt to specification. See Courtesy of Hyundai Motor Co.
Fig. 8. Fig. 9: Installing Timing Belt Cover Bolts
Install Set Screw (09244-28000) or equivalent, in left en-
gine support bracket until set screw end contacts tensioner
arm. Rotate set screw further until locking pin can be re-
moved from automatic tensioner. See Fig. 7. Remove set
screw.
Rotate crankshaft clockwise 2 complete revolutions. Allow
engine to sit in this position for about 15 minutes. Measure
distance between tensioner arm and automatic tensioner
body. Distance should be .15-.18" (3.8-4.5 mm). See Fig.
10, Dimension A. If distance is incorrect, repeat Timing
belt tensioning procedure. If distance is okay, go to next to
last step.
If distance between automatic tensioner and tensioner arm
cannot be measured easily, use this alternate method. In-
stall Set Screw (09244-28000) until it contacts tensioner
arm. Courtesy of Hyundai Motor Co.
Rotate set screw inward while counting number of turns Fig. 10: Measuring Automatic Tensioner Protrusion
until tensioner arm contacts automatic tensioner housing. TORQUE SPECIFICATIONS
Turn set screw 2 1/2 -3 turns to correctly tension belt. Re-
move set screw. Application Ft. Lbs. (N.m)
Install rubber plug in rear timing belt cover. Install timing A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27)
belt covers. Install timing belt cover bolts in correct loca- Automatic Tensioner Bolt .................................. 15-20 (20-27)
tions. See Fig. 9. Balance Shaft Sprocket Bolt ............................. 32-36 (43-49)
To complete installation, reverse removal procedure. Apply Balance Shaft Tensioner Retaining Bolt .......... 11 -16 (15-22)
sealant to contact areas on semi-circular packing and rocker Camshaft Sprocket Bolt .................................. 59-74 (80-100)
cover before installing. Ensure correct bolts are installed in Crankshaft Pulley-To-Sprocket Bolt .................. 15-22 (20-30)
proper location in timing belt covers. Adjust drive belts to Crankshaft Sprocket Center Bolt ................... 81-96 (110-130)
proper tension. See page A-60 for belt tension ranges. Front Tensioner Pulley Bolt ............................... 32-41 (43-55)
Oil Pump Sprocket Nut ..................................... 37-44 (50-60)
Water Pump Mounting Bolt ................................... 9-11 (12-15)
INCH Lbs. (N.m)
Fig. 8: Adjusting Timing Belt Tensioner Pulley

HYUNDAI 305
*2.4L 4-Cylinder
TIMING BELT APPLICATION and align rear belt marks. See Fig. 5. Install crankshaft gear,
camshaft timing belt, washer and bolt. Align timing marks.
Belt See Fig. 1.
Labor Component Part Install rear tensioner. Hold tensioner tight against belt while
Application Time Kit No. No. tightening bolts. Depress belt with finger to ensure deflec-
2.4L 4-Cyl. tion is between .20-30 (5-7 mm). Install camshaft and oil
Sonata pump sprocket (if removed). Tighten camshaft sprocket
retaining bolt to specification while holding hexagon area
1989-91 of camshaft.
Balance Shaft .... 1 .............. TCK124 ....... T159 Install belt tensioner, tension spring and spacer. Ensure
Camshaft ............ 2.7 Hrs. .. TCK124 ....... T124 spring is properly engaged against front case. Rotate
1
- Balance Shaft Belt included in Camshaft Belt tensioner toward water pump and temporarily tighten re-
labor time. taining bolts. Ensure camshaft and crankshaft timing marks
With Air Cond. add .4 hours. are aligned. See Fig. 1. Install timing belt on crankshaft.
Apply pressure on tension side of belt while installing
belt on camshaft sprocket. Loosen tensioner to allow
NOTE: A timing belt component kit is available for spring pressure to timing belt. Rotate camshaft sprocket
this application. See page I for information on component clockwise until timing mark is offset by 2 teeth to apply
kits. tension on belt. Ensure all timing marks are aligned.
Tighten tensioner bolt.
Tighten tensioner spacer. To check belt tension, apply slight
MANUFACTURERS SUGGESTED thumb pressure to measure deflection between camshaft
SCHEDULED MAINTENANCE and oil pump sprocket. Belt deflection should be .55 (14 mm).
The manufacturer recommends the belt be replaced every To install remaining components, reverse removal procedure.
60,000 miles. Adjust drive belts to proper tension. See page A-60 for belt tension
ranges.
* NOTE: This application is an interference engine. TORQUE SPECIFICATIONS
See page A-59 for interference engine cautions. Application Ft. Lbs. (N.m)
REMOVAL & INSTALLATION Camshaft Sprocket Bolt .................................... 58-72 (79-98)
TIMING BELTS Crankshaft Sprocket Bolt ............................. 80-94 (109-127)
Removal: Idler Pulley Bolt ................................................. 25-30 (34-41)
Disconnect negative battery cable. Remove all drive belts Tensioner Pulley Bracket Bolt ........................... 17-20 (23-27)
and crankshaft pulley. Remove upper timing belt cover and Tensioner Pulley Center Bolt ............................ 31-40 (42-54)
gasket. Remove timing belt lower cover and gasket, noting INCH Lbs. (N.m)
bolt lengths and locations. Crank Angle Sensor Nut ................................... 84-108 (9-12)
Remove crankshaft sprocket bolt access cover. Remove Timing Belt Cover Bolt
crankshaft sprocket bolt and washer. Rotate engine clock- Left Lower Rear Cover Bolt ................................. 44-61 (5-7)
wise to align timing mark on camshaft sprocket with mark All Exc. Left Lower Rear Cover Bolt ................. 84-108 (9-12)
on cylinder head. See Fig. 1. Loosen front timing belt Water Pump Pulley Bolt ........................................ 72-84 (8-9)
tensioner adjustment bolt, and move tensioner toward water
pump.
Tighten bolt to secure tensioner. Remove front timing belt.
Remove camshaft sprocket. Remove oil pump sprocket
access plug from cylinder block. Insert 8 mm Phillips screw-
driver to block left silent (counterbalance) shaft. See Fig. 3.
Remove oil pump sprocket nut to remove sprocket.
Remove front crankshaft sprocket and flange. Remove rear
timing belt tensioner assembly. Remove rear timing belt.
Remove right silent shaft sprocket with spacer. Remove
rear crankshaft sprocket with key and inner cover.
Inspection:
Check belt teeth for cracks, damage or oil contamination. Inspect
all sprockets for damage. Check belt tensioner for damage. Check
belt tensioner for signs of grease leakage or roughness in
tensioner rotation. Replace components if damaged.
Installation:
Install rear timing belt gear on crankshaft. Install spacer to
right silent shaft with chamfer of spacer facing toward engine
block. Properly install flange on crankshaft. Install rear belt
Fig. 1: Aligning Front Timing Belt Marks

306
HYUNDAI
Fig. 3: Blocking Left Silent Shaft Fig. 4: Positioning Timing Belt Crankshaft Flange
HYUNDAI 307
Fig. 5: Aligning Rear Timing Belt Marks

308 HYUNDAI
*3.0L V6
TIMING BELT APPLICATION Ensure engine is on No. 1 cylinder compression stroke
and timing marks are aligned. Remove crankshaft pulley
Belt and timing belt covers.
Labor Component Part Rotate crankshaft clockwise to align camshaft and crank-
Application Time Kit No. No. shaft timing marks. See Fig. 3. Loosen timing belt tensioner
3.0L V6 bolt and pivot tensioner counterclockwise. Lock tensioner
Sonata in retracted position. If reusing timing belt, mark rotation
1990-98 .......... 1 3.1 Hrs. .... TCK139 .......... T139 direction on belt. Remove timing belt.
Inspection
1
- With Air Cond. add .4 hours. Check timing belt for cracks, cracked or missing teeth, and
separating canvas. Inspect timing belt tensioner for worn
bearing.
this application. See page I for information on component Align camshaft and crankshaft timing marks. See Fig. 3. If
kits. tensioner spring has been removed, install spring on
tensioner so hook faces away from engine block.
MANUFACTURERS SUGGESTED Route timing belt on crankshaft sprocket and then onto
rear camshaft sprocket. Run timing belt under water pump
SCHEDULED MAINTENANCE pulley, over front camshaft sprocket and then over tensioner
The manufacturer requires the belt be replaced every 60,000 pulley.
miles, except for 1998 California vehicles. For 1998 California Apply force counterclockwise to rear camshaft sprocket,
vehicles, timing belt replacement is recommended, but not applying tension to right side of belt. Ensure timing marks
required at 60,000 miles. are aligned.
Loosen tensioner bolt allowing tensioner to take up slack
*NOTE: This application is an interference engine. in left side of timing belt. Tighten tensioner bolt. Rotate
crankshaft 2 turns clockwise.
See page A-59 for interference engine cautions. Realign timing marks. Measure timing belt tension using
belt tension gauge midway between crankshaft and cam-
REMOVAL & INSTALLATION shaft sprockets, on side opposite tensioner. For new belt,
tension should be 57-84 lbs. (26-38 kg).
TIMING BELT Install flange on crankshaft sprocket with flat side facing
Removal: timing belt. Install front timing belt cover. Install crankshaft
Support engine oil pan with jack and block of wood. Re- pulley and tighten bolt to specification.
move all drive belts. Remove power steering pump with Install engine support bolts and tighten in sequence. See
hoses connected and set aside. Remove engine mount on Fig. 1. To complete installation, reverse removal proce-
timing belt end of engine. Remove engine support bracket dure. Tighten nuts and bolts to specification. See TORQUE
bolts in sequence. Slowly remove reamer bolt. See Fig. 1. SPECIFICATIONS. Adjust drive belts to proper tension. See
NOTE: Reamer bolt may sometimes become seized on engine support
bracket. Remove reamer bolt carefully without damaging threads.
Water Pump Bolt
Headmark 4 Bolt ............................................... 9-11 (12-15)
Headmark 7 Bolt ............................................. 15-20 (20-27)
INCH Lbs. (N.m)
Fig. 1: Engine Support Bolt Loosening & Tightening

Sequence
HYUNDAI 309
*3.0L V6 (Cont.)


310 INFINITI
*3.0L V6 J30
Ensure crankshaft sprocket, camshaft sprockets, idler pul-
Application Labor Time Belt Part No. leys and timing belt are dry and clean. Ensure No. 1 cylin-
3.0L V6 der is at TDC of compression stroke and all timing marks
J30 are still aligned. See Fig. 2. Remove all spark plugs. Install
1993 ....................... 4.4 Hours ................... T180 timing belt with White marks on timing belt aligned with
1994-97 .................. 4.4 Hours ................... T251 timing mark on crankshaft sprocket and camshaft sprock-
ets. Ensure arrow on timing belt points toward front of en-
gine.
SCHEDULED MAINTENANCE SCHEDULE CAUTION: Timing belt must be installed so White marks on timing
belt align with timing mark on crankshaft sprocket and camshaft
The manufacturer recommends the belt be replaced every sprockets. Arrow on timing belt must point toward front of engine.
60,000 miles. DO NOT bend or twist timing belt during installation.

CAUTION: Ensure stopper bolt is removed before adjusting clearance
See page A-59 for interference engine cautions. on automatic tensioner or stopper bolt and automatic tensioner
may be damaged.
REMOVAL & INSTALLATION Remove stopper bolt from automatic tensioner. Using vise,
TIMING BELT adjust tensioner arm on automatic tensioner so .16" (4.0 mm)
clearance exists between pusher and tensioner arm. See
Removal:
Fig. 4. Once correct clearance is obtained, reinstall stopper
Disconnect negative battery cable. Raise and support ve- bolt. Install automatic tensioner on cylinder block with bolts
hicle. Remove lower engine cover. Drain radiator and cylin-
finger tight.
der block. Remove air intake ducts, radiator, drive belts,
cooling fan assembly and starter. Remove crankshaft pul-
Slightly push automatic tensioner inward against timing
belt to prevent timing belt from slipping. DO NOT push to
ley bolt. Using puller, remove crankshaft pulley. Remove
hard or timing belt will be adjusted too tight. Rotate crank-
coolant inlet and outlets for access to timing belt cover.
shaft 10 degrees clockwise. Tighten automatic tensioner
retaining nut and then the bolts to specification in sequence.
NOTE: Crankshaft position sensor is mounted on front of exhaust See Fig. 4. See TORQUE SPECIFICATIONS.
camshaft on driver side. Crankshaft position sensor removal Rotate crankshaft 120 degrees counterclockwise. Loosen
may be required for timing belt cover removal. Mark location automatic tensioner retaining bolts and nut 1/2 turn. Rotate
of crankshaft position sensor before removing to ensure proper automatic tensioner back as far as possible. Rotate crank-
installation during reassembly. shaft clockwise until No. 1 cylinder is at TDC on compres-
sion stroke and all timing marks are aligned. See Fig. 5.
Install a 6x16 mm stopper bolt on automatic tensioner to Using Push-Pull Gauge (J-38387) or equivalent and Hook
prevent tensioner from pushing outward. See Fig. 1. Ro- (KV10112000) or equivalent, push end of pusher on auto-
tate engine so No. 1 cylinder is at TDC on compression matic tensioner inward against timing belt with a force of
stroke. No. 1 cylinder is front cylinder on right side when 13.2 lbs. (6 kg). See Fig. 6. Tighten automatic tensioner
viewed from rear of engine. Ensure timing marks on cam- retaining nut and then the bolts to specification in sequence.
shaft sprockets and crankshaft sprocket are aligned. See See Fig. 4. See TORQUE SPECIFICATIONS.
Fig. 2. Remove bolts and automatic tensioner. Remove
timing belt. DO NOT rotate crankshaft or camshafts with
timing belt removed or engine damage may result.
Inspection:
Inspect timing belt for cracks, worn teeth or oil contamina-
tion. Inspect crankshaft sprocket and camshaft sprockets
for damaged teeth. Inspect automatic tensioner for signs
of oil leakage around the shaft that pushes the pulley out-
ward. Check all idler pulleys for smooth rotation. Replace
components if damaged.
Fig. 1: Installing Stopper Bolt On Automatic Tensioner

INFINITI 311
*3.0L V6 J30 (Cont.)
Courtesy of Nissan Motor Co., U.S.A.

Rotate crankshaft clockwise 120 degrees clockwise from

No. 1 cylinder TDC position. Rotate crankshaft counter-
clockwise 120 degrees back to No. 1 cylinder TDC posi-
tion. Fabricate belt tension plate to proper specification.
See Fig. 7. Using belt tension plate and push-pull gauge,
check timing belt deflection at mid-way distance between
sprockets and idler pulleys using 11 Ibs. (5 kg) force. See
Fig. 7. Timing belt deflection should be .24-.28" (6.0-7.0
mm).
If timing belt deflection is not within specification, repeat
previous four steps until proper timing belt deflection is
obtained. Ensure automatic tensioner retaining nut and
bolts are tightened to specification. See TORQUE SPECI- Fig. 4: Adjusting Automatic Tensioner Clearance &
FICATIONS. Remove stopper bolt from automatic Identifying Bolt/Nut Tightening Sequence
tensioner.
312 INFINITI
*3.0L V6 J30 (Cont.)
Fig. 6: Adjusting Automatic Timing Belt Tensioner
Fig. 5: Aligning Crankshaft & Camshaft Timing Marks Fig. 7: Fabricating Belt Tension Plate & Checking
Timing Belt Deflection
NOTE: If timing belt deflection does not meet specification, it
may be necessary to apply more or less tension against the pusher
on automatic belt tensioner in previous step. Application Ft. Lbs. (N.m)
Automatic Tensioner Bolt/Nut ........................... 12-15 (16-20)
After 5 minutes, ensure clearance between tensioner arm
and pusher on automatic tensioner is .138-.205" (3.50-
Exhaust .......................................................... 11-14 (15-19)
5.20 mm). Ensure timing belt will not slip at any point on
Intake ......................................................... 91-97 (123-132)
camshaft sprockets and crankshaft sprocket.
Crankshaft Position Sensor Brackets .............. 12-15 (16-20)
dure. Tighten all fasteners to specification. See TORQUE
Engine Mount-To-Frame Nut ............................ 41-49 (56-66)
Idler Pulley Nut ................................................. 32-43 (45-58)
Water Pump Bolt .............................................. 12-15 (16-20)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt .................................. 44 (5)
Rear Cover Bolt .......................................................... 53 (6)
Upper & Lower ........................................................... 27 (3)
Valve Cover Bolt/Screw
Exhaust Camshaft Cover ........................................... 71 (8)
Intake Camshaft Cover ............................................... 27 (3)
INFINITI 313
*3.0L V6 M30
TIMING BELT APPLICATION Rotate timing belt tensioner fully outward (away from tim-
ing belt area) and temporarily tighten retaining nut. Align
Belt White marks on timing belt with timing marks on camshaft
Labor Component Part and crankshaft sprocket and install timing belt.
Application Labor Kit No. No.
3.0L V6 CAUTION: Install timing belt with arrow pointing toward timing
belt cover. With timing belt installed, 40 teeth should be between
M30 timing marks on right and left camshafts and 43 teeth between
1990-92 .......... 4.0 Hours ... TCK104 .......... T104 timing mark on left camshaft sprocket and timing mark on crankshaft
sprocket. See Fig. 1.
NOTE: A timing belt component kit is available for Using an Allen wrench, hold tension on timing belt tensioner
this application. See page I for information on component and loosen retaining nut. Rotate timing belt tensioner clock-
kits. wise 70-80 degrees and tighten retaining nut. Rotate crank-
shaft clockwise 2 full revolutions and realign timing marks
so No. 1 cylinder is at TDC on compression stroke. Apply
MANUFACTURERS SUGGESTED 22 lbs (10 kg) of pressure on timing belt at midway point
SCHEDULED MAINTENANCE between timing belt tensioner and camshaft sprocket. See
The manufacturer recommends the belt be replaced every Fig. 2.
60,000 miles. Loosen timing belt tensioner retaining nut while maintaining
pressure on timing belt tensioner using an Allen wrench. In-
* NOTE: This application is an interference engine. sert a .0138" (.350 mm) thick and 1/2" wide feeler gauge be-
tween timing belt tensioner and timing belt. Perform first step
See page A-59 for interference engine cautions. of installation. See Fig. 3.
Rotate crankshaft clockwise until feeler gauge is properly
REMOVAL & INSTALLATION positioned between timing belt and timing belt tensioner.
Perform second step of installation. See Fig. 3. Timing belt
TIMING BELT should move approximately 2 1/2 teeth. Maintain steady
Removal: pressure on timing belt tenisoner. Tighten timing belt
Disconnect negative battery cable. Remove lower engine tensioner retaining nut to specification. See TORQUE
covers. Drain cooling system. Remove radiator, cooling fan SPECIFICATIONS.
and accessory drive belts. Remove water pump pulley, spark Rotate crankshaft clockwise and remove feeler gauge. Ro-
plugs and distributor cover. Remove fresh air tube from tate crankshaft clockwise 2 full revolutions and realign tim-
rocker arm cover. ing marks so No. 1 cylinder is at TDC on compression
Remove A/C drive belt idler bracket. Disconnect coolant stroke. Timing belt deflection should be .51-.59" (13.0-15.0
inlet hose from thermostat housing. Remove crankshaft mm) when applying 22 lbs. (10 kg) pressure on timing belt
pulley retaining bolt. Using puller, remove crankshaft pul- at midway poing between camshaft sprockets.
ley. Remove front upper and lower timing belt covers. See To install remaining components, reverse removal proce-
Fig. 2. dure. Tighten all bolts and nuts to specification. See
Temporarily install crankshaft pulley retaining bolt. Using TORQUE SPECIFICATIONS. Fill and bleed cooling system.
crankshaft pulley retaining bolt, rotate crankshaft until No. Adjust drive belts to proper tension. See page A-60 for belt
1 cylinder is at TDC on compression stroke and all timing tension ranges.
marks are aligned See Fig. 1. Loosen timing belt tensioner
retaining nut. Rotate timing belt tensioner to release timing
belt tension. Remove timing belt.
NOTE: No. 1 cylinder is front cylinder on left when viewed from

front of engine.

belt removed or engine damage may result.
Inspection:
tamination. Ensure timing belt tensioner rotates smoothly.
Inspect tensioner spring for damage. Replace components
if damaged.
Installation:
Ensure No. 1 cylinder is TDC on compression stroke and
all timing marks are aligned. See Fig. 1. Install timing belt
tensioner and tensioner spring (if removed). If tensioner
spring stud was removed from cylinder block, apply thread
sealant to threads before installing.
Fig. 1: Aligning Timing Marks & Checking Belt Tension

314 INFINITI
*3.0L V6 M30 (Cont.)

Camshaft Locating Plate Bolt ........................... 58-65 (79-88)
Crossmember-To-Body Bolt ............................. 32-41 (43-56)
Timing Belt Tensioner Nut ................................ 32-43 (43-58)
Water Pump Bolt .............................................. 12-15 (16-20)
INCH Lbs. (N.m)
Rocker Arm Cover Bolt ............................................ 9-27 (1-3)
Timing Belt Cover Bolt .......................................... 27-44 (3-5)
Fig. 3: Checking Timing Belt Clearance

ISUZU 315

TIMING BELT APPLICATION Installation (DOHC):
Rotate camshafts so timing marks align with cylinder head
Application Labor Time1 Belt Part No. surface. Install 6 mm bolts in lock bolt holes to secure
1.6L 4-Cyl. DOHC camshafts. Ensure timing mark (notch) on crankshaft
I-Mark sprocket aligns with timing mark on oil pump. See Fig. 3.
1989 ......................... 2.0 Hours .................. T169 Install timing belt in the following order: over crankshaft
Impulse sprocket, water pump, idler pulley, exhaust camshaft, in-
take camshaft and belt tensioner. Ensure no slack exists in
1990-92 Non-Turbo . 2.0 Hours .................. T169 belt.
1991-92 Turbo ....... 2.4 Hours .................. T169 Loosen bolt and allow tensioner pulley to apply tension on
Stylus timing belt. Hold tensioner pulley and tighten tensioner pulley
1991 ......................... 2.0 Hours .................. T169 bolt.
1.6L 4-Cyl. SOHC
CAUTION: On new timing belts, push tensioner pulley sightly
Stylus
inward to apply more pressure on timing belt. On used timing
1991-93 .................... 3.0 Hours .................. T177 belts, allow only spring tension to be applied to timing belt.
1.8L 4-Cyl. SOHC
Impulse Rotate crankshaft 2 revolutions in direction of engine rota-
tion. Ensure all timing marks align. Rotate crankshaft 60
1992 ......................... 2.4 Hours .................. T205 degrees. Measure timing belt deflection at midpoint be-
Stylus tween camshaft sprockets. Ensure timing belt defection is
1992-93 .................... 2.4 Hours .................. T205 within specification. See TIMING BELT DEFLECTION
1
- With Air Cond. add .4 hours. SPECIFICATIONS. If belt deflection is not within specifica-
With Pwr. Strng. add .3 hours. tion, repeat the last two steps.
CAUTION: Ensure timing marks align after belt adjustment.

SCHEDULED MAINTENANCE To install remaining components, reverse removal proce-
The manufacturer recommends the belt be replaced every FICATIONS. Adjust drive belts to proper tension.
60,000 miles. TIMING BELT DEFLECTION SPECIFICATIONS
*NOTE: The 1991-93 1.6L (SOHC) engine used in Application In. (mm)
the Stylus is an interference engine. See page A- DOHC
New Belt ..................................................... .28-.33 (7.1-8.4)
59 for interference engine cautions. Used Belt ................................................. .35-.41 (8.9-10.4)
SOHC
REMOVAL & INSTALLATION New Or Used Belt ........................................ .63-.79 (16-20)
TIMING BELT Removal (SOHC):

Removal (DOHC):
Disconnect negative battery cable. Support engine. Remove
right side engine mount. Remove alternator and power steer-
Disconnect negative battery cable. Remove accessory drive ing pump drive belts. Ensure engine is supported. Remove
belts. Remove upper timing belt cover. See Fig. 1. Support engine mounting bracket located at timing belt cover.
engine. Remove engine mounting bracket located at tim- Remove crankshaft pulley bolts. Remove crankshaft pulley
ing belt cover. Rotate crankshaft and position No. 1 cylinder from crankshaft pulley hub. Remove timing belt cover. Ro-
at TDC of compression stroke. Ensure timing mark on crank- tate crankshaft and position No. 4 cylinder at TDC of com-
shaft pulley aligns with 0 timing mark on timing belt cover. pression stroke. Ensure timing mark on camshaft pulley
Ensure timing marks on camshaft sprockets are aligned aligns with cylinder head. See Fig. 4 .
with cylinder head surface. See Fig. 3. Disconnect front Ensure timing mark (notch) on crankshaft sprocket aligns
exhaust pipe. Remove bolts attaching torque rod bracket to with timing mark on oil pump. See Fig. 4. Loosen tensioner
cylinder block. Remove bolt attaching torque rod to vehicle pulley bolt. Rotate tensioner pulley to loosen timing belt
frame. Remove torque rod and bracket as an assembly. tension. Mark timing belt direction of rotation if reusing belt.
Remove engine stiffener brace. See Fig. 2. Remove fly- Remove timing belt.
wheel dust cover. Hold flywheel while removing crankshaft Inspection (SOHC):
pulley bolt. Remove crankshaft pulley. Remove lower tim- Inspect timing belt for damaged teeth, cracking or oil con-
ing belt cover. tamination. Ensure tensioner pulley rotates freely. Replace
Ensure timing mark (notch) on crankshaft sprocket aligns components if damaged.
with timing mark on oil pump. See Fig. 3. Loosen tensioner Installation (SOHC):
pulley bolt 1/2 turn. Rotate tensioner pulley clockwise. Mark Rotate camshaft so timing mark aligns with cylinder head
timing belt direction of rotation if reusing old belt. Remove surface. Ensure dowel pin on camshaft pulley is in the up
timing belt. position. See Fig. 4. Ensure timing mark (notch) on crank-
Inspection (DOHC): shaft sprocket aligns with timing mark on oil pump. See
Inspect timing belt for damaged teeth, cracking or oil con- Fig. 4. Install timing belt in the following order: over crank-
tamination. Ensure tensioner pulley and idler pulley rotate shaft sprocket, camshaft pulley, water pump and belt
freely. Replace components if damaged. tensioner.
316 ISUZU
Insert a hex wrench into belt tensioner. Rotate tensioner
pulley counterclockwise to tension belt. Hold tensioner
pulley, and tighten pulley bolt. Rotate crankshaft back to
approximately 50 degrees BTDC and back to TDC for No. 4
cylinder. Ensure all timing marks align. Measure timing
belt deflection. See Fig. 5. Ensure timing belt defection is
within specification. If belt deflection is not within specifica-
tion, repeat thisstep.
FICATIONS. Adjust drive belts to proper tension. See page
CAUTION: Ensure timing marks align after belt adjustment.
TORQUE SPECIFICATIONS Fig. 2: Engine Stiffener Brace

DOHC ................................................................... 109 (148)
SOHC ....................................................................... 62 (84)
Idler Pulley Bolt ........................................................... 31 (42)
Left Engine Mount Bolt ................................................ 51 (69)
Right Engine Mount Bolt ........................................... 89 (121)
Right Engine Mount Nut ............................................. 37 (50)
Right Engine Mount Through-Bolt .............................. 51 (69)
Tensioner Pulley Bolt
DOHC ....................................................................... 31 (42)
SOHC ....................................................................... 37 (50)
Water Pump Bolt ........................................................ 17 (23)
Wheel Lug Nut .......................................................... 87 (118)
INCH Lbs. (N.m)
Fig. 3: Aligning Timing Marks (DOHC)

Fig. 1: Routing Timing Belt (DOHC)
Fig. 4: Aligning Timing Marks (SOHC)

ISUZU 317
Fig. 5: Checking Timing Belt Tension (SOHC)
Fig. 7: Routing Timing Belt (SOHC)
Fig. 6: Tightening Sequence For Valve Cover Bolts (DOHC)

318 ISUZU
TIMING BELT APPLICATION Check that fixing plate fits smoothly into slot at rear of cam-
shaft, then remove fixing plate. Loosen tensioner pulley
Application 1
Labor Time Belt Part No. pivot bolts and take up timing belt slack. Tighten tensioner
1.8L 4-Cyl. Diesel pulley center bolt, then tighten pivot bolts. Using Tension
I-Mark Gauge (J-29771) or equivalent, check for 47-64 Ibs. (21-29
1981-84 ................. 3.1 Hours ..................... T076 kg) tension between camshaft and injection pump sprock-
ets.
1
- With Air Cond. add .4 hours. Remove crankshaft pulley and install timing belt holder.
With Pwr. Strng. add .3 hours. Ensure that timing belt holder does not rubagainst timing
belt. Reverse removal procedure to complete installation.
MANUFACTURERS SUGGESTED Adjust drive belts to proper tension. See page A-60 for belt
SCHEDULED MAINTENANCE tension ranges.
60,000 miles. Application Ft. Lbs. (N.m)
Camshaft Sprocket ........................................... 43-50 (58-68)
* NOTE: This application is an interference engine. Crankshaft Pulley ............................................. 11-18 (15-24)
See page A-59 for interference engine cautions. Injection Pump Timing Pulley ........................... 42-52 (57-71)
Tensioner Pulley
Center Bolt ...................................................... 47-64 (64-87)
REMOVAL & INSTALLATION Pivot Bolt ......................................................... 11-18 (15-24)
TIMING BELT & VALVE TIMING
Removal:
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.
With piston of No. 1 cylinder at TDC of compression stroke,
check that timing marks on injection pump sprocket and
front plate are aligned. Lock sprocket in place by inserting
a bolt through sprocket and into block. See Fig. 1.
Remove air cleaner and PCV valve hose. Remove valve cover.
Loosen adjusting screws on rocker arms to relieve tension
on camshaft. Lock camshaft in place by installing Fixing
Plate (J-29761) or equivalent, in slot at rear of camshaft.
See Fig. 2.
Ensure that No. 1 piston is still at TDC, then remove crank-
shaft pulley. Remove lower timing belt cover. Remove tim-
ing belt holder. See Fig. 3. Remove tension spring located
behind front plate. Loosen tensioner pulley and pivot bolts.
Remove timing belt.
Installation:
Remove camshaft sprocket center bolt. Using Puller (J-29801) Fig. 1: Aligning Injection Pump Timing Marks
or equivalent, remove camshaft sprocket. Install sprocket on
camshaft. Lightly tighten center bolt so that sprocket can
be turned smoothly by hand. Starting at crankshaft sprocket
and working in a counterclockwise direction, engage new
timing belt over each sprocket and pulley. Check that belt is
properly engaged on all sprockets and pulleys. See Fig. 4.
Take up belt slack at tensioner pulley by depressing pulley
and installing tension spring. Tighten tensioner pulley pivot
bolts just enough to prevent pulley movement. See Fig. 5.
DO NOT tighten pulley center bolt at this time.
Tighten camshaft sprocket bolt. Remove bolt used to lock
injection pump sprocket in place. Remove fixing plate used
to lock camshaft in place. Install crankshaft pulley on hub.
Check that No.1 piston is still at TDC. DO NOT turn crank-
shaft in an attempt to adjust timing mark on pulley. Ensure
that timing marks on injection pump sprocket and front
plate are still aligned.
Fig. 2: Camshaft Fixing Plate

ISUZU 319

Fig. 5: Location Of Tensioner Pulley
Fig. 3: Location Of Timing Belt Holder

320 ISUZU
*2.0L, 2.3L & 2.6L 4-Cylinder
2.0L 4-Cyl. Turbo
Impulse NOTE: Some procedures may differ slightly due to engine construction.
1985-89 Removal:
A/T ..................... 1 3.6 Hours .................... T121 Disconnect negative battery cable. Remove all necessary
M/T .................... 1 3.4 Hours .................... T121 air ducts. Position No. 1 cylinder at TDC of compression
2.3L 4-Cyl. stroke. Align timing marks. See Fig. 1. Remove fan and fan
Amigo shroud. Remove accessory drive belts. Remove water pump
1989-93 pulley. If necessary, remove radiator and splash guard.
A/T ..................... 1 1.9 Hours .................... T122 Prevent engine from rotating and remove crankshaft timing
pulley. Remove upper and lower timing belt covers. Re-
M/T .................... 1 1.6 Hours .................... T122 move spring from tension pulley. Loosen adjusting bolt
Impulse and move pulley toward water pump. Remove timing belt.
1988-89
A/T ..................... 1 3.6 Hours .................... T122 CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft
M/T .................... 1 3.4 Hours .................... T122 or damage may result.
Pickup Inspection:
1986-95 Handle timing belt carefully. Avoid twisting or kinking belt.
A/T ..................... 1 1.9 Hours .................... T122 DO NOT allow belt to become contaminated by water, oil,
M/T .................... 1 1.6 Hours .................... T122 dirt or other contaminates. Inspect belt for cracks or dam-
age. Replace, if necessary.
Trooper II On 2.0L engines, measure outside diameter of crankshaft,
1986-87 camshaft and oil pump sprockets. If specifications are ex-
A/T ..................... 1 1.9 Hours .................... T122 ceeded, replace sprocket(s). See TIMING SPROCKET
M/T .................... 1 1.6 Hours .................... T122 SPECIFICATIONS table.
2.6L 4-Cyl. On all engines, measure tension pulley spring length and
Amigo force. On 2.3L and 2.6L engine, spring length should not
1989-94 exceed 2.76" (70.2 mm) and spring force should not be
less than 60-106 lbs. (27-48 kg).
A/T ..................... 1 1.9 Hours .................... T147 On 2.0L, spring length should not exceed 3.11" (79 mm)
M/T .................... 1 1.6 Hours .................... T147 and spring force should not be less than 53-57 lbs. (24-26
Pickup kg). On all engines, replace tension pulley spring if not
1988-95 within specification.
A/T ..................... 1 1.9 Hours .................... T147 TIMING SPROCKET SPECIFICATIONS
M/T .................... 1 1.6 Hours .................... T147 Application Standard Limit
Rodeo In. (mm) In. (mm)
1991-97 Camshaft ....................... 5.202 ................................ 5.198
A/T ..................... 1 1.9 Hours .................... T147 (132.03) ......................... (131.93)
M/T .................... 1 1.6 Hours .................... T147 Crankshaft ...................... 2.574 ................................ 2.570
Trooper (65.33) ............................. (65.23)
1990-91 Oil Pump ........................ 4.485 ................................ 4.481
(113.84) ......................... (113.74)
A/T ..................... 1 1.9 Hours .................... T147
M/T .................... 1 1.6 Hours .................... T147 Installation:
Trooper II Pull tensioner fully toward water pump side and tempo-
rarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC
1988-89 on compression stroke by rotating crankshaft until keyway
A/T ..................... 1 1.9 Hours .................... T147 aligns with mark on front crankshaft seal housing (12
M/T .................... 1 1.6 Hours .................... T147 oclock). Rotate camshaft until timing mark on cam gear
1
- With Air Cond. add .4 hours. (arrow) aligns with mark on upper camshaft cover (notch).
See Fig. 3.
With Pwr. Strng. add .3 hours. Position timing belt over crankshaft sprocket, oil pump
sprocket, camshaft sprocket and tensioner in that order.
MANUFACTURERS SUGGESTED Ensure belt is positioned in sequence given and without
SCHEDULED MAINTENANCE slack between sprockets. Loosen tensioner pulley adjust-
ing bolt allowing spring tension to tighten belt. Tighten ad-
The manufacturer recommends the belt be replaced every justing bolt temporarily.
60,000 miles. Temporarily install crankshaft pulley bolt and rotate crank-
shaft 2 complete revolutions in opposite direction of en-
*NOTE: This application is an interference engine. gine rotation, until marks on crankshaft and front oil seal
See page A-59 for interference engine cautions. retainer are aligned again. See Fig. 3. Loosen tensioner
lock bolt, allowing tensioner spring to fully adjust tension.
Tighten tensioner lock bolt.
ISUZU 321
*2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
Install timing belt covers. To complete installation, reverse

removal procedures. Tighten all bolts to specification. See
Front Cover ................................................................. 14 (19)
Tensioner Pulley
Bolts ......................................................................... 18 (24)
Nut ............................................................................ 10 (14)
Water Pump ............................................................... 14 (19)
INCH Lbs. (N.m)
322 ISUZU
*2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
Fig. 2: Installing Belt Guide
Fig. 3: Timing Alignment Marks

ISUZU 323

TIMING BELT APPLICATION Install and tighten injection pump pulley flange. Ensure
hole in flange lines up with triangular timing mark on pump
Belt Part No. sprocket. See Fig. 3. Turn crankshaft 2 more turns, bring-
2.2L 4-Cyl. Diesel ing No. 1 cylinder to TDC on compression stroke. Check
LUV (Chevrolet) timing mark alignment. Check timing belt tension with Ten-
1981-82 .................... 2.7 Hours......................T075 sion Gauge (J-29771) or equivalent. Tension should be
Pickup (Isuzu) 33-55 Ibs. (15-25 kg). Reverse removal procedure to com-
plete installation. Adjust drive belts to proper tension. See
1983-85 .................... 2.7 Hours......................T075 page A-60 for belt tension ranges.
PUP
1981-87 .................... 2.7 Hours......................T075
S10 & S15 Pickup (Chevrolet/GMC) Application Ft. Lbs. (N.m)
1983-85 .................... 2.7 Hours......................T075 Camshaft Sprocket Bolt .................................. 72-87 (98-118)
Trooper II Crankshaft Sprocket Bolt .......................... 124-151 (168-205)
Injection Pump Timing Pulley Bolt .................... 42-52 (57-71)
1984-87 ..................... 2.7 Hours ....................T075 Tension Spring Nut ........................................... 22-36 (30-49)
1
- With Air Cond. add .4 hours. Timing Belt Tensioner Bolts ........................ 79-94 (107-127)
60,000 miles.


TIMING BELT
Removal:
cover. Drain cooling system. Remove battery. Remove fan,
fan shroud, top radiator hose and drive belts. Remove 4
crankshaft pulley bolts and crankshaft pulley. Remove tim-
ing belt covers. See Fig. 1.
Remove tension spring. See Fig. 2. Position No. 1 cylinder
at TDC of compression stroke. Ensure injection pump and
camshaft sprocket timing marks are aligned. See Fig. 3. Fig. 1: Removing Timing Belt Covers
Remove injection pump pulley flange bolts and remove
flange. Remove tensioner spring without using excess force
on spring. Remove tension pulley nut and tensioner as-
sembly. Remove timing belt.
Installation:
Ensure that timing marks on injection pump, camshaft
sprockets, crankshaft pulley and timing pointer are aligned.
See Fig. 4. Install timing belt over crankshaft sprocket, cam-
shaft sprocket and injection pump sprocket.
Install tensioner assembly so that end of tensioner is in
contact with 2 pins on timing pulley housing. See Fig. 5.
Hand tighten nut. Install tension spring. Tighten nut to 22-
36 ft. Ibs. (30-49 N.m). Turn crankshaft 2 complete revolu-
tions in normal direction of rotation, then turn crankshaft 90
degrees past TDC. Loosen tensioner nut completely and
allow tensioner to take up slack. Tighten nut.
Fig. 2: Removing Tension Spring

324 ISUZU
Fig. 5: Timing Belt Tensioner Installation
Fig. 3: Timing Belt Sprocket Alignment
Fig. 6: Injection Pump Timing Alignment Marks
Fig. 4: Timing Mark Alignment

ISUZU 325

TIMING BELT APPLICATION Remove timing belt cover. If reusing old belt, place mark
on belt to indicate direction of belt rotation.
Application Labor Time Belt Part No. Rotate crankshaft so camshaft and crankshaft timing marks
2.2L 4-Cyl. DOHC are aligned. See Fig. 1. Loosen timing belt tensioner pulley
Amigo bolt, and move tensioner away from timing belt. Remove
1998-00 timing belt.
Auto. Trans. ....... 1 1.9 Hours .................... T305 Inspection:
Man. Trans. ....... 1 1.6 Hours .................... T305 Check timing belt for cracks, cracked or missing teeth, and
separating canvas. Inspect timing belt tensioner and idler
Rodeo pulley for worn bearings.
1998-01 Installation:
Auto. Trans. ....... 1 1.9 Hours .................... T305 Ensure camshaft and crankshaft timing marks are still
Man. Trans. ....... 1 1.6 Hours .................... T305 aligned. See Fig. 1. Place Camshaft Locking Tool (J-43037)
between camshafts to prevent movement.
1
- With Air Cond. add .4 hours. Install timing belt on engine. If reusing old belt, install belt
in original position. Ensure there is no slack in belt. Loosen
MANUFACTURERS SUGGESTED tensioner pulley center bolt. Move timing belt tensioner to-
ward belt.
For 1998 vehicles, the manufacturer recommends the belt be NOTE: Adjust timing belt tension with engine cold.
replaced every 75,000 miles. For 1999-00 vehicles, the manu- To tension timing belt, align timing belt tensioner arrow in
facturer recommends the belt be replaced every 100,000 miles correct position for new or used belt. See Fig. 2. Tighten
for normal service, or 75,000 miles for severe service. timing belt tensioner to specification. See TORQUE SPECI-
For 2001 vehicles, the manufacturer recommends the belt be FICATIONS.
replaced every 75,000 miles for normal service, or 60,000 Remove camshaft locking tool. Turn crankshaft 2 turns in
miles for severe service. normal direction of rotation until No. 1 cylinder is at TDC.
Check alignment of timing belt tensioner pointer. If marks
*NOTE: This application is an interference engine. do NOT align, repeat timing belt tensioning procedure.
See page A-59 for interference engine cautions. Install timing belt cover. Install engine harness cover. Con-
nect engine harness electrical connectors. Continue in-
REMOVAL & INSTALLATION stallation in reverse of removal procedure.
TIMING BELT
Removal:
Disconnect negative battery cable. Remove serpentine drive
belt. Remove engine wiring harness cover, and disconnect
3 connectors from left rear side of engine compartment.
Remove 4 crankshaft pulley bolts and remove pulley from
crankshaft. It is NOT necessary to remove the crankshaft
center bolt. Remove engine harness cover from front of
engine.
Courtesy of Isuzu Motor Co. Courtesy of Isuzu Motor Co.
Fig. 1: Aligning Timing Marks Fig. 2: Adjusting Timing Belt Tension

326 ISUZU
Camshaft Sprocket Bolt 1
Step 1 ........................................................................... 36 (50)
Step 2 ................................................................ + 60 Degrees
Step 3 (1998-00 Engines Only) ......................... +15 Degrees
Step 1 ......................................................................... 94 (130)
Step 2 ................................................................ + 45 Degrees
Water Pump Bolt ........................................................... 18 (25)
INCH Lbs. (N.m)
Engine Harness Cover-To-Engine .................................. 53 (6)
1
Replace bolt if loosened or removed.
ISUZU 327
*2.2L 4-Cylinder Oasis

Belt
2.2L 4-Cyl. RA1
Oasis
1996-97
Balancer Shaft .................. TCK186 ....... T186
Camshaft ....... 1, 2 2.7 Hrs. .. TCK186 ........ T187
1
- Balancer shaft belt included in camshaft belt
labor time.
2

kits.
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).
*NOTE: This application is an interference engine. 96H14628 Courtesy of American Honda Motor Co., Inc.
See page A-59 for interference engine cautions. Fig. 1: Timing Belt, Balancer Belt & Related Components

TIMING BELT
Removal:
signs of seal leakage.
and connector. Raise and support vehicle. Remove
wheelwell splash shield. Using a jack with block of wood
to support engine, remove side engine mount.
Remove upper and lower timing belt covers. Loosen tim-
ing belt tension adjuster bolt 145-180 degrees. Push
tensioner to release belt tension from timing belt and bal-
ancer belt. Retighten tension adjuster bolt. Mark rotation
direction of timing belt if it is to be reused. Remove timing
belt from pulleys.
Installation:
Ensure cylinder No. 1 is at TDC of compression stroke. 96I14629 Courtesy of American Honda Motor Co., Inc.
Install timing belt in sequence shown. See Fig. 6. Tighten Fig. 2: Removing/Installing Timing Belt Covers
bolts to specification. See TORQUE SPECIFICATIONS. To
ranges.
328 ISUZU
*2.2L 4-Cylinder Oasis (Cont.)



Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark TORQUE SPECIFICATIONS
INCH Lbs. (N.m)
Timing Belt Cover Bolt .................................. 86-104 (7.2-8.7)
Valve Cover Nut ......................................................... 86 (9.8)
ISUZU 329
*2.3L 4-Cylinder Oasis

2.3L 4-Cyl. F23A, SOHC
Oasis
1998-99
Balancer Shaft .. 1 4.0 Hours ................... T186
Camshaft ........... 1 4.0 Hours ................... T244
1
labor time.
Replace at 60,000 miles if vehicle is regularly driven in ex-
treme temperatures (over 110 degrees F, or under -20 de-
grees F).


TIMING & BALANCER SHAFT BELTS

Removal:
signs of seal leakage. Raise and support vehicle. Remove 96H14628 Courtesy of American Honda Motor Co., Inc.
engine lower splash shield. Fig. 1: Timing Belt, Balancer Belt & Related Components
and connector. Remove alternator and alternator bracket.
Using a jack with a block of wood to support engine, re-
move side engine mount from front of engine. Remove
dipstick tube from front of engine.
Insert a 6 mm timing cover bolt through the hole in the end
of the timing belt adjuster arm. This will temporarily lock
the arm in place.
Loosen belt tension adjusting nut about 1 turn. See Fig. 3.
Push outer balancer shaft belt tensioner pulley up to take
tension off of the balancer belt. Retighten belt tension ad-
justing nut. Remove balancer shaft belt.
Loosen belt tension adjusting nut about 1 turn. See Fig. 3.
Push camshaft timing belt tensioner pulley down to take
tension off of camshaft timing belt. Retighten belt tension
adjusting nut. Remove camshaft timing belt.
Installation:
Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by
aligning dimple on timing belt drive pulley with pointer on
oil pump housing. See Fig. 4. Ensure camshaft pulley TDC
marks are aligned. See Fig. 5.
Install camshaft timing belt in sequence shown. See Fig.
6. Loosen and retighten tensioner adjusting nut to tension
camshaft timing belt. Install balancer belt drive pulley and 96I14629 Courtesy of American Honda Motor Co., Inc.
lower cover. Install crankshaft pulley. Install bolt. Fig. 2: Removing/Installing Timing Belt Covers
330 ISUZU

Remove crankshaft pulley and lower cover. Set timing belt
drive pulley to TDC position.
Rotate crankshaft pulley COUNTERCLOCKWISE about 5- Lock camshaft timing belt adjuster arm in place by install-
6 turns so timing belt positions on pulley. Set No. 1 piston ing a 6x10 mm timing cover bolt. Loosen belt tension ad-
at TDC of compression stroke. Loosen belt tensioner adjusting nut about 1 turn. See Fig. 3. Verify balancer belt
justing nut about 1 turn. Rotate crankshaft counterclock- tensioner pulley moves freely. Push balancer belt tensioner
wise 3 teeth on camshaft pulley. Tighten belt tensioner ad- up then retighten belt tensioner adjusting nut.
justing nut to specification. See TORQUE SPECIFICA- Remove sealing bolt from maintenance hole on sideof en-
TIONS. gine block. See Fig. 7. Scribe a line 2.9 (74 mm) from end
Rotate crankshaft so that crankshaft and camshaft pulleys of of 6x100 mm bolt. Install 6x100 mm bolt into mainte-
are at TDC position. Ensure camshaft UP mark is facing nance hole to lock balancer shaft in place.
up. If they are not, timing belt will have to be repositioned. Align front balancer shaft pulley groove with pointer on oil
pump housing. See Fig. 8. Install balancer belt. Loosen
tensioner adjusting nut about 1 turn to tension balancer
shaft belt. Remove 6x100 mm bolt from rear of balancer
shaft. Install sealing bolt with new washer.
ISUZU 331

Temporarily install crankshaft pulley and bolt. Turn crank-
shaft pulley about 1 turn counterclockwise, then tighten
tensioner adjusting nut. Remove the 6x10 mm bolt that
locked camshaft timing belt adjuster arm in place.
Remove crankshaft pulley. Install lower cover with new gas-
ket or liquid gasket. Install rubber seal around belt
tensioner adjusting nut. DO NOT loosen nut. Install crank-
shaft pulley. Lubricate crankshaft pulley bolt and underside
of bolt shoulder. Install and tighten crankshaft pulley bolt to
specification.
Install dipstick tube with new O ring. When installing cyl-
inder head cover gasket, apply liquid gasket (Part No. 08718-
0001 or -0003) to 4 corners where gasket meets cam-
shafts.
Install alternator and harness. Install accessory drive belts.
Install engine mount bracket to engine and frame. Connect
negative battery cable. Adjust drive belts to proper tension.
Fig. 8: Aligning Balancer Belt Drive Pulley
Alternator Adjusting Locknut ........................................... 16 (22)
Engine Block Sealing Bolt .............................................. 22 (29)
Engine Bracket-To-Engine Side Mount Nut/Bolt
Oasis ........................................................................... 40 (54)
Engine Side Mount Through-Bolt
Oasis ........................................................................... 47 (64)
Engine Side Mount-To-Bracket Nut/Bolt
Oasis ........................................................................... 47 (64)
Timing Belt Tensioner Adjusting Nut .......................... 33 (44)
INCH Lbs. (N.m)
Cylinder Head Cover Nut ........................................... 86 (9.8)
Fig. 7: Locking Balancer Belt Shaft In Place Dipstick Tube Bolt ........................................................ 106 (12)
Engine Lower Splash Shield ......................................... 89 (10)
Water Pump Bolts ........................................................ 106 (12)
332 ISUZU
3.2L V6 1993-97
TIMING BELT APPLICATION SPECIFICATIONS. Adjust drive belts to proper tension. See
3.2L V6 DOHC
Trooper Application Ft. Lbs. (N.m)
1992-95 ................ 1 2.6. Hours ................... T220 Camshaft Pulley Bolt .................................................. 41 (56)
3.2L V6 SOHC Crankshaft Pulley Bolt ............................................ 123 (167)
Rodeo Fan Pulley Bolt ............................................................ 16 (22)
1993-97 ................ 1 2.8 Hours .................... T221 Front Plate Bolt ........................................................... 14 (19)
Trooper Idler Arm Retaining Bolt .............................................. 33 (44)
1992-97 ................ 1 2.8 Hours .................... T221 Power Steering Pump Bolt .......................................... 34 (46)
1
- With Air Cond. add .4 hours. Timing Belt Tensioner Pulley Bolt ............................... 32 (43)
With Pwr. Strng. add .3 hours. Timing Belt Tensioner Pusher Bolt ............................. 14 (19)
Upper Intake Manifold Bolt .......................................... 18 (24)
MANUFACTURERS SUGGESTED INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt ........................................ 87 (10)
SCHEDULED MAINTENANCE Cooling Fan Assembly Nut ........................................... 69 (8)
60,000 miles.
TIMING BELT
Removal:
sembly. Remove upper fan shroud. Remove cooling fan
assembly. Remove all accessory drive belts.
Remove fan pulley assembly. Remove crankshaft pulley
bolt. Using Puller (J-8614-01) or equivalent, remove crank-
shaft pulley pulley. Remove oil cooler hose from timing
cover. Remove timing belt cover. Align all timing marks prior
to belt removal. See Figs. 1, 2 and 3. Remove belt tensioner
pusher and timing belt.
Installation: Fig. 1: Aligning Timing Marks (DOHC)
Ensuring all timing marks are aligned. Install belt over one
pulley at a time staring at crankshaft sprocket working coun-
terclockwise. Belt should go over tensioner last. Secure
belt at each pulley during installation with pinch clips. See
Fig. 4.
CAUTION: To ensure correct timing belt installation, ensure

direction of rotation arrows are pointing in proper direction.
If timing belt is being reused, install belt in original direction
of rotation.
Compress timing belt tensioner pusher and insert pin to
retain pusher. Apply pressure to tensioner against belt and
install tensioner pusher. Tighten bolts to specification. See
Loosen tensioner pulley bolt. Apply pressure on belt by
rotating tensioner. Tighten tensioner pulley bolt to specifi- Fig. 2: Aligning Camshaft Timing Marks (SOHC)
cation. Remove pin from timing belt tensioner pusher.
Remove pinch clips from timing belt, (if used). Install crank-
shaft pulley, tightening center bolt finger tight. Rotate crank-
shaft 2 turns clockwise. Ensure timing belt tensioner pusher
rod protrudes proper amount. See Fig. 5.
If timing belt tensioner pusher rod protrusion is not within
specification, remove pusher, loosen tensioner pulley bolt
and readjust. Reset timing belt tensioner pusher rod and
repeat step 3). Remove crankshaft pulley and install timing
belt cover. To complete installation, reverse removal proce-
dure. Tighten nuts and bolts to specification. See TORQUE
ISUZU 333
3.2L V6 1993-97 (Cont.)
Fig. 3: Aligning Crankshaft Timing Marks (All Models)
Fig. 6: Exploded View Of SOHC Cylinder Head Components

(DOHC Is Similar)
Fig. 4: Installing Pinch Clip On Timing Belt
Fig. 7: Aligning Timing Belt Sprockets (DOHC)
Fig. 5: Adjusting Timing Belt Tensioner Pusher

334 ISUZU
3.2L & 3.5L V6 DOHC, 1998-01
3.2L V6
Amigo
1998-99 ................ 1 2.8 Hours .................... T303
Rodeo
1998-01 ................ 1 2.8 Hours .................... T303
3.5L V6
Trooper
1998-01 ................ 1 2.4 Hours .................... T303
VehiCROSS
1999-01 ................ 1 2.0 Hours .................... T303
1
- With Air Cond. add .4 hours. Fig. 2: Aligning Crankshaft Timing Marks
MANUFACTURERS SUGGESTED TIMING BELT
SCHEDULED MAINTENANCE Removal:
TIMING BELT REPLACEMENT INTERVALS sembly. Remove upper fan shroud. Remove serpentine
Application Miles drive belt.
3.2L V6 Remove cooling fan and drive pulley. Remove serpentine
Amigo drive belt idler pulley assembly. Remove serpentine drive
1998 ...................................................................... 75,000 belt tensioner assembly.
1999 Remove power steering pump with hoses attached, and
Normal Service .................................................... 100,000 set aside. Remove crankshaft pulley bolt. Using Puller (J-
Severe Service ....................................................... 75,000 8614-01) or equivalent, remove crankshaft pulley.
Rodeo Remove timing belt covers. Rotate crankshaft to align tim-
1998 ...................................................................... 75,000 ing marks. See Figs. 1 and 2. When timing marks are
1999-01 aligned, No. 2 piston will be at TDC.
Normal Service .................................................... 100,000 If reusing timing belt, mark belt with arrow to indicate origi-
Severe Service ....................................................... 75,000 nal rotation direction. Also place mating marks on timing
3.5L V6 belt and camshaft sprockets for reassembly reference. Re-
Trooper move timing belt tensioner, and set aside with push rod
1998 ...................................................................... 75,000 facing up. Remove timing belt.
1999-01
Normal Service .................................................... 100,000 CAUTION: To prevent air from entering timing belt tensioner,
tensioner rod must always face up.
Severe Service ....................................................... 75,000
VehiCROSS
1999-01 NOTE: For correct timing belt installation, lettering on belt must
Normal Service .................................................... 100,000 be able to be read as viewed from the front of the vehicle. Also,
Severe Service ...................................................... 75,000 note arrow on belt which indicates direction of rotation.
Installation:
Align grove on crankshaft sprocket with mark on oil pump.
See Fig. 2. Install timing belt on crankshaft pulley, aligning
White dotted line on belt with timing mark on crankshaft
pulley. Secure belt to sprocket with spring clip.
Align timing mark on right hand (passenger side) cam-
shaft sprocket with alignment mark on valve cover. See Fig.
3. Install timing belt on right hand camshaft sprocket, align-
ing the White alignment mark on timing belt with camshaft
sprocket mark. If reusing old timing belt, align mating marks
on belt and camshaft sprocket that were made during re-
moval. Secure belt with spring clip.
Align timing mark on left hand (driver side) camshaft
sprocket with alignment mark on valve cover. See Fig. 4.
Route timing belt around water pump pulley and install on
other left hand camshaft sprocket, aligning the White align-
ment mark on timing belt with camshaft sprocket mark.
Install pinch clip to hold belt on sprocket. Ensure there is
Courtesy of Isuzu Motor Co. no slack in belt between camshaft pulleys.
ISUZU 335
3.2L & 3.5L V6 DOHC, 1998-01 (Cont.)

Fig. 3: Installing Timing Belt on Right Hand Camshaft Courtesy of American Honda Motor Co.
Sprocket Fig. 5: Installing Locking Pin in Timing Belt Tensioner

Remove crankshaft pulley and install timing belt covers.
Fig. 4: Installing Timing Belt on Left Hand Camshaft belt cover bolts. See Fig. 6.
Sprocket Install crankshaft pulley. Tighten center bolt to specifica-
Install timing belt around idler pulley and tensioner pulley. tion. Install cooling fan pulley. Install power steering pump.
Temporarily install crankshaft pulley. Turn pulley clockwise Install cooling fan. Install serpentine drive belt idler pulley
slightly to give some belt slack between the crankshaft and tensioner assemblies. Install radiator fan shroud. Con-
sprocket and right hand camshaft sprocket. nect battery.
tensioner rod. Application Ft. Lbs. (N.m)
Holding tensioner upright, SLOWLY compress timing belt Cooling Fan Pulley Bolt .............................................. 16 (22)
tensioner rod until hole in top of rod and holes in housing Crankshaft Pulley Bolt ............................................ 123 (167)
are aligned. Install a locking pin through the holes. See Power Steering Pump Bolt
Fig. 5. M8 Bolt ......................................................................... 16 (22)
Install tensioner on engine with locking pin in place. Tighten M10 ............................................................................. 34 (46)
bolts to specification. See TORQUE SPECIFICATIONS. Timing Belt Cover Bolt ................................................ 14 (19)
Remove locking pin from timing belt tensioner. Remove Timing Belt Idler Pulley Bolt ........................................ 38 (52)
clips from camshaft and crankshaft sprockets. Timing Belt Tensioner Bolt ......................................... 18 (25)
Rotate crankshaft 2 turns clockwise. Ensure timing marks Timing Belt Tensioner Pulley Pivot Bolt ...................... 31 (42)
are still aligned. Water Pump Bolt ......................................................... 18 (25)
336 KIA
TIMING BELT APPLICATION deflection should be .36-45" (9.0-10.7 mm). If timing belt
deflection is not within specification, repeat timing belt
Belt tensioning procedure or replace tensioner spring. If timing
Labor Component Part belt deflection is within specification, reverse removal pro-
Application Time Kit No. No. cedure to complete installation.
1.6L 4-Cyl. Before installing valve cover, apply silicone sealer to areas
Sephia next to front camshaft journals and rear distributor mount-
1996-97 .......... 1 2.4 Hrs. .... TCK179 .......... T179 ing cap. Also apply thin bead of silicone sealer around
spark plug holes on underside of valve cover. Adjust drive
1.8L 4-Cyl. belts to proper tension. See page A-60 for belt tension
Sephia ranges.
1995-97 .......... 1 2.4 Hrs. .... TCK179 .......... T179 TORQUE SPECIFICATIONS
1
- With Air Cond. add .2 hours. Application Ft. Lbs. (N.m)
With Pwr. Strng. add . 2 hours. Crankshaft Pulley Center Bolt ................... 116-123 (157-167)
Spark Plug ........................................................ 14-17 (19-23)
NOTE: A timing belt component kit is available for Timing Belt Tensioner Bolt ............................... 28-38 (38-51)
this application. See page I for information on component INCH Lbs. (N.m)
kits. Timing Belt Cover Bolt ..................................... 69-97 (7.8-11)
Valve Cover Bolt .............................................. 44-78 (5.0-8.8)
MANUFACTURERS SUGGESTED Water Pump Pulley Bolt ................................... 69-97 (7.8-11)
California Models The manufacturer recommends inspect-
ing the belt at 60,000 miles, 90,000 miles, and replacing belt
at 105,000 miles.
Except California Models The manufacturer recommends


TIMING BELT
Removal:
drive belts. Remove water pump pulley. Remove crank-
shaft pulley bolts, and remove pulley only.
Disconnect spark plug wires and remove spark plugs.
Rotate crankshaft clockwise until No. 1 cylinder is at TDC
of compression stroke. Ensure camshaft sprockets and
crankshaft sprocket timing marks align. See Fig. 2. Courtesy of Kia Motors of America, Inc.
If timing belt is to be reused, mark direction of timing belt Fig. 1: Identifying Timing Belt Covers
rotation. Loosen timing belt tensioner lock bolt. Tempo-
rarily secure tensioner away from belt with spring fully ex-
tended. Remove timing belt.
Inspection:
Check timing belt for cracks, peeling, abrasion or other
damage. Check tensioner bearing for looseness or rough-
ness of rotation. Inspect tensioner spring for stretching.
Replace parts as necessary.
Installation:
aligned. See Fig. 2. Install belt around crankshaft sprocket.
Keeping belt pulled tight on right side (facing engine), route
belt around camshaft sprockets.
Loosen timing belt tensioner lock bolt, and allow spring to
apply tension on belt. Snug tensioner lock bolt. Rotate crank-
shaft clockwise 2 complete turns. Ensure timing marks
align. If timing marks are not aligned, remove belt, realign
all timing marks, and repeat installation procedure.
Check timing belt deflection. Check timing belt deflection Courtesy of Kia Motors of America, Inc.
with 22 lbs. (10 kg) of pressure applied to belt. Timing belt Fig. 2: Aligning Camshaft Sprocket Timing Marks
KIA 337
*1.6L & 1.8L 4-Cylinder SOHC

TIMING BELT APPLICATION Rotate crankshaft clockwise 2 more turns, and check tim-
ing belt deflection. Check timing belt deflection with 22 lbs.
Belt Part No. (10 kg) of pressure applied to belt, midway between cam-
1.6L 4-Cyl. shaft and crankshaft pulleys, on side opposite tensioner.
Sephia Timing belt deflection should be .43-51" (10.9-13.0 mm).
1994-95 ................. 2.0 Hours ..................... T185 If timing belt deflection is not within specification, repeat
1.8L 4-Cyl procedure or replace tensioner spring. If timing belt de-
flection is within specification, reverse removal proce-
Sephia dure to complete installation. Adjust drive belts to proper
1996-97 ................. 2.0 Hours ..................... T185 tension. See page A-60 for belt tension ranges.
1
- With Air Cond. add .2 hours. TORQUE SPECIFICATIONS
With Pwr. Strng. add . 2 hours.
MANUFACTURERS SUGGESTED Crankshaft Pulley Lock Bolt ...................... 116-123 (157-167)
SCHEDULED MAINTENANCE Spark Plug ........................................................ 14-17 (19-23)
INCH Lbs. (N.m)
ing the belt at 60, 000 miles, 90,000 miles, and replacing belt
Camshaft Thrust Plate Bolt .......................................... 71 (8)
at 105,000 miles.
Timing Belt Cover Bolt ..................................... 69-97 (7.8-11)
Water Pump Pulley Bolt ................................... 69-97 (7.8-11)

TIMING BELT
Removal:
drive belts. Remove water pump pulley. Remove crankshaft
pulley bolts, and remove pulley only. See Fig. 2. Remove
upper and lower timing belt covers. Disconnect spark plug
wires and remove spark plugs. Rotate crankshaft clock-
wise until No. 1 cylinder is at TDC of compression stroke.
Ensure camshaft sprocket and crankshaft sprocket timing
marks align. See Fig. 1.
Loosen timing belt tensioner lock bolt. Temporarily secure
tensioner away from belt with spring fully extended. Re-
move timing belt.
Inspection:
Installation: Courtesy of Kia Motors America, Inc.
Ensure camshaft and crankshaft timing marks are still Fig. 1: Aligning Timing Marks
aligned. See Fig. 1. Install belt around crankshaft sprocket.
Keeping belt pulled tight on right side (facing engine), route
belt around camshaft sprocket.
Loosen timing belt tensioner lock bolt, and allow spring to
shaft clockwise 2 complete turns. Ensure timing marks
align. If timing marks are not aligned, remove belt, realign
all timing marks, and repeat installation procedure.
338 KIA
*1.6L & 1.8L 4-Cylinder SOHC (Cont.)
Courtesy of Kia Motors America, Inc.

KIA 339

1.8L 4-Cyl. Removal:
Sephia Disconnect negative battery cable. Remove all accessory
1998-01 ................ 1 2.4 Hours .................... T302 drive belts. Remove water pump pulley. Remove crank-
Spectra shaft pulley bolt, and remove pulley and timing belt guide
2000-01 ................ 1 2.4 Hours .................... T302 plate. See Fig. 1.
Remove upper and lower timing belt covers. Rotate crank-
1
- With Air Cond. add .2 hours. shaft clockwise until No. 1 piston is at TDC of compression
With Pwr. Strng. add . 2 hours. stroke. Ensure camshaft sprockets and crankshaft sprocket
timing marks align. See Figs. 2 and 3. Camshaft sprocket
MANUFACTURERS SUGGESTED I and E marks must face up and align with marks on
rear timing belt cover.
SCHEDULED MAINTENANCE If reusing old timing belt, mark belt with arrow to indicate
California Models The manufacturer recommends inspect- original direction of rotation. Remove timing belt tensioner
ing the belt at 60,000 miles, 90,000 miles, and replacing belt pulley. See Fig. 4. Remove timing belt.
at 105,000 miles. Inspection:
Except California Models The manufacturer recommends Check timing belt for cracks, peeling, abrasion or other
the belt be replaced every 60,000 miles. damage. Check tensioner and idler pulley bearings for
looseness or roughness of rotation. Inspect tensioner
*NOTE: This application is an interference engine. spring for stretching. Replace parts as necessary.
NOTE: Manufacturer recommends replacing timing belt tensioner
spring whenever timing belt is replaced. See Fig. 5.
Installation:
Install tensioner pulley with NEW spring. Move tensioner
away from timing belt and tighten center bolt. Ensure cam-
shaft and crankshaft timing marks are still aligned. See
Figs. 2 and 3.
Install timing belt around crankshaft sprocket. If reusing
old belt, ensure belt is installed in original direction of rota-
tion. Keeping belt pulled tight on right side (facing engine),
route belt around idler pulley, camshaft sprockets, and
tensioner pulley.
Loosen timing belt tensioner center bolt, and allow spring
to apply tension on belt. Tighten tensioner center bolt. Ro-
tate crankshaft clockwise 2 complete revolutions. Ensure
timing marks align. If timing marks are not aligned, remove
belt, realign all timing marks, and repeat installation proce-
dure.
Check timing belt deflection with 22 lbs. (10 kg) of down-
ward pressure applied to belt, midway between camshaft
Courtesy of Kia Motors of America, Inc. sprockets. Timing belt deflection should be .36-.45 (9.0-
Fig. 1: Removing Timing Belt Guide Plate 11 mm).
Courtesy of Kia Motors of America, Inc. Courtesy of Kia Motors of America, Inc.
Fig. 2: Aligning Camshaft Timing Marks Fig. 3: Aligning Crankshaft Timing Marks
340 KIA
Courtesy of Kia Motors of America, Inc. Courtesy of Kia Motors of America, Inc.
Fig. 4: Timing Belt Tensioner & Idler Pulley Fig. 5: Cross-Section Of Timing Belt Tensioner
If timing belt deflection is not within specification, repeat

timing belt tensioning procedure. If timing belt deflection is
within specification, Install timing belt covers. Install crank-
shaft and water pump pulleys. Continue installation in re-
verse of removal procedure.
tension ranges.
INCH Lbs. (N.m)
Crankshaft Pulley-To-Crankshaft Bolt .......... 106-152 (12-17)
Timing Belt Cover Bolt ..................................... 69-97 (7.8-11)
Water Pump Pulley Bolt ............................... 106-152 (12-17)
KIA 341

2.0L 4-Cyl. Camshaft Pulley Center Bolt .............................. 35-48 (47-65)
Cooling Fan Clutch-To-Pulley Nuts ............................ 24 (32)
Sportage Crankshaft Center Bolt ........................................... 120 (162)
1995-01 ................ 1 3.2 Hours .................... T281 Crankshaft Pulley-to-Crankshaft Bolts .................. 9-13 (12-17)
1
- With Air Cond. add .2 hours. Generator Mount Bolts
With Pwr. Strng. add .2 hours. Top Generator Bolt .................................................... 16 (22)
Bottom Generator Bolt ................................................ 32 (45)
MANUFACTURERS SUGGESTED Power Steering Pump Bolts ................................ 27-34 (37-46)
SCHEDULED MAINTENANCE Timing Belt Tensioner Bolt ............................... 27-38 (37-52)
Water Pump Bolt ............................................................ 16 (22)
California Models The manufacturer recommends inspect- INCH Lbs. (N.m)
ing the belt at 60,000 miles, 90,000 miles, and replacing belt Cooling Fan Shroud Bolts ............................................ 74 (8)
at 105,000 miles. Fresh Air Duct Mounting Bolts ..................................... 84 (10)
Except California Models The manufacturer recommends Timing Belt Cover Bolts ........................................ 61-87 (7-10)


TIMING BELT
Removal:
Disconnect negative battery cable. Remove 2 air ducts
mounting bolts from radiator. Loosen fresh air duct clamp
at intake housing. Remove hose at resonance chamber.
Remove fresh air duct. Remove cooling fan shroud. Re-
move cooling fan clutch-to-pulley nuts.
Remove accessory drive belts. Remove cooling fan and
pulley. Remove lower engine splash guard. Remove crank-
shaft pulley from crankshaft. It is NOT necessary to remove
center bolt. Remove upper and lower timing belt covers.
See Fig. 1.
Rotate crankshaft to align camshaft and crankshaft timing
marks. See Figs. 3 and 4. Camshaft I and E marks
should align with marks on rear cover.
Loosen tensioner pulley bolt. Pivot tensioner pulley out- 96D14491 Courtesy of Kia Motors America, Inc.
ward to remove tension from timing belt, then retighten
tensioner lock bolt. See Fig. 2. Mark timing belt rotation Fig. 1: Timing Belt & Related Components
direction if old belt is to be reinstalled. Remove timing belt.
Installation:
Ensure crankshaft and camshaft pulleys are still aligned.
Install timing belt so that there is no looseness at tension
side, and at camshaft pulleys. If reusing old belt, ensure
belt is installed in original direction of rotation. Loosen
tensioner pulley bolt.
Turn crankshaft 2 revolutions in normal direction of rota-
tion. Check that timing marks are correctly aligned. If timing
marks are not correctly aligned, remove belt and realign.
Turn crankshaft to align S mark of exhaust camshaft pul-
ley with rear cover mating mark. Tighten tensioner pulley
bolt.
Check that belt deflection is .30-.33" (7.5-8.5 mm) with 22
lbs. (10 kg) of downward pressure on belt, midway be-
tween two camshaft pulleys.
Install timing belt guide plate with flat side toward belt.
Install timing belt covers.
To complete installation, reverse removal procedure. Ad- 96E14492 Courtesy of Kia Motors America, Inc.
Fig. 2: Loosening Tensioner
tension ranges.
342 KIA
96F14493 Courtesy of Kia Motors America, Inc.

96G14494 Courtesy of Kia Motors America, Inc.
Fig. 3: Aligning Crankshaft Pulley Timing Marks
Fig. 4: Aligning Camshaft Pulley Mating Marks
KIA 343

Appication Labor Time Belt Part No.
2.0L 4-Cyl. SOHC
Sportage
1995 ..................... 1 2.3 Hours .................... T264
1
ing the belt at 60,000 miles, 90,000 miles, and replacing belt
at 105,000 miles.

96A14498 Courtesy of Kia Motors America, Inc.
Fig. 1: Timing Belt & Related Components
TIMING BELT
Removal:
Disconnect negative battery cable. Remove timing belt cover.
Remove accessory drive belts. Turn crankshaft and align
timing mark on front housing and arrow at 2 on camshaft
pulley. See Fig. 1. Remove damper pulley. Remove timing
belt guide plate from timing belt pulley.
Loosen tensioner lock bolt. Pry tensioner outward as far as
possible from timing belt. Temporarily tighten tensioner
lock bolt. Mark timing belt rotation direction if old belt is to
be reinstalled. Remove timing belt.
Installation:
Check that timing belt tensioner spring has a free length of
2.24" (56.5 mm). Replace if necessary. Ensure timing belt
pulley mark is aligned with timing mark. Ensure that arrow
at 2 on camshaft pulley is aligned with timing mark on
front housing. Install timing belt so that there is minimal
slack from timing belt pulley to water pump and from water
pump to camshaft pulley.
Loosen tensioner bolt to apply tension to timing belt. Turn 96J14497 Courtesy of Kia Motors America, Inc.
crankshaft 2 turns clockwise and verify that timing marks Fig. 2: Camshaft Pulley Mating Marks
are correctly aligned. If not, repeat installation procedure.
Tighten belt tensioner lock bolt. Check that belt deflection
is .43-.51" (11-13 mm) at 22 lbs. (10 kg) pressure on belt
between camshaft pulley and crankshaft pulley. To com-
plete installation, reverse removal procedure. Adjust drive
ranges.
Accessory Belt Lock Bolts .................................. 24-30 (32-42)
Cooling Fan Assembly ............................................... 27 (37)
Cooling Fan Nuts ....................................................... 16 (22)
Crankshaft Damper Bolts ......................................... 132 (15)
Timing Belt Tensioner Lock Bolt ....................... 27-38 (37-52)
INCH Lbs. (N.m)
Cooling Fan Shroud Bolts ............................................ 74 (8)
Fresh Air Duct Mounting Bolts ..................................... 84 (10)
Timing Belt Cover Bolts .............................................. 84 (10)
96J14497 Courtesy of Kia Motors America, Inc.
Fig. 3: Crankshaft Pulley Mating Marks

344 LANCIA
*1.8L 4-Cylinder
Belt Part No. Application Ft. Lbs. (N. m)
1.8L 4-Cyl. Camshaft Housing Nuts ............................................ 16 (22)
Timing Belt Tensioner ................................................ 33 (45)
Beta
1976-78 ................. 2.7 Hours ..................... T020
1
25,000 miles.


TIMING BELT
Removal:
Disconnect negative battery cable. Remove timing gear
cover, spark plugs, and valve covers. Install handles
(88013344) or equivalent, on flywheel. Turn crankshaft in
direction of rotation until holes in camshaft drive gears align
with timing reference pointers. See Fig. 1.
Remove reference pointers bracket. Attach locking fixture
(88013039) or equivalent, by engaging dowel pins in cam- Fig. 1: Align Camshaft Timing Marks With Bearing
shaft gear timing holes. Attach fixture to cylinder head. Re- Reference Marks When Installing Timing Belt
move belt tensioner nut and bolt and release tension from
belt. Remove timing belt.
Installation:
Align reference mark on crankshaft pulley with timing mark
on locking fixture (88013039) or equivalent. When both
marks correspond exactly, cylinders No. 1 and No. 4 will be
at TDC. Fixture reference hole should also line up with
ancillary drive shaft reference hole. Check alignment by
inserting dowel pin.
Install timing belt. Unlock the belt stretcher bolt applying
pressure to the belt. Tighten bolt and nut to 33 ft. lbs. (45
N.m). Once tensioning bolt is torqued, remove locking fix-
ture. Turn the crankshaft a few times, partially release the
belt stretcher and finally relock it properly. Install timing
reference pointers bracket. Adjust drive belts to proper ten-
VALVE TIMING
To check valve timing, turn crankshaft until reference mark
on sheave aligns with long mark on timing gear cover. See Fig. 2: Valve Timing Reference Marks
Fig. 2. Check that the holes in camshaft gears (one in each)
are aligned with reference marks on front camshaft bear-
ings. See Fig. 2. If adjustment is necessary, use locking
fixture (88013039) or equivalent, as instructed under TIM-
ING BELT.
LEXUS 345
2.5L & 3.0L V6 1990-98

TIMING BELT APPLICATION TIMING BELT
Removal (2.5L & 1992-93 3.0L V6):
Disconnect negative battery cable. Remove cruise control
2.5L V6 actuator and vacuum pump. Remove power steering res-
ES250 ervoir with hoses attached, and secure them aside. Raise
1990-91 ................. 3.8 Hours ..................... T157 and support vehicle. Remove right front wheel. Remove
3.0L V6 right lower engine cover. Remove all drive belts.
ES300 Remove top braces on right engine mount at timing belt
1992-93 ................. 3.0 Hours ..................... T200 cover. Slightly raise engine to remove weight from right
engine mount. Remove retaining bolts/nuts and right en-
1994-98 ................. 3.0 Hours ..................... T257 gine mount assembly. Remove spark plugs. Remove re-
taining bolts, No. 2 timing belt cover, gasket and right en-
MANUFACTURERS SUGGESTED gine mount bracket. See Fig. 1. Note bolt length and loca-
SCHEDULED MAINTENANCE tion of No. 2 timing belt cover bolts for reassembly refer-
ence.
scheduled maintenance interval for normal operating condi- CAUTION: If timing belt is to be reused, mark direction of timing
tions, belt manufacturers suggest the belt be replaced at 60,000 belt rotation and location on camshaft sprockets for reassembly
mile intervals. The manufacturer recommends the belt be re- reference. Also place reference mark on timing belt at upper
placed at 60,000 miles or 96 months for severe operating edge of No. 1 timing belt cover.
conditions.
Rotate crankshaft clockwise so No. 1 cylinder is at TDC of
REMOVAL & INSTALLATION compression stroke. Ensure timing mark on crankshaft
pulley aligns with 0 mark on No. 1 timing belt cover. En-
sure timing marks on camshaft sprockets are aligned with
WARNING: To prevent air bag deployment, disconnect negative
timing marks on No. 3 timing belt cover. See Fig. 2. Re-
battery cable at least 90 seconds before working on vehicle.
move retaining bolts and timing belt tensioner.

346 LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
Install Camshaft Sprocket Holder (SST 09278-54012) or Installation (2.5L & 1992-93 3.0L V6):
equivalent, in holes on front of right camshaft sprocket. Install No. 1 idler pulley (if removed). Apply Loctite 242 on
Slightly rotate right camshaft sprocket clockwise to release threads of No. 1 idler pulley retaining bolt. Install and tighten
tension on timing belt between camshaft sprockets. Re- retaining bolt to specification. See TORQUE SPECIFICA-
move timing belt from camshaft sprockets. TIONS. Ensure idler pulley is clean, and pulley rotates
Using Pulley Holder (SST 09213-54014) or equivalent, and smoothly.
Handle (SST 0933000021), hold crankshaft pulley, and re- Install timing belt on crankshaft sprocket with installation
move retaining bolt. If timing belt is to be reused, ensure mark on timing belt aligned with timing mark on crankshaft
reference mark placed on timing belt aligns with upper sprocket. See Fig. 2. Install timing belt guide with cupped
edge of No. 1 timing belt cover when timing mark on crank- side away from crankshaft sprocket. Install No. 1 timing
shaft pulley is aligned with 0 mark on No.1 timing belt belt cover and gasket. Align crankshaft key with key groove
cover. of crankshaft pulley and install crankshaft pulley. Tighten
Using puller, remove crankshaft pulley. DO NOT allow crank- retaining bolt to specification.
shaft to rotate. Remove No. 1 timing belt cover and gasket.
If timing belt is to be reused, mark direction of belt rotation, CAUTION: If reusing timing belt, ensure timing mark on crankshaft
and place reference marks on timing belt and crankshaft sprocket is aligned with reference mark placed on timing belt,
sprocket for reassembly reference. Note direction of timing and timing belt is installed in original direction of rotation.
belt guide installation for reassembly reference. See Fig. Install No. 2 idler pulley. Tighten retaining bolt to specifica-
1. Remove timing belt guide and timing belt. Remove idler tion. Ensure idler pulley rotates smoothly. Rotate crank-
pulleys (if necessary). shaft pulley so timing mark on crankshaft pulley aligns with
Removal (1994-98 3.0L V6): 0 mark on No. 1 timing belt cover. Rotate left camshaft so
Disconnect negative battery cable. Remove coolant reser- timing mark on camshaft sprocket aligns with timing mark
voir. Raise and support vehicle. Remove right side front on No. 3 timing belt cover. See Fig. 2.
wheel. Remove right lower engine cover. Remove acces- Rotate right camshaft so knock pin hole in camshaft aligns
sory drive belts. with timing mark on No. 3 timing belt cover. See Fig. 2. If
Remove engine stabilizer rod, engine mounting bracket reusing timing belt, ensure reference mark placed on tim-
and right engine mount brace, located near timing belt ing belt aligns with upper edge of No. 1 timing belt cover
cover. Remove the alternator bracket for access to timing when timing mark on crankshaft pulley is aligned with 0
belt covers. Remove No. 2 timing belt cover. See Fig. 1. mark on No. 1 timing belt cover.
Use Pulley Holder (SST 09213-54015) or equivalent, and Using camshaft sprocket holder, slightly rotate left cam-
Handle (SST 0933000021) or equivalent, to hold crankshaft sprocket clockwise, and install timing belt on cam-
shaft pulley. Remove crankshaft pulley bolt. Using puller, shaft sprocket. Ensure reference mark on timing belt aligns
remove crankshaft pulley. Remove No. 1 timing belt cover. with timing mark on camshaft sprocket.
See Fig. 1.
Remove engine mounting bracket. Note direction of timing
belt guide installation for reassembly reference. Remove
timing belt guide.
Temporarily install crankshaft pulley bolt in crankshaft. Us-
ing crankshaft pulley bolt, rotate crankshaft clockwise until
timing mark on crankshaft sprocket aligns with timing mark
on oil pump body. See Fig. 3. Ensure timing marks on cam-
shaft sprockets are aligned with timing mark on No. 3 tim-
ing belt cover. See Fig. 3. If timing marks are not aligned,
rotate crankshaft clockwise one full revolution (360 de-
grees).
Remove retaining bolts, timing belt tensioner and dust boot.
Remove crankshaft pulley bolt from crankshaft. Install cam-
shaft sprocket holder (SST 09278-54012) or equivalent, in
holes on front of right camshaft sprocket. Slightly rotate
right camshaft sprocket clockwise to release tension on
timing belt between camshaft sprockets. Remove timing
belt from camshaft sprockets.
Inspection (2.5L & 3.0L V6):
tamination. Ensure idler pulleys rotate freely. Replace dam-
aged components. Inspect timing belt tensioner for signs
of oil leakage. Replace timing belt tensioner if oil leakage
exists. Hold timing belt tensioner body. Press rod against
solid surface. Replace timing belt tensioner if rod moves.
Measure timing belt tensioner rod protrusion from end of
rod to edge of timing belt tensioner housing. See Fig. 5. On
2.5L engines, replace timing belt tensioner if distance is
not .413-.453 (10.5-11.5 mm). On 3.0L engines, replace
timing belt tensioner if distance is not .394-.413" (10.01-
10.49 mm). Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)
LEXUS 347
2.5L & 3.0L V6 1990-98 (Cont.)

Using camshaft sprocket holder, slightly rotate left cam- Place washer on bottom side of timing belt tensioner. Us-
shaft sprocket, and align timing mark on camshaft sprocket ing press, apply pressure on rod of timing belt tension until
with timing mark on No. 3 timing belt cover. Ensure tension rod is retracted, and holes in rod and housing are aligned.
exists on timing belt between crankshaft sprocket and left Install hexagon wrench through holes in housing and rod
camshaft reference mark on timing belt with timing mark to hold rod in retracted position. See Fig. 6. Release press,
on right camshaft sprocket. Install right camshaft sprocket and install dust boot on timing belt tensioner. Install timing
on camshaft with flange side toward cylinder head. Ensure belt tensioner. Tighten retaining bolts to specification. See
timing mark on right camshaft sprocket aligns with timing TORQUE SPECIFICATIONS.
mark on No. 3 timing belt cover. See Fig. 2. Remove hexagon wrench from timing belt tensioner. Ro-
Using camshaft sprocket holder, slightly rotate right cam- tate crankshaft clockwise 2 full revolutions from TDC to
shaft sprocket so knock pin hole in camshaft sprocket aligns TDC. Ensure timing marks on camshaft sprockets align
with knock pin hole in camshaft. Install knock pin in right with those on No. 3 timing belt cover. See Fig. 2.
camshaft. Install right camshaft sprocket retaining bolt, and
tighten it to specification. See TORQUE SPECIFICATIONS. CAUTION: Crankshaft must always be rotated clockwise. DO
NOT rotate crankshaft counterclockwise.
Installation (1994-98 3.0L V6):
Install timing belt plate. Install and tighten bolt to specifica-
tion. Install No. 1 and No. 2 idler pulleys (if removed). Install
and tighten bolts to specification. See TORQUE SPECIFI-
CATIONS. Ensure idler pulleys are clean and rotate
smoothly.
on oil pump body. See Fig. 3.
Using camshaft sprocket holder, rotate each camshaft
sprocket so timing mark on camshaft sprocket aligns with
timing mark on No. 3 timing belt cover. See Fig. 3. Align
reference marks on timing belt with dot on crankshaft
sprocket and timing marks on camshaft sprocket. Ensure
front mark is pointing toward timing belt end of engine.
CAUTION: Ensure reference marks on timing belt align with timing

mark on camshaft sprockets and dot on crankshaft sprocket
Fig. 3: Aligning Timing Marks (1994-98 3.0L) when installing timing belt. Front mark must face toward timing
belt end of engine.
Install timing belt on crankshaft sprocket, water pump pul-
ley, left camshaft sprocket, No. 2 idler pulley, right camshaft
sprocket, and then on No. 1 idler pulley. Using press, apply
pressure on rod of timing belt tension until rod is retracted
and holes in rod and housing are aligned. Install hexagon
wrench through holes in housing and rod to hold rod in
retracted position. See Fig. 6. Release press and install
dust boot on timing belt tensioner. Install timing belt
tensioner. Install and alternately tighten bolts to specifica-
tion. See TORQUE SPECIFICATIONS.
Remove hexagon wrench from timing belt tensioner. Ro-
tate crankshaft clockwise until timing mark on crankshaft
sprocket aligns with timing mark on oil pump body. See
Fig. 3. Ensure timing mark on each camshaft sprocket is
aligned with timing mark on No. 3 timing belt cover. See
Fig. 3. If all timing marks are not aligned, remove timing
belt and reinstall. Remove crankshaft pulley bolt.
Install timing belt guide with cupped side away from crank-
shaft sprocket and flat side toward timing belt. Install en-
gine mounting bracket on front of cylinder block. Install and
tighten bolts to specification. Using new gaskets, install
Fig. 4: Identifying Timing Belt Reference Marks (1994-98 3.0L) No. 1 and No. 2 timing belt covers. Install and tighten bolts
348 LEXUS
2.5L & 3.0L V6 1990-98 (Cont.)
Align crankshaft key with key groove of crankshaft pulley. TORQUE SPECIFICATIONS (2.5L V6)
Install crankshaft pulley. Install and tighten crankshaft pul-
ley bolt to specification. To install remaining components,
reverse removal procedure. Tighten fasteners to specifica-
tion. See TORQUE SPECIFICATIONS. Adjust drive belts to
Engine Crossmember-To-Body Bolt .......................... 29 (39)
Engine Mount Through-Bolt ........................................ 64 (87)
Crossmember Bolt .................................................. 54 (73)
Idler Pulley Bolt
No. 1 Idler Pulley ....................................................... 25 (34)
No. 2 Idler Pulley ....................................................... 29 (39)
Idler Pulley Support Bolt ............................................. 13 (18)
Right (Timing Belt Side) Engine Mount
Bolt ........................................................................... 47 (64)
Nut
Bracket Side .......................................................... 38 (52)
Body Side .............................................................. 65 (88)
Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion
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)

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)
Fig. 6: Retracting Timing Belt Tensioner Rod Power Steering Pump Bracket
To-Cylinder Head Bolt .............................................. 32 (43)
Pulsation Damper ...................................................... 24 (33)
Right Engine Mount Brace Bolt ................................... 23 (31)
Stabilizer Bar Link-To
Lower Control Arm Nut ............................................. 29 (39)
Timing Belt Idler Pulleys
No. 1 Idler Pulley Bolt ............................................... 25 (34)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
No. 1 & 2 Timing Belt Cover Bolt ................................ 75 (8.5)
No. 3 Timing Belt Cover Bolt ...................................... 75 (8.5)
Timing Belt Plate Bolt ................................................ 71 (8.0)
Valve Cover Bolt ......................................................... 71 (8.0)
Water Pump Bolt/Nut ................................................. 71 (8.0)
LEXUS 349
3.0L V6 1999-01
TIMING BELT APPLICATION Inspect timing belt tensioner for signs of oil leakage. Re-
place timing belt tensioner if oil leakage exists. Hold timing
Application Labor Time Belt Part No. belt tensioner body with push rod facing upward. Press rod
3.0L V6 1MZFE against solid surface. Replace timing belt tensioner if push
ES300 rod moves.
1999-01 ................. 3.0 Hours ..................... T257 Measure timing belt tensioner push rod protrusion from
RX300 end of rod to edge of timing belt tensioner housing. See
Fig. 4. Replace timing belt tensioner if distance is not .394-
1999-01 ................. 4.4 Hours ..................... T257 .425" (10.01-10.8 mm).
MANUFACTURERS SUGGESTED NOTE: Engine should be cold when installing timing belt.
SCHEDULED MAINTENANCE Installation (ES300):
The manufacturer recommends the belt be replaced every Install No. 1 and No. 2 idler pulleys (if removed). On No. 1
90,000 miles or 72 months. idler pulley bolt, coat threads with Loctite 242 or equivalent.
Install and tighten bolts to specification. See TORQUE
REMOVAL & INSTALLATION SPECIFICATIONS. Ensure idler pulleys are clean and ro-
tate smoothly.
Temporarily install crankshaft pulley bolt in crankshaft. If
battery cable at least 90 seconds before working on vehicle. necessary, use crankshaft pulley bolt to rotate crankshaft
clockwise until timing mark on crankshaft sprocket aligns
TIMING BELT with timing mark on oil pump body. See Fig. 2.
Removal (ES300):
Using spanner wrench, rotate each camshaft sprocket so
timing mark on camshaft sprocket aligns with timing mark
Raise and support vehicle. Remove right side front wheel. on No. 3 timing belt cover. See Fig. 2.
Remove right fender apron seal. Remove accessory drive
belts. Lower vehicle. Disconnect engine coolant reservoir
ley, left camshaft sprocket (front of vehicle side), No. 2 idler
hose from water outlet. Disconnect ground strap connec-
pulley, right camshaft sprocket (firewall side), and then on
tors.
No. 1 idler pulley. If reusing old belt, ensure belt installation
Remove engine stabilizer rod, engine mounting bracket marks align with camshaft and crankshaft sprocket marks.
and right engine mount brace, located near timing belt
Ensure front (or rotation direction mark) points in correct
cover. Remove generator-to-engine bracket for access to
direction.
timing belt covers.
Using Pulley Holder (SST 09213-54015) or equivalent, and Using press, SLOWLY apply about 200-2200 lbs. of pres-
sure on push rod of timing belt tension until rod is retracted
Handle (SST 09330-00021) or equivalent, hold crankshaft
and holes in rod and housing are aligned. See Fig. 5. Align
pulley. Remove crankshaft pulley bolt. Using puller, remove
holes in housing and push rod to hold rod in retracted
crankshaft pulley. Remove No. 1 and No. 2 timing belt cov-
position. Install hexagon wrench through housing and push
ers and gaskets. See Fig. 1. Remove engine mounting
rod hole to secure push rod. Release press and install
bracket from front of engine. Note direction of timing belt
dust boot on timing belt tensioner.
guide installation for reassembly reference. Remove tim-
ing belt guide.
NOTE: Always turn crankshaft clockwise, as viewed from timing

belt side of engine.
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).
If reusing old belt, ensure there are 3 installation marks
and front arrow marked on belt. See Fig. 3. If not, place
mating mark on belt where it contacts the crankshaft and
camshaft sprockets. Also, mark belt with arrow showing
Alternately loosen 2 bolts, and remove timing belt tensioner
and dust boot. DO NOT hold tensioner with push rod facing
downward. Remove timing belt.
Inspection (ES300):
tamination. Ensure idler pulleys rotate freely and are not
leaking oil. Replace damaged components. Check water
pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with push rod facing Fig. 1: Exploded View Of Timing Belt & Components
downward.
350 LEXUS
3.0L V6 1999-01 (Cont.)
Using new gaskets, install No. 1 and No. 2 timing belt
covers. Ensure there are no gaps in gasket. Cut off any
excess gasket. Install and tighten bolts to specification.
Align crankshaft key with key groove of crankshaft pulley.
ley bolt to specification. See TORQUE SPECIFICATIONS.
Install generator bracket. Install engine mount brace and
stabilizer rod. Install fender apron seal and right front wheel.
dure. Tighten fasteners to specification. Connect engine
ground strap. Adjust drive belts to proper tension. See page
Removal (RX300):
Remove the outer cowl top panel along with ventilation lou-
vers and windshield wiper arm assembly. See Fig. 6. Re-
move shock tower suspension brace. Raise and support
vehicle.
Remove right side front wheel. Remove right fender apron
seal. Remove accessory drive belts. Lower vehicle. Re-
move cruise control actuator from right side engine com-
partment.
Disconnect engine coolant reservoir hose from water out-
let. Disconnect ground strap connectors.
Remove engine stabilizer rod and engine mounting bracket,
located near timing belt cover. Remove generator-to-en-
gine bracket for access to timing belt covers.
Using Pulley Holder (SST 09213-54015) or equivalent, and
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.

with timing mark on No. 3 timing belt cover. See Fig. 2. If
timing marks are not aligned, rotate crankshaft clockwise
Courtesy of Toyota Motor Sales, U.S.A., Inc. direction of rotation.
Fig. 3: Identifying Timing Belt Reference Marks & Front Mark
Install timing belt tensioner. Install and alternately tighten

Remove hexagon wrench from timing belt tensioner. Slowly
rotate crankshaft clockwise 2 revolutions until timing mark
on crankshaft sprocket aligns with timing mark on oil pump
body.
Ensure timing mark on each camshaft sprocket is aligned
with timing mark on No. 3 timing belt cover. See Fig. 2. If all
timing marks are not aligned, remove timing belt and rein-
stall. Remove crankshaft pulley bolt.
Install timing belt guide with cupped side away from crank- Fig. 4: Measuring Timing Belt Tensioner Rod Protrusion
tighten bolts to specification.
LEXUS 351
3.0L V6 1999-01 (Cont.)
Fig. 5: Retracting Tlming Belt Tensloner Rod

Alternately loosen 2 bolts, and remove timing belt tensioner
and dust boot. DO NOT hold tensioner with push rod facing
downward. Remove timing belt.
Inspection (RX300):
tamination. 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.
Inspect timing belt tensioner for signs of oil leakage. Re-
belt tensioner body with push rod facing upward. Press rod
against solid surface. Replace timing belt tensioner if push
rod moves.
Measure timing belt tensioner push rod protrusion from
end of rod to edge of timing belt tensioner housing. See
.425" (10.01-10.8 mm). Courtesy of Toyota Motor Sales, U.S.A., Inc.
Installation (RX300):
Fig. 6: Exploded View Of Outer Cowl Top Panel (RX300)
Install No. 1 and No. 2 idler pulleys (if removed). On No. 1
idler pulley bolt, coat threads with Loctite 242 or equivalent. Remove hexagon wrench from timing belt tensioner. Slowly
Install and tighten bolts to specification. See TORQUE rotate crankshaft clockwise 2 revolutions until timing mark
SPECIFICATIONS. Ensure idler pulleys are clean and ro-
tate smoothly. body.
Temporarily install crankshaft pulley bolt in crankshaft. If Ensure timing mark on each camshaft sprocket is aligned
necessary, use crankshaft pulley bolt to rotate crankshaft
clockwise until timing mark on crankshaft sprocket aligns timing marks are not aligned, remove timing belt and rein-
with timing mark on oil pump body. See Fig. 2. stall. Remove crankshaft pulley bolt.
Using spanner wrench, rotate each camshaft sprocket so Install timing belt guide with cupped side away from crank-
timing mark on camshaft sprocket aligns with timing mark shaft sprocket and flat side toward timing belt. Install en-
on No. 3 timing belt cover. See Fig. 2. gine mounting bracket on front of cylinder block. Install and
NOTE: Engine should be cold when installing timing belt. tighten bolts to specification. See TORQUE SPECIFICA-
TIONS.
Install timing belt on crankshaft sprocket, water pump pul- Using new gaskets, install No. 1 and No. 2 timing belt
ley, left camshaft sprocket (front of vehicle side), No. 2 idler covers. Ensure there are no gaps in gasket. Cut off excess
pulley, right camshaft sprocket (firewall side), and then on gasket. Install and tighten bolts to specification.
No. 1 idler pulley. If reusing old belt, ensure belt installation Align crankshaft key with key groove of crankshaft pulley.
marks align with camshaft and crankshaft sprocket marks. Install crankshaft pulley. Install and tighten crankshaft pul-
Ensure front (or rotation direction mark) points in correct ley bolt to specification. See TORQUE SPECIFICATIONS.
direction. Install generator bracket. Connect engine ground strap.
Using press, SLOWLY apply about 200-2200 lbs. of pres- Install engine mount brace and stabilizer rod. Install cruise
sure on push rod of timing belt tension until rod is retracted control actuator (if equipped).
and holes in rod and housing are aligned. See Fig. 5. Align Install right hand fender apron seal. Install front wheel. In-
holes in housing and push rod. Install hexagon wrench stall shock tower suspension brace. Install outer cowl top
through housing and push rod hole to secure push rod. panel.
Release press and install dust boot on timing belt tensioner. To install remaining components, reverse removal proce-
Install timing belt tensioner. Install and alternately tighten dure. Tighten fasteners to specification. Adjust drive belts
bolts to specification. See TORQUE SPECIFICATIONS. to proper tension. See page A-60 for belt tension ranges.
352 LEXUS
3.0L V6 1999-01 (Cont.)
Left Hand (Front End of Vehicle Side) ......................... 94 (125)
Right Hand (Firewall Side of Vehicle) ........................... 65 (88)
Engine Stabilizer Rod Bolts ............................................ 47 (64)
Generator Adjusting Lock Bolt ........................................ 13 (18)
Generator Pivot Bolt ........................................................ 41 (56)
Power Steering Pump Bracket
Right Engine Mount Brace-To-Body Bolt ..................... 23 (31)
Shock Tower Brace-To-Shock Tower Nuts .................... 59 (80)
Timing Belt Idler Pulleys
No. 1 Idler Pulley Bolt .............................................. 1 25 (34)
Wheel Lug Nut .......................................................... 76 (103)
Wiper Arm Nuts .............................................................. 18 (24)
INCH Lbs. (N.m)
Water Pump Bolt/Nut ........................................................ 71 (8)
1
- Apply Loctite 242 or equivalent to bolt threads.
LEXUS 353
3.0L 6-Cylinder 1993-97

Application Labor Time Belt Part No. tamination. Replace timing belt if damaged or contami-
3.0L 6-Cyl. nated. Check idler pulley and drive belt tensioner for smooth
GS300 rotation. Replace idler pulley or drive belt tensioner if de-
1993-97 ................. 3.4 Hours ..................... T215 fective.
SC300 Inspect timing belt tensioner for signs of oil leakage. Re-
place timing belt tensioner if oil leakage exists.
1993-97 ................. 3.4 Hours ..................... T215 Hold timing belt tensioner body, and press rod against solid
surface. Replace timing belt tensioner if rod moves.
MANUFACTURERS SUGGESTED Measure timing belt tensioner rod protrusion from end of
SCHEDULED MAINTENANCE rod to edge of housing. See Fig. 3. Replace timing belt
tensioner if distance is not .315-.343" (8.00-8.80 mm).
scheduled maintenance interval for normal operating condi- NOTE: Tlming belt tensioner may have a small amount of oil
tions, belt manufacturers suggest the belt be replaced at 60,000 on rod seal under normal conditions. If excessive amount of oil
mile intervals. The manufacturer recommends the belt be re- exists, replace timing belt tensioner
placed at 60,000 miles or 96 months for severe operating
conditions. Installation:
Install idler pulley and plate washer (if removed). Apply Loctite
REMOVAL & INSTALLATION 242 on threads of idler pulley bolt. Install and tighten bolt to
specification. See TORQUE SPECIFICATIONS. Ensure idler
TIMING BELT pulley is clean and rotates smoothly, and idler pulley bracket
moves freely.
Using crankshaft pulley bolt, rotate crankshaft and align
WARNING: To prevent air bag deployment, disconnect negative timing mark on crankshaft sprocket with timing mark on oil
battery cable at least 90 seconds before working on vehicle. pump body. See Fig. 2. Install timing belt on crankshaft
Removal: sprocket.
Disconnect battery cables and remove battery. Drain cool- CAUTION: If reusing timing belt, ensure reference marks on timing
ing system. Place reference mark on fan clutch and water
belt and crankshaft sprocket align and timing belt is installed
pump for reassembly reference. Remove drive belt, cool- in original direction of rotation.
ing fan, fan clutch and water pump pulley.
Remove radiator and lower engine cover. Remove oil filler Install timing belt guide with cupped side away from crank-
cap, No. 2 and No. 3 timing belt covers, gaskets and drive shaft sprocket and flat side against timing belt. Install gas-
belt tensioner. See Fig. 1. kets and No. 1 timing belt cover.
Rotate crankshaft clockwise so cylinder No. 1 (front cylin- Align crankshaft pulley key groove with crankshaft key. In-
der) is at TDC on compression stroke. Ensure timing mark stall crankshaft pulley. Install and tighten crankshaft pulley
on crankshaft pulley aligns with 0 mark on timing belt bolt to specification. See TORQUE SPECIFICATIONS.
cover. If installing camshaft sprocket, align hole in camshaft
Timing marks on camshaft sprockets must align with tim- sprocket with dowel pin in camshaft. Install camshaft
ing marks on No. 4 timing belt cover. See Fig. 2. If condi- sprocket. Hold camshaft sprocket with sprocket holder, and
tions are not as described, rotate crankshaft clockwise one tighten bolt to specification. See TORQUE SPECIFICA-
complete revolution clockwise. TIONS.
Rotate crankshaft clockwise so cylinder No. 1 (front cylin-
CAUTION: If reusing timing belt, place arrow on timing belt to der) is at TDC on compression stroke. Ensure timing mark
indicate direction of rotation. Place reference mark on timing on crankshaft pulley aligns with 0 mark on timing belt
belt and each camshaft sprocket for reassembly reference. cover.
Alternately loosen timing belt tensioner bolts. Remove bolts, Using sprocket holder, rotate camshaft sprockets so tim-
timing belt tensioner and dust boot. See Fig. 1. Remove ing marks on camshaft sprockets align with timing marks
timing belt from camshaft sprockets. on No. 4 timing belt cover. See Fig. 2. Install timing belt on
Using Handle (SST 09330-00021) or equivalent, and Pul- camshaft sprockets. Ensure tension exists on timing belt
ley Holder (SST 0921370010), or equivalent, hold crank- between camshaft sprockets.
shaft pulley and remove crankshaft pulley bolt. Using puller,
CAUTION: If reusing timing belt, ensure reference marks on timing
remove crankshaft pulley.
belt and camshaft sprockets align and timing belt is installed
Remove No. 1 timing belt cover and gaskets. Note direc-
in original direction of rotation.
tion of timing belt guide installation for reassembly refer-
ence. See Fig. 1. Remove timing belt guide. Using press, apply pressure on rod of timing belt tensioner
until rod is retracted and holes in rod and housing are
CAUTION: If reusing timing belt, place reference mark on timing aligned. See Fig. 3.
belt and crankshaft sprocket tor reassembly reference. Install hexagon wrench through holes in housing and rod
Remove timing belt. Remove bolt, idler pulley and plate to hold rod in retracted position. See Fig. 4. Release press.
washer (if necessary). Install dust boot on timing belt tensioner. Install timing belt
tensioner. Alternately tighten timing belt tensioner bolts to
354 LEXUS
3.0L 6-Cylinder 1993-97 (Cont.)
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
crankshaft counterclockwise.
tate crankshaft clockwise 2 full revolutions from TDC to
TDC. DO NOT rotate crankshaft counterclockwise.
Ensure timing marks on camshaft sprockets align with tim-
ing marks on No. 4 timing belt cover, and timing mark on
crankshaft pulley aligns with 0 mark on timing belt cover.
See Fig. 2. If timing marks are not aligned, remove timing
belt and reinstall.
dure. Use care when installing drive belt tensioner bolts to
avoid dropping bolts into timing belt cover. Adjust drive belts
A/C Compressor
Bolt ........................................................................... 36 (49)
Nut ............................................................................ 22 (30)
Air Intake Chamber Bolt/Nut ....................................... 13 (18) Fig. 2: Aligning Timing Marks
Distributor Housing Bolt ............................................. 13 (18)
Drive Belt Idler Pulley Bolt ........................................... 27 (37)
Drive Belt Tensioner Bolt/Nut ...................................... 12 (16)
Power Steering Pump
Bolt ........................................................................... 29 (39)
Nut ............................................................................ 32 (43)
Power Steering Pump Pulley Nut ................................ 32 (43)
Spark Plug .................................................................. 13 (18)
Courtesy of Toyota Motor Sales, U.S.A, Inc.
Water Pump Bolt/Nut .................................................. 13 (18) Fig. 3: Measuring Timing Belt Tensioner Rod Protrusion
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ............................... 57 (6.4)
Valve Cover Bolt ......................................................... 52 (5.9)
Fig. 4: Retracting Timing Belt Tensioner Rod

LEXUS 355
3.0L 6-Cylinder 1998-2001

TIMING BELT APPLICATION Timing marks on camshaft timing pulleys must align with
timing marks on timing belt cover. See Fig. 1. If not, rotate
Application Labor Time Belt Part No. crankshaft clockwise one complete revolution (360 de-
3.0L 6-Cyl. 2JZ-GE grees).
GS300
1998-01 ................. 3.4 Hours ..................... T215 CAUTION: Crankshaft must be correctly positioned by aligning
sub-timing mark with 0 mark on timing belt cover to prevent
SC300 valves from contacting pistons.
1998-00 ................. 3.4 Hours ..................... T215
Rotate crankshaft pulley 60 degrees counterclockwise. Align
sub-timing mark with 0 mark on timing belt cover. See
MANUFACTURERS SUGGESTED Fig. 3, STEP 1. Ensure the dot marks of camshaft timing
SCHEDULED MAINTENANCE pulleys are aligned with the timing marks of No. 4 timing
The manufacturer recommends the belt be replaced every belt cover. See Fig. 3, STEP 2.
90,000 miles or 72 months.
CAUTION: It reusing timing belt, place arrow on timing belt to
REMOVAL & INSTALLATION indicate direction of rotation. Place reference mark on timing
belt and each camshaft timing pulley for reassembly reference.
TIMING BELT DO NOT allow the crankshaft pulley to rotate, and remove
crankshaft pulley bolt.
Removal: Alternately loosen timing belt tensioner bolts. Remove bolts,
Raise and support vehicle. Remove engine undercover. timing belt tensioner, and dust boot. See Fig. 2. Remove
Drain cooling system. timing belt from camshaft sprockets.
On GS300, remove air cleaner inlet, air cleaner, and MAF Remove crankshaft pulley using gear puller. Remove No. 1
assembly. Remove radiator and electric cooling fan as- timing belt cover and gaskets. Note direction of timing belt
sembly. On 1999-98 models, rotate serpentine drive belt guide installation for reassembly reference (flat side to-
tensioner counterclockwise and remove belt. Tensioner bolt ward timing belt). See Fig. 2. Remove timing belt guide. If
is left-hand threaded. On 2001-00 models, rotate tensioner reusing timing belt, place mating reference marks on tim-
clockwise to remove serpentine belt. ing belt and crankshaft sprocket. Remove timing belt.
On SC300, remove battery and battery tray. Drain coolant. Inspection:
Remove lower fan shroud. Remove radiator. Loosen 4 nuts Inspect timing belt for damaged teeth, cracking or oil con-
holding fan clutch to water pump. Rotate serpentine drive tamination. Replace timing belt if damaged or contami-
belt tensioner bolt clockwise, and remove drive belt. Re- nated. Check idler pulley and drive belt tensioner pulley for
move cooling fan, fan clutch, and water pump pulley. smooth rotation. Replace idler pulley or drive belt tensioner
On all models, remove power steering pump front bracket. if defective. Inspect timing belt tensioner for signs of oil
Remove pump with hoses attached, and hang out of way. leakage. Replace timing belt tensioner if oil leakage ex-
Remove No. 2 and No. 3 timing belt covers and gaskets. ists.
See Fig. 2. Remove serpentine drive belt tensioner.
Using Handle (SST 09330-00021) and Pulley Holder (SST NOTE: Timing belt tensioner may have a small amount of oil
09213-70010) or equivalent to hold crankshaft pulley, on rod seal under normal conditions. If excessive amount of oil
loosen crankshaft pulley bolt. Rotate crankshaft clockwise exists, replace timing belt tensioner.
so cylinder No. 1 (front cylinder) is at TDC on compression
stroke. Ensure timing mark on crankshaft pulley aligns with Hold timing belt tensioner body, and press push rod against
0 mark on timing belt cover. See Figs. 1 and 3. 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).
Installation:
242 or equivalent on threads of idler pulley pivot bolt. Install
and tighten bolt to specification. See TORQUE SPECIFICA-
TIONS. Ensure idler pulley is clean and rotates smoothly,
and idler pulley bracket moves freely.
timing mark on crankshaft timing pulley with timing mark
on oil pump body. See Fig. 3, STEP 3. Clean oil or water off
of crankshaft timing pulley, and install timing belt on crank-
shaft timing pulley and around idler pulley.

belt and crankshaft timing pulley align, and timing belt is installed
Courtesy of Toyota Motor Sales, U.S.A., Inc. in original direction of rotation.
Fig. 1: Aligning Camshaft Timing Marks Install timing belt guide with cupped side away from crank-
shaft timing pulley and flat side against timing belt. Install
gaskets and No.1 timing belt cover. Align crankshaft pulley
key groove with crankshaft key. Install crankshaft pulley.
356 LEXUS
3.0L 6-Cylinder 1998-2001 (Cont.)

Fig. 2: Exploded View Of Typical Timing Belt & Components
Ensure sub-timing mark (60 degrees BTDC) of crankshaft If necessary, use spanner wrench to rotate camshaft tim-
pulley is aligned with 0 timing mark of No. 1 timing belt ing pulleys so timing marks on camshaft timing pulleys
cover. See Fig. 3, STEP 4. Temporarily install crankshaft align with timing marks on No. 4 timing belt cover. See Fig.
pulley bolt. 1. Install timing belt on camshaft timing pulleys. Ensure
tension exists on timing belt between camshaft timing pul-
CAUTION: If reusing timing belt, ensure reference marks on timing leys.
belt and camshaft timing pulleys align and timing belt is in- Using press, SLOWLY apply pressure on push rod of tim-
stalled in original direction of rotation. ing belt tensioner until rod is retracted and holes in rod and
housing are aligned. See Fig. 5.
LEXUS 357
3.0L 6-Cylinder 1998-2001 (Cont.)

Install 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

TDC.
Ensure timing marks on camshaft timing pulleys align with
timing marks on timing belt cover, and timing mark on crank-
shaft pulley aligns with 0 mark on timing belt cover. If
stall.
Tighten crankshaft pulley bolt to specification. Install drive
belt tensioner. Install No. 2 and No. 3 timing belt covers. To
install remaining components, reverse removal procedure.
Use care when installing drive belt tensioner bolts to avoid
dropping bolts into timing belt cover.
Tighten fasteners to specification. See TORQUE SPECIFI-
CATIONS. Fill and bleed air from cooling system.
Camshaft Timing Pulley Bolt ...................................... 60 (81)
Drive Belt Tensioner Bolt ............................................ 15 (21)
Fan Clutch-To-Water Pump Nut (SC300) ..................... 12 (16)
Idler Pulley Bolt ........................................................... 1 26 (35)
Power Steering Pump-To-Front Bracket ......................... 42 (58)
Water Pump Bolt ........................................................ 15 (21)
INCH Lbs. (N.m)
Fan-To-Fan Clutch Nuts (SC300) .................................. 65 (7.5)
No. 1 & No. 2 Timing Belt Cover Bolt ................................ 71 (8)
1
Fig. 3: Aligning Sub-Timing Marks

358 LEXUS
4.0L V8 1990-97
TIMING BELT APPLICATION Rotate crankshaft clockwise so cylinder No. 1 is at TDC on
compression stroke. Cylinder No. 1 is front cylinder on left
Application Labor Time Belt Part No. side when viewed from rear of engine. Ensure timing mark
4.0L V8 on crankshaft pulley aligns with 0 mark on No. 1 timing
LS400 belt cover. See Fig. 1.
1990-97 ................. 4.5 Hours ..................... T190 Timing marks on camshaft sprockets must align with tim-
SC400 ing marks on timing belt rear plates. See Fig. 1. If timing
marks are not aligned, rotate crankshaft clockwise one
1992-97 ................. 4.8 Hours ..................... T190 complete revolution. Alternately loosen timing belt tensioner
bolts. Remove bolts, timing belt tensioner and dust boot.
MANUFACTURERS SUGGESTED See Fig. 3. Using Sprocket Holder (SST 09278-54012) or
SCHEDULED MAINTENANCE equivalent, slightly rotate right camshaft sprocket clockwise
to release tension on timing belt. Remove timing belt from
For 1990-94 model years, although the manufacturer does camshaft sprockets.
not recommend a specific scheduled maintenance interval Using Pulley Holder (SST 09213-70010) or equivalent and
for normal operating conditions, belt manufacturers suggest Handle (SST 0933000021) or equivalent, hold crankshaft
the belt be replaced at 60,000 mile intervals. The manufac- pulley. Remove crankshaft pulley bolt. Using puller, remove
turer recommends the belt be replaced at 60,000 miles or 96 crankshaft pulley. On LS400, remove bolts/nuts and fan
months or severe operating conditions. bracket. On SC400, remove bolts/nuts and hydraulic pump.
For 1995-97 model years, the manufacturer recommends the On all models, remove No. 1 timing belt cover, gaskets,
belt be replaced at 90,000 miles for normal service and 60,000 timing belt cover spacer and gasket. See Fig. 3.
miles for severe service. Note direction of timing belt guide installation for reassem-
bly reference. Remove timing belt guide. Remove timing
REMOVAL & INSTALLATION belt. Remove bolt, idler pulleys and plate washer (if neces-
sary).
TIMING BELT
CAUTION: If reusing timing belt, ensure installation mark exists
WARNING: To prevent air bag deployment, disconnect negative at crankshaft sprocket. If installation mark does not exist, place
battery cable at least 90 seconds before working on vehicle. installation mark on timing belt and crankshaft sprocket.
Removal: Inspection:
Remove battery. Remove lower engine cover Drain cooling Inspect timing belt for damaged teeth, cracking or oil con-
system. On LS400, remove air duct located above top of tamination. Replace timing belt if damaged or contami-
radiator and air cleaner cover. Remove air cleaner assem- nated. Check idler pulleys for smooth rotation. Replace
bly. Remove V-bank cover. Remove drive belt, fan clutch idler pulleys if defective. Inspect timing belt tensioner for
assembly and fan pulley. On SC400, rotate drive belt signs of oil leakage. Replace timing belt tensioner if oil
tensioner counterclockwise. Remove drive belt. Remove leakage exists.
coolant reservoir.
NOTE: Timing belt tensioner may weep a small amount of oil
On all models, remove radiator. Remove A/C compressor on rod seal under normal conditions. If excessive amount of oil
with hoses attached and secure aside. Remove air intake exists, replace timing belt tensioner.
pipe between air cleaner hose and throttle body. Remove
upper spark plug wiring cover. Remove engine wiring cov- Hold timing belt tensioner body and press rod against solid
ers located near valve covers. Remove No. 3 (upper) timing surface. Replace timing belt tensioner if rod moves. Mea-
belt covers. Remove spark plug wire clamps. Disconnect sure timing belt tensioner rod protrusion from end of rod to
spark plug wires from distributor caps. edge of housing. See Fig. 4. Replace timing belt tensioner
Disconnect high-tension wire from ignition coils. Remove if distance is not .413-.453" (10.50-11.50 mm).
spark plug wires and clamps. See Fig. 2. Remove bolt,
plate and drive belt idler pulley. Remove left (drivers side)
ignition coil. Disconnect cam position sensor electrical
connector from clamp on No. 2 timing belt cover. Remove
bolts, No. 2 timing belt covers and gaskets. See Fig. 3. It
may be necessary to remove coolant pipe to access No. 2
timing belt covers.
Remove bolts, distributor caps and rotors. Mark compo-
nent location for reassembly reference. Disconnect electri-
cal connector at distributor housings. Remove bolts and
distributor housings. See Fig. 3. Remove alternator, drive
belt tensioner and spark plugs.
CAUTION: If reusing timing belt, ensure the 4 installation marks

exist on timing belt. If installation marks do not exist, place installation
mark on timing belt, all sprockets and edge of fan bracket (LS400)
or hydraulic pump (SC400).
Fig. 1: Checking Camshaft Timing Mark Alignment

LEXUS 359
4.0L V8 1990-97 (Cont.)

Installation: Install hexagon wrench through holes in housing and rod
Install No.1 idler pulley and plate washer (if removed). Ap- to hold rod in retracted position. See Fig. 6. Release press.
ply Loctite 242 on threads of idler pulley bolt. Install and Install dust boot on timing belt tensioner. Install timing belt
tighten bolt to specification. See TORQUE SPECIFICA- tensioner. Alternately tighten bolts to specification. See
TIONS. Install No. 2 idler pulley and bolt. Tighten bolt to TORQUE SPECIFICATIONS.
specification. See TORQUE SPECIFICATIONS. Ensure idler
pulleys are clean and rotate smoothly. Ensure idler pulley CAUTION: Always rotate crankshaft clockwise as viewed from
bracket moves freely. front of engine. DO NOT rotate crankshaft counterclockwise.
Using crankshaft pulley bolt, rotate crankshaft and align Remove hexagon wrench from timing belt tensioner. Ro-
timing mark on crankshaft sprocket with timing mark on oil tate crankshaft 2 full revolutions clockwise from TDC to
pump body. Install timing belt on crankshaft sprocket so TDC. Ensure timing marks on camshaft sprockets align
CR installation mark on timing belt aligns with dot on crank- with timing marks on timing belt rear plate. See Fig. 1. If
shaft sprocket. See Fig. 5. Install timing belt on No.1 and timing marks are not aligned, remove timing belt and rein-
then No. 2 idler pulley. stall. To install remaining components, reverse removal
Install timing belt guide with cupped side away from crank- procedure.
shaft sprocket. Flat side should be against timing belt. In- Ensure distributor housings are installed in correct loca-
stall gasket and timing belt cover spacer. Install gaskets tion according to identification mark on front of distributor
and No. 1 timing belt cover. On LS400, install fan bracket. housing. Right distributor housing (viewed from rear of
Install and tighten bolts/nuts to specification. See TORQUE engine) contains an R identification mark. Left distributor
SPECIFICATIONS. housing contains an L identification mark.
On SC400, install hydraulic pump. Install and tighten bolts/ Install rotors so rotor protrusion aligns with camshaft
nuts to specification. See TORQUE SPECIFICATIONS. On sprocket groove. See Fig. 7. Ensure spark plug wires are
all models, align crankshaft key with key groove of crank- properly positioned and installed in retainers. See Fig. 2.
shaft pulley. Using hammer and Pulley Installer (SST 09223- Tighten all bolts/nuts to specification. See TORQUE SPECI-
46011) or equivalent, install crankshaft pulley. Install and FICATIONS. Adjust drive belts to proper tension. See page
tighten crankshaft pulley bolt to specification. See TORQUE A-60 for belt tension ranges.
SPECIFICATIONS.
CAUTION: Ensure camshaft sprocket is installed with identification

mark facing forward, toward timing belt end of engine. Identification
mark is located on camshaft sprocket, below timing belt area.
Right camshaft sprocket contains an R identification mark,
and left camshaft sprocket contains an L identification mark.
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 tim-
ing marks on camshaft sprockets with timing marks on
timing belt rear plate. See Fig. 1. Align installation mark on
timing belt with end of fan bracket (LS400) or hydraulic
pump (SC400).
Ensure timing mark on camshaft sprockets align with tim-
ing mark on timing belt rear plate. See Fig. 1. Align installa-
tion mark on timing belt with timing mark on left camshaft
sprocket. See Fig. 1. Install timing belt on left camshaft
sprocket.
Ensure timing mark on left camshaft sprocket still aligns
with timing mark on timing belt rear plate. Ensure tension
exists on timing belt between left camshaft sprocket and
crankshaft sprocket. Ensure timing mark on right camshaft
sprocket still aligns with timing mark on timing belt rear
plate.
Align installation mark on timing belt with timing mark on
right camshaft sprocket. See Fig. 1. Install timing belt on
right camshaft sprocket. Ensure timing mark on right cam-
shaft sprocket still aligns with timing mark on timing belt
rear plate. Ensure tension exists on timing belt between Fig. 2: Removing/Installing Spark Plug Wires & Retainers
right and left camshaft sprockets. Using press, apply pres-
sure on rod of timing belt tensioner until rod is retracted
and holes in rod and housing arealigned. See Fig. 6.
360 LEXUS
4.0L V8 1990-97 (Cont.)

LEXUS 361
4.0L V8 1990-97 (Cont.)

Fig. 7: Installing Rotors
A/C Compressor
Bolt ........................................................................... 36 (49)
Nut ............................................................................ 22 (30)
Air Intake Chamber Bolt/Nut ....................................... 13 (18)
Fig. 5: Identifying Timing Belt Installation Marks Distributor Housing Bolt ............................................. 13 (18)
Drive Belt Tensioner Bolt/Nut ...................................... 12 (16)
Power Steering Pump
Bolt ........................................................................... 29 (39)
Nut ............................................................................ 32 (43)
Power Steering Pump Pulley Nut ................................ 32 (43)
Spark Plug .................................................................. 13 (18)
Water Pump Bolt/Nut .................................................. 13 (18)
INCH Lbs. (N.m)
Crankshaft Position Sensor Bolt ............................... 57 (6.4)
Valve Cover Bolt ......................................................... 52 (5.9)
362 LEXUS
*4.0L V8 1998-00
TIMING BELT APPLICATION Using Pulley Holder (SST 09213-70010) or equivalent and
Application Labor Time Belt Part No. pulley. Loosen, but do not remove crankshaft pulley bolt.
4.0L V8 Rotate crankshaft clockwise so cylinder No. 1 is at TDC on
GS400 compression stroke. Cylinder No. 1 is front cylinder on left
1998-00 ................. 4.5 Hours ..................... T298 side when viewed from rear of engine. Ensure timing mark
LS400 on crankshaft pulley aligns with 0 mark on No. 1 timing
1998-00 ................. 4.5 Hours ..................... T298 Timing marks on camshaft sprockets must align with tim-
SC400 ing marks on timing belt rear plates. See Fig. 1. If timing
1998-00 ................. 4.8 Hours ..................... T298 marks are not aligned, rotate crankshaft CLOCKWISE one
complete revolution.
MANUFACTURERS SUGGESTED Rotate crankshaft clockwise about 50 degrees clockwise.
Place timing mark on crankshaft pulley in line with centers
SCHEDULED MAINTENANCE of crankshaft pulley bolt and No. 2 timing belt idler pulley
The manufacturer recommends the belt be replaced at 90,000 bolt. See Fig. 3.
miles or 72 months.
CAUTION: If timing belt is disengaged, having crankshaft at incorrect
*NOTE: This application is an interference engine. angle can cause piston to contact valves while removing crankshaft
See page A-59 for interference engine cautions. pulley.

TIMING BELT
Removal:
cover. Drain cooling system. Remove air cleaner inlet. Re-
move V bank cover from top of engine. Remove air cleaner
assembly and intake air connector pipe.
On all models, drain engine coolant. Remove upper radia-
tor hose.
On GS400 and LS400, remove serpentine drive belt by turn-
ing drive belt tensioner pulley bolt counterclockwise.
Tensioner pulley bolt is LEFT HAND threaded. On SC400,
turn serpentine drive belt tensioner bolt CLOCKWISE to
relieve tension.
On LS400, remove fan and fan clutch and fan pulley. On
GS400, remove electric cooling fan assembly. On SC400,
disconnect hydraulic fan motor pressure and return pipes
from fan. Disconnect cooling fan inlet pipe and reservoir
tank from fan shroud.
On all models, remove the radiator assembly. Remove No.
2 drive belt idler pulley. See Fig. 2. Disconnect camshaft
position sensor wiring connector from No. 3 left side belt Courtesy of Toyota Motor Sales, U.S.A., Inc.
cover. Move engine wiring harness out of way and remove Fig. 1: Crankshaft & Camshaft Timing Mark Alignment
No. 3 left side (driver side) belt cover. See Fig. 2.
On GS400 and LS400, disconnect power steering air hose Without moving crankshaft pulley, remove pulley bolt. Alter-
from clamp on No. 3 right side belt cover. On LS400, dis- nately loosen 2 bolts, and remove timing belt tensioner.
connect coolant reservoir-to-engine pipe from in front of DO NOT hold timing belt tensioner with push rod facing
No. 3 right side belt cover. On all models, remove No. 3 downward. See Fig. 2.
right side (passenger side) belt cover. See Fig. 2. Using spanner wrench, slightly rotate right side camshaft
Remove A/C compressor from engine mount with hoses pulley clockwise to relieve tension on timing belt. Remove
attached. Move A/C compressor out of way. On GS400, re- timing belt from camshaft pulleys.
move No. 1 drive belt idler pulley and mount from engine. On GS400, remove power steering pump pulley bolt and
See Fig. 2. On LS400, remove fan bracket from front of pulley. On all models, remove generator. Remove serpen-
engine. On SC400, remove fan hydraulic pump from front tine drive belt tensioner. Using gear puller, remove crank-
of engine. See Fig. 7. shaft pulley without rotating crankshaft.
Remove No. 1 timing belt cover. See Fig. 4. Noting installed
CAUTION: If reusing timing belt, check that there are 3 mating direction for reassembly reference, remove timing belt
marks on belt to show installed position on crankshaft and camshaft guide from end of crankshaft. Remove timing belt cover
timing pulleys. If marks are missing, place installation mating spacer.
marks on timing belt and camshaft and crankshaft pulleys. Also,
mark belt with arrow to indicate original direction of rotation.
LEXUS 363
*4.0L V8 1998-00 (Cont.)
Fig. 2: Exploded View Of Timing Belt Covers (GS400 Shown; Others Similiar)
364 LEXUS
*4.0L V8 1998-00 (Cont.)
Fig. 3: Setting Crankshaft At 50 Degrees ATDC
If reusing timing belt, place mating mark on timing belt and

crankshaft timing pulley. Remove timing belt.
Inspection:
tamination. Replace timing belt if damaged or contami-
nated. Check idler pulleys for smooth rotation and oil seal
leakage. Replace idler pulleys if defective.
CAUTION: Never hold timing belt tensioner facing downward.

on rod seal under normal conditions. If excessive amount of oil
exists, replace timing belt tensioner.
place timing belt tensioner if there are excessive oil leaks.
Hold timing belt tensioner body with push rod facing UP-
WARD. Press push rod against solid surface. Replace tim- Courtesy of Toyota Motor Sales, U.S.A., Inc.
ing belt tensioner if push rod moves. Measure timing belt Fig. 4: Exploded View Of Timing Belt & Idler Pulleys
tensioner push rod protrusion from end of rod to edge of
housing. See Fig. 5. Replace timing belt tensioner if dis- Ensure camshaft timing pulleys are still aligned with mat-
tance is not .413-.453" (10.50-11.50 mm). Inspect water ing marks on rear plate. See Fig. 1. Clean camshaft timing
pump for leaks or worn bearing. pulleys (do not use solvent). Install timing belt on left side
Installation: (drivers side) camshaft pulley. If reusing old timing belt,
Install No.1 idler pulley and plate washer (if removed). Ap- ensure mating mark on belt aligns with mark on left side
ply Loctite 242 or equivalent on threads of idler pulley pivot camshaft pulley.
bolt. Install and tighten bolt to specification. See TORQUE Using spanner wrench, turn left side camshaft pulley until
SPECIFICATIONS. there is tension on timing belt between crankshaft timing
If removed, install No. 2 idler pulley and bolt. Tighten bolt to pulley and left side camshaft pulley.
specification. See TORQUE SPECIFICATIONS. Ensure idler Install timing belt on right side camshaft pulley. If reusing
pulleys are clean and rotate smoothly. Ensure idler pulley old belt, ensure mating mark on belt aligns with mark on
bracket moves freely. right side camshaft pulley. Ensure there is tension on tim-
ing belt between left side and right side camshaft pulleys.
NOTE: Engine should be cold when installing timing belt. Using press, SLOWLY apply about 200-2205 lbs. of pres-
Clean any oil or water off of crankshaft timing pulley. DO sure on push rod of timing belt tensioner until rod is re-
NOT use solvent. Temporarily Install timing belt on crank- tracted. Ensure timing belt tensioner is held with push rod
shaft timing pulley, No. 1 idler pulley, and No. 2 idler pulley. facing upward. Holes in push rod and housing must be
If reusing old belt, ensure mating mark on timing belt aligns aligned. See Fig. 6.
with mark on crankshaft timing pulley. Install hexagon wrench through holes in housing and rod
Install timing belt guide in original direction on end of crank- to hold rod in retracted position. See Fig. 6. Release press.
shaft. Install gasket and timing belt cover spacer. Install Install dust boot on timing belt tensioner. Install timing belt
gaskets and No. 1 timing belt cover. tensioner. Alternately tighten bolts to specification. See
Without rotating crankshaft, align crankshaft key with key TORQUE SPECIFICATIONS.
groove of crankshaft pulley. Using hammer and Pulley In-
staller (SST 09223-46011) or equivalent, install crankshaft CAUTION: Always rotate crankshaft clockwise as viewed from
front of engine. DO NOT rotate crankshaft counterclockwise.
pulley.
Install serpentine drive belt tensioner. Tighten bolts to speci- Remove hexagon wrench from timing belt tensioner. Tem-
fication. See TORQUE SPECIFICATIONS. Install generator. porarily install crankshaft pulley bolt. Slowly rotate crank-
On GS400, install power steering pump pulley. On all mod- shaft 2 full revolutions clockwise from TDC to TDC. Ensure
els, ensure crankshaft is still at 50 degrees ATDC position.
See Fig. 3.
LEXUS 365
*4.0L V8 1998-00 (Cont.)
Courtesy ofToyota Motor Sales, U.S.A., Inc.
timing marks on camshaft sprockets align with timing marks

on timing belt rear plate. See Fig. 1. If timing marks are not
aligned, remove timing belt and reinstall. Courtesy ofToyota Motor Sales, U.S.A., Inc.
Tighten crankshaft pulley bolt to specification. On GS400, Fig. 6: Retracting Timing Belt Tensioner Rod
install No. 1 drive belt idler pulley. On LS400, install fan
bracket. On SC400, install fan hydraulic pump and attach
lines.
On all models, install A/C compressor. Install No. 2 timing
belt cover. Install No. 3 timing belt covers. Connect cam-
shaft position sensor electrical connectors. Install serpen-
tine drive belt idler pulley.
Install radiator assembly. Install air cleaner assembly. Fill
and bleed cooling system. Start engine and open heater
water valve. Maintain engine speed at 2000-2500 RPM un-
til engine is warm. Stop engine. When engine is cool, refill
coolant reservoir.
A/C Compressor
Bolt ........................................................................... 36 (49)
Nut ............................................................................ 22 (30)
Drive Belt Tensioner Bolt/Nut ...................................... 12 (16) Courtesy of Toyota Motor Sales, U.S.A., Inc.
Fan Bracket-To-Engine Bolts (LS400) Fig. 7: Timing Belt Components (LS400 & SC400)
12 mm Head ................................................................ 12 (16)
14 mm Head ................................................................ 24 (32)
Generator Pivot & Lock Bolt ............................................ 29 (39)
Hydraulic Pump-To-Engine Bolts (SC400)
12 mm Head ................................................................ 12 (16)
14 mm Head ................................................................ 24 (32)
No. 1 Drive Belt Idler Pulley Mount-To-Engine Bolts (GS400)
12 mm Head ................................................................ 12 (16)
14 mm Head ................................................................ 24 (32)
No. 2 Timing Belt Cover Bolt .......................................... 12 (16)
No. 1 Timing Belt Idler Pulley Pivot Bolt ........................ 1 25 (35)
No. 2 Timing Belt Idler Pulley Bolt .................................. 25 (35)
Power Steering Pump
Bolt ........................................................................... 29 (39)
Nut ............................................................................ 32 (43)
Power Steering Pump Pulley Center Nut
GS400 .......................................................................... 32 (43)
Spark Plug .................................................................. 13 (18)
Water Pump Bolt
GS400 & SC400 ........................................................... 15 (21)
LS400 ........................................................................... 13 (18)
INCH Lbs. (N.m)

Camshaft Timing Pulley Bolt ......................................... 66 (7.5)
No. 3 Camshaft Belt Cover Bolts ................................... 66 (7.5)
1
Use Loctite 242 on bolt threads.
366 LEXUS & TOYOTA
*4.7L V8
4.7L V8
Land Cruiser
1998-01 ................. 4.5 Hours ..................... T298
LX470
1998-01 ................. 4.5 Hours ..................... T298
Tundra
2000-01 ................. 4.5 Hours ..................... T298
miles or 72 months.


TIMING BELT
Removal (Land Cruiser & LX470):
Raise and support vehicle. Remove lower engine cover.
Drain cooling system. Remove intake manifold cover lo-
cated on top of engine. Remove air cleaner assembly with
air intake hose that goes to throttle body.
Loosen 4 bolts holding fluid coupling to cooling fan bracket.
See Fig. 1. Remove serpentine drive belt, cooling fan fluid
coupling assembly, and fan pulley.
Remove radiator assembly. Remove accessory drive belt
idler pulley. Remove No. 3 timing belt cover from front of
passengers side camshaft.
Disconnect engine wiring harness clamps for access to
No. 3 timing belt cover at front of drivers side camshaft.
Disconnect electrical connectors from camshaft position
sensor on No. 3 timing belt cover. Remove No. 3 timing belt
cover. See Fig. 1.
Remove oil cooler pipe. Remove No. 2 timing belt cover.
Remove A/C compressor with hoses attached and set
aside. Remove cooling fan bracket.
Using Pulley Holder (SST 09213-70010) and Handle (SST
9330-00021), hold crankshaft pulley. Loosen crankshaft
pulley bolt.

at crankshaft and camshaft sprockets. If installation mark does
not exist, place mating marks on timing belt and crankshaft sprocket.
See Fig. 2. Also, place arrow on belt indicating direction of rotation.
Rotate crankshaft clockwise (viewed from front of engine)
so crankshaft pulley groove aligns with 0 timing mark on
No. 1 (lower) timing belt cover. See Fig. 7. Ensure timing
marks on camshaft sprockets align with marks on the tim-
ing belt rear plates. See Fig. 2. If timing marks are not
aligned, rotate crankshaft clockwise one full revolution.
Realign crankshaft pulley groove with 0 timing mark on
No. 1 (lower) timing belt cover.
CAUTION: Crankshaft must be properly positioned BEFORE removing
timing belt to prevent pistons from hitting valves. DO NOT allow
engine to rotate when removing crankshaft pulley bolt.
LEXUS & TOYOTA 367
*4.7L V8 (Cont.)

Remove serpentine drive belt tensioner. See Fig. 1. Re-

move generator. Without letting crankshaft rotate, use puller
to remove crankshaft pulley. Remove No. 1 timing belt cover.
Noting direction of timing belt guide for installation refer-
ence, remove timing belt guide and timing belt cover spacer.
Remove timing belt.
CAUTION: DO NOT use solvent to clean crankshaft or camshaft

sprockets. Wipe clean only.
Inspection (Land Cruiser & LX470):
nated. Check idler pulleys for smooth rotation. Replace
idler pulleys if defective. Inspect timing belt tensioner for
signs of oil leakage. Replace timing belt tensioner if oil
leakage exists.

exists, replace timing belt tensioner. NEVER hold timing belt tensioner
with push rod facing DOWNWARD.
DO NOT allow tensioner push rod to face downward. Hold
Courtesy of Toyota Motor Sales, U.S.A., Inc. timing belt tensioner body and press rod against solid sur-
Fig. 2: Locating Timing Belt Alignment Marks
face. Replace timing belt tensioner if rod moves.
Using crankshaft pulley bolt, rotate crankshaft clockwise rod to edge of housing. See Fig. 4. Replace timing belt
(viewed from front of engine) about 50 degrees ATDC. This tensioner if distance is not .413-.453" (10.50-11.50 mm).
will align crankshaft pulley groove with centerline of crank- Inspect water pump for leaks or bearing failure.
shaft pulley bolt and No. 2 idler pulley bolt. See Fig. 3. This
NOTE: Install timing belt with engine cold.
prevents valves from contacting pistons. Remove crank-
shaft pulley bolt. Installation (Land Cruiser & LX470):
Alternately loosen bolts and remove timing belt tensioner If No. 1 idler pulley was removed, apply Loctite 242 or equiva-
and dust boot. Using spanner wrench in holes in camshaft lent to bolt threads. Ensure pulley bracket moves freely.
sprocket, slightly rotate passengers side camshaft Install timing belt on crankshaft sprocket. If reusing old
sprocket clockwise to release timing belt tension. Remove belt, ensure match marks made on removal are properly
timing belt from camshaft sprockets. aligned.
Place timing belt around No. 1 and No. 2 idler pulleys.
Install gasket and timing belt cover spacer. Install timing
belt guide with cupped side away from crankshaft sprocket
and flat side toward timing belt.
Install No. 1 timing belt cover. Align groove of crankshaft
pulley with key in crankshaft. Tap crankshaft pulley until
seated on crankshaft.
Install serpentine drive belt tensioner. Install generator.
Tighten all fasteners to specification. See TORQUE SPECI-
FICATIONS. Ensure crankshaft pulley groove aligns with
centerline of crankshaft and No. 2 idler pulley bolts. See
Fig. 3.
Ensure timing mark on drivers side camshaft sprocket is
correctly aligned. See Fig. 6. Install timing belt on drivers
side camshaft sprocket. If reusing old belt, ensure match-
ing marks are aligned. Rotate drivers side camshaft
sprocket counterclockwise until tension exists on timing
Fig. 3: Positioning Crankshaft Pulley belt between crankshaft sprocket and drivers side cam-
shaft sprocket.
368 LEXUS & TOYOTA
*4.7L V8 (Cont.)
Ensure passengers side camshaft sprocket timing mark
is still aligned. Install timing belt on passengers side cam-
shaft sprocket. If reusing old belt, ensure matching marks
Using press, SLOWLY apply about 220-2200 lbs. of pres-
sure on timing belt tensioner rod until rod is retracted and
holes in rod and housing are aligned. See Fig. 5. Install
hexagon wrench through holes in housing and rod to hold
rod in retracted position.
Release press and install dust boot on timing belt tensioner.
Install timing belt tensioner on engine. Install and alter-
nately tighten bolts to specification.
CAUTION: When checking valve timing, only rotate crankshaft

clockwise as viewed from front of engine. DO NOT rotate crankshaft
counterclockwise.
Remove hexagon wrench from timing belt tensioner. To
check valve timing, rotate crankshaft pulley clockwise 2 full
revolutions from TDC to TDC. Crankshaft pulley groove
must align with 0 timing mark on No. 1 (lower) timing belt
cover.
With crankshaft at TDC position, ensure camshaft sprock-
ets align with timing marks on rear plates. If installing old
belt, ensure belt matching marks are aligned with cam-
shaft sprockets. If timing marks are not aligned, timing belt
will have to be removed and repositioned.
Tighten crankshaft pulley bolt to specification. Install fan Courtesy of Toyota Motor Sales, U.S.A., Inc.
bracket. Install A/C compressor to engine mount bracket. Fig. 6: Installing Timing Belt On Camshaft Sprocket
Install No. 2 and No. 3 timing belt covers. Install drive belt
idler pulley. Install radiator. Install cooling fan assembly.
dure. Tighten all fasteners to specification. Fill and bleed
air from cooling system.
Cooling System Bleeding:
Fill cooling system. Install radiator cap. Move heater con-
trol to warmest position. Start engine. Maintain engine speed
at 2000-2500 RPM until engine is at normal operating tem-
perature.
Shut engine off. Allow engine to cool. Recheck coolant level.
Fill coolant level to FULL line on coolant reservoir if neces-
sary.
Removal (Tundra):
Raise and support vehicle. Remove lower engine cover.
Drain cooling system. Remove radiator assembly. Remove Courtesy of Toyota Motor Sales, U.S.A., Inc.
throttle body cover. Remove intake air connector assembly. Fig. 7: Aligning Crankshaft Timing Marks
Loosen 4 bolts holding fluid coupling to cooling fan bracket.
See Fig. 1. Remove serpentine drive belt, cooling fan fluid Disconnect engine wiring harness clamps for access to
coupling assembly, and fan pulley. No. 3 timing belt cover at front of drivers side camshaft.
Remove power steering pump from engine with hoses at- Disconnect electrical connectors from camshaft position
tached and secure out of way. Remove serpentine drive sensor on No. 3 timing belt cover. Remove No. 3 timing belt
belt idler pulley. Remove No. 3 timing belt cover from front cover. See Fig. 1.
of passengers side camshaft. Remove oil cooler pipe. Remove No. 2 timing belt cover.
Remove A/C compressor with hoses attached and set
aside. Remove cooling fan bracket.
Using Pulley Holder (SST 09213-70010) and Handle (SST
9330-00021), hold crankshaft pulley. Loosen crankshaft
pulley bolt.

at crankshaft and camshaft sprockets. If installation mark does
not exist, place matching marks on timing belt and crankshaft
sprocket. See Fig. 2. Also, place arrow on belt indicating direction
of rotation.
Rotate crankshaft clockwise (viewed from front of engine)
so crankshaft pulley groove aligns with 0 timing mark on
No. 1 (lower) timing belt cover. See Fig. 7.
LEXUS & TOYOTA 369
*4.7L V8 (Cont.)
Ensure timing marks on camshaft sprockets align with Using press, SLOWLY apply about 220-2200 lbs. of pres-
marks on the timing belt rear plates. See Fig. 2. If timing sure on timing belt tensioner rod until rod is retracted and
marks are not aligned, rotate crankshaft clockwise one full holes in rod and housing are aligned. See Fig. 5. Install
revolution. Realign crankshaft pulley groove with 0 timing hexagon wrench through holes in housing and rod to hold
mark on No. 1 (lower) timing belt cover). rod in retracted position.
Alternately loosen bolts and remove timing belt tensioner Release press and install dust boot on timing belt tensioner.
and dust boot. Using spanner wrench in holes in camshaft Install timing belt tensioner on engine. Install and alter-
sprocket, slightly rotate passengers side camshaft nately tighten bolts to specification.
sprocket clockwise to release timing belt tension. Remove
timing belt from camshaft sprockets. CAUTION: When checking valve timing, only rotate crankshaft
Remove serpentine drive belt tensioner. See Fig. 1. With- clockwise as viewed from front of engine. DO NOT rotate crankshaft
out letting crankshaft rotate, use puller to remove crank- counterclockwise.
shaft pulley. Remove No. 1 timing belt cover. Noting direc- Remove hexagon wrench from timing belt tensioner. To
tion of timing belt guide for installation reference, remove check valve timing, rotate crankshaft pulley clockwise 2 full
timing belt guide and timing belt cover spacer. Remove revolutions from TDC to TDC. Crankshaft pulley groove
timing belt. must align with 0 timing mark on No. 1 (lower) timing belt
cover.
CAUTION: DO NOT use solvent to clean crankshaft or camshaft
sprockets. Wipe clean only.
With crankshaft at TDC position, ensure camshaft sprock-
ets align with timing marks on rear plates. If installing old
Inspection (Tundra): belt, ensure belt matching marks are aligned with cam-
Inspect timing belt for damaged teeth, cracking or oil con- shaft sprockets. If timing marks are not aligned, timing belt
tamination. Replace timing belt if damaged or contami- will have to be removed and repositioned.
nated. Check idler pulleys for smooth rotation. Replace Tighten crankshaft pulley bolt to specification. Install fan
idler pulleys if defective. Inspect timing belt tensioner for bracket. Install A/C compressor to engine mount bracket.
signs of oil leakage. Replace timing belt tensioner if oil Install No. 2 and No. 3 timing belt covers. Install drive belt
leakage exists. idler pulley. Install radiator. Install cooling fan assembly.
NOTE: Timing belt tensioner may weep a small amount of oil dure. Tighten all fasteners to specification. Fill and bleed
on rod seal under normal conditions. If excessive amount of oil air from cooling system.
exists, replace timing belt tensioner. NEVER hold timing belt tensioner Cooling System Bleeding:
with push rod facing DOWNWARD. Fill cooling system. Install radiator cap. Move heater con-
DO NOT allow tensioner push rod to face downward. Hold trol to warmest position. Start engine. Maintain engine speed
timing belt tensioner body and press rod against solid sur- at 2000-2500 RPM until engine is at normal operating tem-
face. Replace timing belt tensioner if rod moves. perature.
Measure timing belt tensioner rod protrusion from end of Shut engine off. Allow engine to cool. Recheck coolant level.
rod to edge of housing. See Fig. 4. Replace timing belt Fill coolant level to FULL line on coolant reservoir if neces-
tensioner if distance is not .413-.453" (10.50-11.50 mm). sary.
Inspect water pump for leaks or bearing failure. TORQUE SPECIFICATIONS
NOTE: Install timing belt with engine cold. Application Ft. Lbs. (N.m)
Accessory Drive Belt Tensioner Bolt ............................... 12 (16)
Installation (Tundra): A/C Compressor-To-Mount Bolt ................................. 36 (49)
If No. 1 idler pulley was removed, apply Loctite 242 or equiva- Air Intake Chamber Bolt/Nut ....................................... 13 (18)
lent to bolt threads. Ensure pulley bracket moves freely. Camshaft Sprocket Bolt ............................................ 80 (109)
Install timing belt on crankshaft sprocket. If reusing old Cooling Fan Bracket
belt, ensure match marks made on removal are properly 12 mm Head ................................................................ 12 (16)
aligned. 14 mm Head ................................................................ 24 (32)
Place timing belt around No. 1 and No. 2 idler pulleys. Cooling Fan Fluid Coupling-To-Cooling
Install gasket and timing belt cover spacer. Install timing Fan Bracket .................................................................. 16 (21)
belt guide with cupped side away from crankshaft sprocket Crankshaft Pulley Bolt ............................................ 181 (245)
and flat side toward timing belt. Drive Belt Idler Pulley Bolt ........................................... 27 (37)
Install No. 1 timing belt cover. Align groove of crankshaft Drive Belt Tensioner Bolt/Nut ...................................... 12 (16)
pulley with key in crankshaft. Tap crankshaft pulley until Generator Bolt/Nut .......................................................... 12 (16)
seated on crankshaft. No. 1 & No. 2 Idler Pulley Bolts ..................................... 1 25 (35)
Install serpentine drive belt tensioner. Install generator. No. 2 Timing Belt Cover Bolt .......................................... 12 (16)
Tighten all fasteners to specification. See TORQUE SPECI- Radiator Bracket-To-Body Bolts ...................................... 12 (18)
FICATIONS. Ensure the crankshaft pulley groove aligns with Spark Plug .................................................................. 13 (18)
0 timing mark on No. 1 timing belt cover. See Fig. 7. Timing Belt Tensioner Bolt ......................................... 19 (26)
Ensure timing mark on drivers side camshaft sprocket is Water Pump
correctly aligned. See Fig. 6. Install timing belt on drivers Stud Bolt & Nut ........................................................... 13 (18)
side camshaft sprocket. If reusing old belt, ensure match- Bolt ............................................................................... 15 (21)
ing marks are aligned. Rotate drivers side camshaft INCH Lbs. (N.m)
sprocket counterclockwise until tension exists on timing No. 3 Timing Belt Cover Bolts .................................... 66 (7.5)
belt between crankshaft sprocket and drivers side cam- 1
- Apply Loctite 242 or equivalent to No. idler pulley bolt
shaft sprocket. threads.
Ensure passengers side camshaft sprocket timing mark
is still aligned. Install timing belt on passengers side cam-
shaft sprocket. If reusing old belt, ensure matching marks
370 MAZDA
1.5L 4-Cylinder
TIMING BELT APPLICATION Check timing belt deflection with 22 lbs. (10 kg) of pres-
sure applied to belt. See Fig. 3. Ensure timing belt deflec-
Application Labor Time Belt Part No. tion is .28-.35 (7.0-9.0mm).
1.5L 4-Cyl. Ensure grooves on valve cover are free of oil, water, and
Protege dirt. Using new valve cover gasket, install valve cover.
1995-97 ................. 2.4 Hours .................... T266 Tighten valve cover bolts in sequence. See Fig. 1. Com-
1998 plete installation in reverse of removal procedure.
Up To Engine No. TORQUE SPECIFICATIONS
194742 ............... 2.4 Hours .................... T266 Application Ft. Lbs. (N.m)
From Engine No. Camshaft Sprocket Bolt .................................... 36-45 (49-61)
194743 ............... 2.4 Hours .................... T308 Crankshaft Pulley-to-Pulley Boss Bolt ............... 9-13 (12-18)
Crankshaft Pulley Boss Bolt ..................... 116-123 (157-167)
MANUFACTURERS SUGGESTED Wheel Lug Nuts ....................................................... 80 (110)
SCHEDULED MAINTENANCE INCH Lbs. (N.m)
The manufacturer suggests the belt be replaced at 60,000 Timing Chain Adjuster Bolt ................................. 71-97 (8-11)
mile intervals for vehicles sold outside of California and Mas- Timing Cover Bolt ................................................... 71-97 (8-11)
sachusetts. For vehicles sold in California and Massachu- Valve Cover Bolt ...................................................... 62-97 (7-11)
setts, inspect timing belt at 60,000 and 90,000 miles, and
replace timing belt at 105,000 miles.
TIMING BELT
Removal:
hicle. Remove right front wheel. Remove right side cover
and undercover.
Remove 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 crank-
shaft pulley hub bolt and hub.
Remove spark plug wires. Remove valve cover bolts in Courtesy of Mazda Motors Corp.
reverse order of tightening sequence. See Fig. 1. Remove Fig. 1: Valve Cover Bolt Tightening Sequence
valve cover. Remove dipstick tube.
Remove upper timing belt cover. Support engine with jack.
Remove engine mount bracket from timing belt end of en-
gine. If timing belt is to be reused, mark timing belt rotation
direction. Ensure timing marks on camshaft and crank-
shaft sprockets are aligned. See Fig. 2.
Remove lower and middle timing belt covers. Loosen tim-
ing belt tensioner lock bolt, and move tensioner away from
belt with spring fully expanded. Remove timing belt.
Inspection:
ness of rotation. Inspect tensioner spring free length. Speci-
fied length is 2.80 (71mm). Replace parts as necessary. Courtesy of Mazda Motors Corp.
Installation: Fig. 2: Aligning Camshaft & Crankshaft Timing Marks
Position notch on crankshaft sprocket to 12 oclock posi-
tion (aligned with mark on oil pump). Align timing marks on
camshaft sprocket and crankshaft. See Fig. 2. Ensure crank-
shaft timing mark is at TDC of compression stroke. Install
belt around crankshaft sprocket. Working in a counterclock-
wise direction, route belt around pulleys and camshaft
sprocket.
Loosen timing belt tensioner lock bolt and allow spring to
shaft 2 complete turns in direction of normal engine rota-
tion. Ensure timing marks align.
Letter Z on camshaft pulley and pin on crankshaft pulley
boss should face upward. If timing marks are not aligned,
remove belt, realign all timing marks, and repeat installa- Courtesy of Mazda Motors Corp.
tion procedure.
MAZDA 371

TIMING BELT APPLICATION Temporarily install crankshaft pulley boss and bolt. Loosen
timing belt tensioner lock bolt, and allow spring to apply
Application Labor Time Belt Part No. tension on belt. Rotate crankshaft clockwise almost 2 com-
1.6L 4-Cyl. DOHC plete turns.
Protege Remove the crankshaft pulley boss bolt and pulley boss.
1999-01 ................ 1 2.7 Hours .................... T308 Ensure the crankshaft timing belt pulley mark is aligned
with tensioner set mark. See Fig. 4. If not, rotate crankshaft
1
- With Air Cond. add .2 hours. to align.
With Pwr. Strng. add .2 hours. While holding timing belt tensioner, tighten lock bolt to speci-
MANUFACTURERS SUGGESTED Install crankshaft boss and tighten bolt to specification.
Turn crankshaft clockwise 2 revolutions. Face pin on crank-
SCHEDULED MAINTENANCE shaft pulley boss straight up. Ensure camshaft sprocket
For 1999-00 vehicles, the manufacturer recommends belt re- timing marks are correctly aligned. See Fig. 2. If timing
placement interval at 60,000 miles except for vehicles regis- marks are not aligned, remove belt, realign all timing
tered in California, Connecticut, Delaware, Maine, Maryland, marks, and repeat installation procedure.
Massachusetts, New Hampshire, New Jersey, New York, Penn- Check timing belt deflection with 22 lbs. (10 kg) of down-
sylvania, Rhode Island, Vermont, and Washington D.C. For ward pressure applied to belt, midway between camshaft
these states, inspect timing belt at 60,000 and 90,000 miles, sprockets. Timing belt deflection should be 0.24-0.29 (6.0-
and replace timing belt at 105,000 miles. 7.5 mm). If not, readjust timing belt tension.
For 2001 vehicles, the replacement interval is 105,000 miles, To complete installation, reverse removal procedure. When
UNLESS the vehicle is operated in outside temperatures un- installing valve cover, tighten valve cover bolts in correct
der 0F (-18C). Under this condition, replace timing belt at sequence. See Fig. 5.
60,000 miles. Adjust air gap between crankshaft plate and Crankshaft
Position (CKP) sensor. With a plate tooth directly centered
REMOVAL & INSTALLATION over CKP sensor, air gap should be 0.020-0.059 (0.5-1.54
mm). Adjust accessory drive belts to proper tension. See
TIMING BELT page A-60 for belt tension ranges.
Removal:
Disconnect negative battery cable. Remove camshaft po-
sition sensor from left side (exhaust) of engine. Remove
ignition coils. Remove valve cover.
Remove accessory drive belts and water pump pulley. Align
crankshaft pulley timing mark with cylinder No. 1 at TDC of
compression stroke. Groove in crankshaft pulley should
align with T mark on timing belt cover.
Remove crankshaft pulley from pulley boss. See Fig. 1.
Note installed position, and remove plate from pulley boss.
Holding crankshaft , loosen crankshaft pulley boss bolt.
Support engine with jack or from above with support bar.
Remove engine mount from timing belt end of engine.
Remove timing belt covers. See Fig. 1. If timing belt is to be
reused, mark timing belt rotation direction.
Ensure camshaft and crankshaft timing marks are aligned
correctly. See Fig. 2. Pulley boss position pin on crankshaft
should be facing up. If not, rotate crankshaft until marks are
aligned. Remove crankshaft pulley boss.
Loosen timing belt tensioner lock bolt. Temporarily secure
tensioner away from belt with spring fully expanded. Re-
move timing belt.
Inspection:
Tensioner spring free length should be 2.43 (61.8 mm).
Installation:
Install tensioner spring with damper rubber closing face Courtesy of Mazda Motors Corp.
on side away from tensioner. See Fig. 3. Fig. 1: Exploded View Of Timing Belt Components
aligned. See Fig. 2. Temporarily secure tensioner with
spring fully extended. Install belt around crankshaft sprocket,
idler pulley, exhaust camshaft, intake camshaft, then
tensioner.
372 MAZDA
Courtesy of Mazda Motors Corp. Courtesy of Mazda Motors Corp.

Fig. 2: Aligning Crankshaft & Camshaft Timing Marks Fig. 5: Valve Cover Bolt Tightening Sequence
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

Fig. 4: Aligning Timing Belt At Tensioner Set Mark
MAZDA 373
1.6L & 1.8L 4-Cylinder 1988-95

TIMING BELT APPLICATION Removal (MX-3, Protege & 323):
Belt hicle. Remove right front wheel. Remove right splash pan-
Labor Component Part els.
Application Time Kit No. No. Remove drive belts and water pump pulley. Align crank-
1.6L 4-Cyl. DOHC shaft pulley timing mark with cylinder No. 1 at TDC of com-
MX-3 pression stroke. Hold crankshaft stationary, and remove
crankshaft pulley bolts and pulley. Remove crankshaft pul-
1994-95 .......... 1 2.9 Hrs. .... TCK179 .......... T179 ley hub bolt and hub.
MX-5 Miata Remove timing belt covers. If timing belt is to be reused,
1990-93 ......... 1 3.0 Hrs. .... TCK179 .......... T179 mark timing belt rotation direction. Align timing marks on
323 camshaft sprocket(s). See Figs. 5 and 6. Loosen timing
1988-89 .......... 1 2.8 Hrs. .............................. T149 belt tensioner lock bolt. Temporarily secure tensioner away
1.6L 4-Cyl. SOHC from belt with spring fully expanded. Remove timing belt.
MX-3 Inspection (All Models):
1992-93 .......... 1 2.0 Hrs. .............................. T185
323 ness of rotation. Inspect tensioner spring for stretching.
1986 ............... 1 2.0 Hrs. .............................. T123 Replace parts as necessary.
1987-89 .......... 1 2.0 Hrs. .... TCK141 .......... T141 Installation (All Models):
1990-94 .......... 1 2.0 Hrs. .............................. T185 Position notch on crankshaft sprocket to 12 oclock posi-
1.8L 4-Cyl. DOHC tion (aligned with mark on oil pump). Align timing marks on
camshaft sprocket(s). See Figs. 5 and 6. Ensure crank-
Protege
shaft timing mark is at TDC. Install belt around crankshaft
1990-95 .......... 1 2.8 Hrs. .... TCK179 .......... T179 sprocket then working in a counterclockwise direction, route
1.8L 4-Cyl. SOHC belt around camshaft sprocket(s).
Protege Loosen timing belt tensioner lock bolt, and allow spring to
1990-94 .......... 1 2.0 Hrs. .............................. T185 apply tension on belt. Snug tensioner lock bolt. Rotate crank-
shaft 2 complete turns in direction of normal engine rota-
1
- With Air Cond. add .2 hours. tion. Ensure timing marks align. If timing marks are not
With Pwr. Strng. add .2 hours. aligned, remove belt, realign all timing marks, and repeat
installation procedure.
NOTE: A timing belt component kit is available for On all engines, check timing belt deflection with 22 lbs. (10
kg) of pressure applied to belt. See Fig. 7. Ensure timing
belt deflection is within specification. See TIMING BELT
kits. DEFLECTION. Adjust drive belts to proper tension. See page
For 1992 and earlier model years, the manufacturer recom-
belt be replaced at 60,000 mile intervals for vehicles sold
outside of California. For vehicles sold in California, inspect
timing belt at 60,000 and 90,000 miles, and replace timing
belt at 105,000 miles.

TIMING BELT
Removal (MX-5 Miata):
Remove radiator hose and by-pass hoses from thermo-
stat housing. Remove air cleaner intake duct assembly
from throttle body to air cleaner filter housing. Remove
splash shield.
Remove drive belt(s) and water pump pulley. Align crank-
shaft pulley timing mark with cylinder No. 1 at TDC of com-
pression stroke. Hold crankshaft pulley stationary. Remove
crankshaft pulley bolts. Remove pulley. Remove crankshaft
pulley hub bolt and hub.
Remove cylinder head cover. Remove upper, center and
lower timing belt cover. If timing belt is to be reused, mark
timing belt rotation direction. Ensure timing marks on cam- Fig. 1: Exploded View Of Timing Belt Components
shaft sprockets are aligned. See Fig. 5. Loosen timing belt (1989 SOHC)
tensioner lock bolt, and move tensioner away from belt
with spring fully expanded. Remove timing belt.
374 MAZDA
1.6L & 1.8L 4-Cylinder 1988-95 (Cont.)
TIMING BELT DEFLECTION
Application 1
Deflection in. (mm)
1989-87 .................................................... .47-.51 (11.9-13.0)
1995-90
DOHC ........................................................ .35-.45 (9.0-11.5)
SOHC ..................................................... .43-.51 (11.0-13.0)
1
- Deflection measurement is with 22 lbs. (10 kg) of pressure
applied to timing belt. See Fig. 7.
A/C Compressor Bracket
MX-5 Miata ...................................................... 11-16 (15-22)
MX-3, Protege & 323 ....................................... 17-26 (23-35)
Alternator Top Bolt ............................................ 27-38 (37-52)
Crankshaft/Timing Belt Sprocket Bolt
1991-86 ...................................................... 80-87 (109-118)
1996-92 .................................................. 116-123 (157-167)
Power Steering Pump-To-Bracket Bolt
MX-3, Protege & 323 ....................................... 27-38 (37-52)
DOHC ............................................................. 27-38 (37-52)
SOHC ............................................................. 14-19 (19-26) Fig. 3: Exploded View Of Timing Belt Components (DOHC)
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)
Fig. 4: Exploded View Of Timing Belt Components (Miata)

(1990 & Later SOHC)
MAZDA 375
1.6L & 1.8L 4-Cylinder 1988-95 (Cont.)
Fig. 5: Aligning Camshaft Timing Marks (DOHC Engines)
Fig. 6: Aligning Camshaft Timing Marks (SOHC Engines)

376 MAZDA
1.8L 4-Cylinder DOHC, BP Engine
TIMING BELT APPLICATION pulley boss stationary, remove crankshaft pulley boss bolt.
Remove pulley boss.
Belt Remove upper, middle, and lower timing belt covers. If tim-
Labor Component Part ing belt is to be reused, mark timing belt with arrow to
Application Time Kit No. No. indicate rotation direction.
1.8L 4-Cyl. DOHC Ensure timing marks on camshaft sprockets and crank-
MX-5 Miata shaft sprockets are aligned. See Fig. 4 . Loosen timing belt
tensioner lock bolt. Move tensioner away from belt with
1994-01 .......... 1 2.6 Hrs. .... TCK179 .......... T179 spring fully expanded, and tighten lock bolt. Remove timing
Protege belt.
1995-98 .......... 1 2.4 Hrs. .... TCK179 .......... T179 Removal (Protege):
1
- With Air Cond. add .2 hours. Disconnect negative battery cable. Raise and support ve-
hicle. Remove right front wheel. Remove right splash shield
With Pwr. Strng. add .2 hours. from wheelwell.
Remove drive belts and water pump pulley. Align crank-
NOTE: A timing belt component kit is available for shaft pulley timing mark with cylinder No. 1 at TDC of com-
this application. See page I for information on component pression stroke. Hold crankshaft stationary, and remove
crankshaft pulley pulley from crankshaft pulley boss. See
kits. Fig. 2 and 3.
Remove spark plug wires from spark plugs. Remove valve
NOTE: Engine identification code is on machined pad at left cover. Remove dipstick pipe. and stay. Remove upper tim-
rear end of engine, at transmission mating flange. ing belt cover. If timing belt is to be reused, mark timing belt
rotation direction.
MANUFACTURERS SUGGESTED Support engine from above and remove engine mount
bracket from timing belt end of engine. Remove middle
SCHEDULED MAINTENANCE and lower timing belt covers.
For 1994-96 vehicles, the manufacturer recommends the belt Holding crankshaft stationary, remove crankshaft pulley
be replaced at 60,000 mile intervals for vehicles sold outside boss. Align timing marks on crankshaft and camshaft
of California. For vehicles sold in California, inspect timing sprocket(s). See Fig. 4. Loosen timing belt tensioner lock
belt at 60,000 and 90,000 miles, and replace timing belt at bolt. Temporarily secure tensioner away from belt with spring
105,000 miles. fully expanded. Remove timing belt.
For 1997-98 vehicles, the manufacturer recommends the belt Inspection (All Models):
be replaced at 60,000 mile intervals for vehicles sold outside Check timing belt for cracks, peeling, abrasion or other
of California and Massachusetts. For vehicles sold in Califor- damage. Check tensioner and idler pulley bearing for loose-
nia and Massachusetts, inspect timing belt at 60,000 and ness or roughness of rotation. Replace parts as neces-
90,000 miles, and replace timing belt at 105,000 miles. sary.
For 1999-00 vehicles, the replacement interval is 60,000 miles
except for vehicles registered in California, Connecticut, Dela-
ware, Maine, Maryland, Massachusetts, New Hampshire, New
Jersey, New York, Pennsylvania, Rhode Island, Vermont, Vir-
ginia and Washington D.C. For these states, inspect timing
belt at 60,000 and 90,000 miles, and replace timing belt at
105,000 miles.
For 2001 MX-5 Miata, the replacement interval is 60,000 miles.

TIMING BELT
Removal (MX-5 Miata):
Remove radiator hose and by-pass hoses from thermo-
stat housing. If equipped with an control valve and pipe,
remove oil pipe and cover with a shop rag to prevent oil
spill. Remove oil control valve case. Remove Crankshaft
Position (CKP) and Camshaft Position (CMP) sensors from
front of engine (if equipped).
Keeping ignition wires attached, remove ignition coil pack
from front (timing belt end) of engine. Remove spark plugs.
Remove air cleaner intake duct assembly from throttle body
to air cleaner filter housing.
Remove drive belt(s) and water pump pulley. See Fig. 1.
Remove valve cover. Align crankshaft pulley timing mark
with cylinder No. 1 at TDC of compression stroke.
Remove crankshaft pulley from crankshaft pulley boss. Re- Courtesy of Mazda Motors Corp.
move plate with crankshaft pulley. Ensure crankshaft pul- Fig. 1: Exploded View Of Timing Belt Components (Miata)
ley boss locating pin faces straight up. Holding crankshaft
MAZDA 377
1.8L 4-Cylinder DOHC, BP Engine (Cont.)
Fig. 2: Exploded View Of Timing Belt Components (Protege)
Inspect tensioner spring for stretching. Replace tensioner Install timing belt tensioner spring with damper rubber clos-
spring if free length is not greater than 2.33 (59.2 mm). ing face away from tensioner. See Fig. 5. Temporarily se-
Free length is measured between inside edge to inside of cure the timing belt tensioner with tensioner spring fully
hooked portion of spring. expanded.
Installation (All Models): Install timing belt around crankshaft sprocket, then work-
Position notch on crankshaft sprocket to 12 oclock posi- ing in a counterclockwise direction, route belt around idler
tion (aligned with mark on oil pump). See Fig. 4. Align tim- pulley, camshaft sprocket(s), and tensioner pulley. Ensure
ing marks on camshaft sprocket(s). there is no slack in belt between crankshaft sprocket, idler
pulley, and camshaft sprockets.
NOTE: Timing mark on intake camshaft sprocket is an I; timing
mark on exhaust camshaft is an E.
378 MAZDA

Fig. 3: Exploded View Of Timing Belt Components (Miata With Oil Control Valve - Protege Similar)
Temporarily install the crankshaft pulley boss and bolt. Ro- Check timing belt deflection with 22 lbs. (10 kg) of pres-
tate crankshaft about 2 turns in direction of normal engine sure applied to belt. See Fig. 7. Ensure timing belt deflec-
rotation. Align timing belt pulley boss mark with tensioner tion is within specification. See TIMING BELT DEFLECTION
set mark for correct timing belt tension adjustment. See table.
Fig. 6. TIMING BELT DEFLECTION
Holding crankshshaft stationary, remove the crankshaft
pulley boss and bolt. Ensure the crankshaft and camshaft Application 1
Deflection in. (mm)
timing marks are still aligned. Loosen timing belt tensioner DOHC, BP Engine ....................................... .35-.45 (8.5-11.5)
lock bolt to apply tension to timing belt. Without moving
1
- Deflection measurement is with 22 lbs. (10 kg) of pressure
tensioner, tighten tensioner lock bolt to specification. See applied to timing belt. See Fig. 6.
TORQUE SPECIFICATIONS. To install remaining components, reverse removal proce-
Install crankshaft pulley boss and final tighen bolt to speci- dure. While installing valve cover gasket, apply light bead
fication. Rotate crankshaft 2 1/6 times. Camshaft timing of silicone sealer to 6 corners where gasket meets ends of
marks should be aligned with marks on rear cover, and the camshafts. Tighten all valve cover bolts in the correct se-
crankshaft pulley boss locating pin should point straight quence. See Fig. 8.
up. If timing marks are not aligned, remove belt, realign all
timing marks, and repeat installation procedure.
MAZDA 379

Fill and bleed cooling system. Fill with 50/50 mix of water
and coolant. To bleed system, fill system. Run engine at
2500 RPM for 5 minutes. Run engine 3000 RPM for 5 min-
utes. Recheck coolant level and fill as necessary. On Pro-
tege, check ignition timing.
Crankshaft Pulley-To-Pulley Boss .......................... 9-13 (12-18)
Crankshaft Pulley Boss Bolt ....................... 116-123 (157-167)
Engine Mount Bracket (Protege)
Nuts ................................................................ 55-77 (75-104)
Alternator Top Bolt ............................................ 14-18 (19-25)
Alternator Pivot Bolt ............................................. 28-38 (38-51)
Idler Pulley Bolt ................................................... 28-38 (38-51)
Spark Plugs .......................................................... 11-16 (15-22)
Timing Belt Tensioner Bolt ................................. 28-38 (38-51)
Wheel Lug Nut (Protege) .................................. 66-94 (89-127)
INCH Lbs. (N.m) Fig. 6: Aligning Timing Belt Tensioner Set Mark
Timing Belt Cover Bolt ............................................ 71-97 (8-11)
Valve Cover Bolt ...................................................... 43-78 (5-9)


Fig. 8: Valve Cover Bolt Tightening Sequence

Fig. 5: Installing Timing Belt Tensioner Spring
380 MAZDA
1.8L 4-Cylinder FP Engine
Install tensioner, and idler pulley (if removed). Temporarily
Application Labor Time Belt Part No. tighten tensioner with spring fully retracted. Ensure cam-
1.8L 4-Cyl. DOHC shaft and crankshaft timing marks are aligned. See Fig. 1.
Protege Install timing belt around crankshaft sprocket, water pump
1999-00 ................ 1 2.4 Hours .................... T316 sprocket, idler pulley, and camshaft sprockets. Ensure
slack does not exist on idler side of timing belt.
1
- With Air Cond. add .2 hours. Complete timing belt installation on slack (tensioner) side.
With Pwr. Strng. add .2 hours. Allow tensioner to ride against timing belt. Turn crankshaft
2 revolutions in normal direction of rotation. Ensure cam-
shaft and crankshaft timing marks are still correctly aligned.
NOTE: Engine code is stamped on machined pad on lower left
If not, timing belt will have to be removed and repositioned.
end of engine, on transaxle mating flange.
If all timing marks are okay, turn tensioner clockwise by
using a hex wrench. Connect tensioner spring to pin on
MANUFACTURERS SUGGESTED engine block. Turn crankshaft 2 revolutions. Ensure cam-
SCHEDULED MAINTENANCE shaft and crankshaft timing marks are still aligned.
The replacement is 60,000 miles except for vehicles regis- dure. Tighten valve cover bolts in correct sequence. See
tered in California, Connecticut, Delaware, Maine, Maryland, Fig. 3. Install water pump pulley with stamped F mark
Massachusetts, New Hampshire, New Jersey, New York, Penn- away from engine. Adjust drive belts to proper tension. See
sylvania, Rhode Island, Vermont, and Washington D.C. For page A-60 for belt tension ranges.
these states, inspect timing belt at 60,000 and 90,000 miles, Inspect crankshaft position sensor air gap. Air gap between
and replace timing belt at 105,000 miles. 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
REMOVAL & INSTALLATION is not adjustable. If gap is incorrect, check for damage parts.
TIMING BELT TORQUE SPECIFICATIONS
Removal: Application Ft. Lbs. (N.m)
Disconnect negative battery cable. Remove Crankshaft Po- Camshaft Pulley Bolt .......................................... 37-44 (50-60)
sition (CKP) and Camshaft Position (CMP) sensors from Crankshaft Pulley Bolt .............................. 116-123 (157-167)
front of engine. Timing Belt Idler Pulley Bolt .............................. 28-38 (38-52)
Remove accessory drive belt. Remove the water pump pul- Timing Belt Tensioner Bolt ............................... 28-38 (38-52)
ley. See Fig. 2. Rotate crankshaft so No. 1 cylinder is on INCH Lbs. (N.m)
TDC of compression stroke. CKP & CMP Sensor Bolts ...................................... 71-97 (8-11)
Timing Belt Covers ............................................. 61-87 (7-10)
CAUTION: Crankshaft position sensor rotor is on rear of crankshaft Valve Cover Bolts .................................................. 62-89 (7-10)
pulley. DO NOT damage rotor when removing crankshaft pulley. Water Pump Pulley Bolts ....................................... 71-97 (8-11)
Remove crankshaft pulley and guide plate (large
washer). Loosen valve cover bolts in 2-3 steps. See Fig. 3.
Remove valve cover and gasket.
Remove dipstick tube. Remove upper and lower timing
belt covers. Support engine from above. Remove engine
mount at timing belt end of engine.
If reusing timing belt, mark arrow on belt to indicate direc-
tion of rotation. Install crankshaft pulley bolt finger-tight to
retain crankshaft sprocket. Rotate crankshaft clockwise (as
viewed from timing belt end of engine) until cylinder No. 1
piston is at TDC of compression stroke and timing marks
Turn tensioner clockwise with a hex wrench to relieve spring
tension, and then disconnect spring. Remove timing belt.
Remove tensioner and idler pulley (if necessary). Courtesy of Mazda Motors Corp.
Inspection: Fig. 1: Aligning Camshaft & Crankshaft Timing Marks
Tensioner spring free length should be 1.44 (36.6 mm).
MAZDA 381
1.8L 4-Cylinder FP Engine (Cont.)

Loosening Sequence Tightening Sequence

Fig. 3: Valve Cover Bolt Loosening & Tightening Sequence
382 MAZDA
*2.0L 4-Cylinder DOHC, Except Tribute
TIMING BELT APPLICATION CAUTION: On models with a crankshaft position sensor, rotor
Belt is on rear of crankshaft pulley. DO NOT damage rotor when removing
crankshaft pulley.
Application Time Kit No. No. Remove crankshaft pulley and guide plate (large
2.0L 4-Cyl. DOHC washer). Loosen valve cover bolts in 2-3 steps. See Fig. 2.
MX-6 Remove valve cover and gasket.
1993-97 .......... 1 2.5 Hrs. .... TCK228 .......... T228 Remove dipstick tube. Remove upper and lower timing
belt covers. Support engine from above. Remove engine
Protege mount at timing belt end of engine.
2001 ............... 1 2.4 Hrs. .... TCK228 .......... T228 If reusing timing belt, mark arrow on belt to indicate direc-
626 tion of rotation. Install crankshaft pulley bolt finger-tight to
1993-01 .......... 1 2.5 Hrs. .... TCK228 .......... T228 retain crankshaft sprocket. Rotate crankshaft clockwise (as
viewed from timing belt end of engine) until cylinder No. 1
1
- With Air Cond. add .2 hours. piston is at TDC of compression stroke and timing marks
With Pwr. Strng. add .2 hours are aligned. See Fig. 1.
Turn tensioner clockwise with a hex wrench to relieve spring
tension, and then disconnect spring. Remove timing belt.
NOTE: A timing belt component kit is available for Remove crankshaft sprocket, tensioner and idler pulley (if
this application. See page I for information on component necessary).
kits. Inspection:
MANUFACTURERS SUGGESTED ness of rotation. Inspect tensioner spring for stretching.
SCHEDULED MAINTENANCE Tensioner spring free length should be 1.44 (36.6 mm).
For 1993 model year, the manufacturer recommends the belt Measure spring free length from inside edge to inside edge
be replaced at 60,000 miles. of hooked portion of spring. Replace parts as necessary.
For 1994-96 models years, the manufacturer recommends Installation:
the belt be replaced at 60,000 mile intervals for vehicles sold Install crankshaft sprocket, tensioner, and idler pulley (if
outside of California. For vehicles sold in California, inspect removed). Temporarily tighten tensioner. DO NOT install
timing belt at 60,000 and 90,000 miles, and replace timing tensioner spring yet. Ensure all timing marks are aligned.
belt at 105,000 miles. See Fig. 1.
For 1997-98 model years, the manufacturer suggests the belt Install timing belt around crankshaft sprocket, water pump
be replaced at 60,000 mile intervals for vehicles sold outside sprocket, idler pulley, and camshaft sprockets. Ensure
of California and Massachusetts. For vehicles sold in Califor- slack does not exist on idler pulley side of timing belt.
nia and Massachusetts, inspect timing belt at 60,000 and Complete timing belt installation on slack (tensioner) side.
90,000 miles, and replace timing belt at 105,000 miles. With tensioner spring removed, allow tensioner to ride
For 1999-00 model years, the manufacturer recommends the against timing belt. Turn crankshaft 2 revolutions in normal
belt be replaced at 60,000 mile intervals except for vehicles direction of rotation. Ensure camshaft and crankshaft tim-
registered in California, Connecticut, Delaware, Maine, Mary- ing marks are still correctly aligned. If not, timing belt will
land, Massachusetts, New Hampshire, New Jersey, New York, have to be removed and repositioned.
Pennsylvania, Rhode Island, Vermont, Virginia and Washing- If all timing marks are okay, turn tensioner clockwise using
ton D.C. For these states, inspect timing belt at 60,000 and a hex wrench. Connect tensioner spring to pin on engine
90,000 miles, and replace timing belt at 105,000 miles. block. Turn crankshaft 2 revolutions. Ensure camshaft and
For 2001 models, the manufacturer recommends the belt be crankshaft timing marks are still aligned.
replaced at 105,000 miles, UNLESS the vehicle is operated in
temperatures under 0F (-18C). Under this condition, replace


TIMING BELT
Removal:
Disconnect negative battery cable. Remove Crankshaft Po-
sition (CKP) and Camshaft Position (CMP) sensors from
front of engine (if equipped). Remove spark plugs.
Remove accessory drive belts. Leaving hoses attached,
remove power steering pump and position aside. Remove
the water pump pulley. Rotate crankshaft so No. 1 cylinder
is on TDC of compression stroke. Courtesy of Mazda Motors Corp.
MAZDA 383
*2.0L 4-Cylinder DOHC, Except Tribute (Cont.)

dure. When installing valve cover gasket apply small amount
of silicone sealer to 4 corners of gasket where the front of
both camshafts go through cylinder head. Tighten valve
cover bolts in correct sequence. See Fig. 2. Adjust drive
ranges.
Inspect crankshaft position sensor air gap. Air gap between
outer edge of crankshaft pulley rotor tooth and center of
CKP sensor should be 0.029-0.059 (0.5-1.5 mm). Air gap
is not adjustable. If gap is incorrect, check for damage parts.
Camshaft Pulley Bolt .......................................... 37-44 (50-60)
Loosening Sequence Crankshaft Pulley Bolt .............................. 116-123 (157-167)
Timing Belt Idler Pulley Bolt .............................. 28-38 (38-51)
INCH Lbs. (N.m)
CKP & CMP Sensor Bolts ...................................... 71-97 (8-11)
Valve Cover Bolts .................................................. 62-89 (7-10)
Water Pump Pulley Bolts ....................................... 71-97 (8-11)
Tightening Sequence
Fig. 2: Valve Cover Bolt Loosening & Tightening Sequences
384 MAZDA
2.0L 4-Cylinder DOHC, Tribute
TIMING BELT APPLICATION Rotate crankshaft to just before No. 1 cylinder TDC. See
Fig. 2. Remove stud and install Crankshaft TDC Timing
Application Labor Time Belt Part No. Peg (303-574). See Fig. 3.
2.0L 4-Cyl. VIN 3
Tribute NOTE: Make sure second notch in pulley is indexed to lower
cylinder block. See Fig. 2.
2001 ...................... 3.6 Hours ..................... T294
Rotate crankshaft clockwise against peg to bring it to TDC.
MANUFACTURERS SUGGESTED Loosen water pump pulley bolts.
SCHEDULED MAINTENANCE Remove timing belt cover by removing crankshaft pulley,
then remove lower timing belt cover bolts and lower timing
The manufacturer recommends the belt be replaced every belt cover. See Fig. 4. Install Engine Support Bar (303-F072).
120,000 miles. See Fig. 5.
Remove ground strap and engine mount upper bracket
REMOVAL & INSTALLATION and studs. See Fig. 6. Remove upper timing belt cover
bolts and cover. See Fig. 7.
TIMING BELT Remove water pump pulley and accessory drive belt idler
pulley. Install Camshaft Alignment Tool (303-465) and align
CAUTION: DO NOT rotate crankshaft or camshafts with timing camshafts. See Fig. 8.
belt removed, damage to valves and pistons may result.
NOTE: Installation of Camshaft Alignment Tool (303-465) into
Removal:
exhaust camshaft may require camshafts to be rotated slightly
Disconnect negative battery cable. Remove accessory drive clockwise.
belt. Remove air cleaner outlet pipe and ignition wires from
spark plugs. Disconnect throttle cables and cruise control Raise and support vehicle. Remove engine mount lower
actuator cable. Disconnect accelerator cable. Remove valve bracket. See Fig. 9.
cover. See Fig. 1. Loosen timing belt tensioner pulley and allow it to slide
Remove spark plugs. Remove catalytic converter. Remove down to bottom of its travel. Slide timing belt off of camshaft
coolant tube bolt and nut. Position coolant tube to side. and crankshaft sprockets.
CAUTION: DO NOT reuse old timing belt. Replace with a NEW

belt.
Fig. 1: Removing Valve Cover

Fig. 3: Removing Stud For Installation Of Crankshaft TDC

Timing Peg (303-574)
Fig. 2: Aligning Crankshaft Timing Marks Before TDC
Fig. 4: Removing Lower Timing Belt Cover

MAZDA 385
2.0L 4-Cylinder DOHC, Tribute (Cont.)

Fig. 5: Installing Engine Support Bar (303-F072) Fig. 9: Removing Engine Mount Lower Bracket
Courtesy of Ford Motor Co. Courtesy of Ford Motor Co.
Fig. 6: Removing Engine Mount Upper Bracket Fig. 10: Installing Timing Belt Tensioner
Installation:
Slide crankshaft pulley onto crankshaft. Ensure crankshaft
position is at No. 1 TDC by rotating it clockwise against
Crankshaft TDC Timing Peg (303-574). Ensure second
notch in pulley is indexed to lower cylinder block. See Fig.
2. Remove crankshaft pulley.
Ensure timing belt tensioner is installed correctly with tab
positioned in slot in inner timing cover. See Fig. 10.
Install new timing belt onto timing belt sprockets and ad-
just timing belt tensioner using a 6 mm Allen wrench to
rotate adjuster counterclockwise and align marks. See
Figs. 11 and 12. Tighten tensioner pulley bolt to specifica-
Install front engine mount lower bracket. Install accessory
Courtesy of Ford Motor Co. drive belt idler pulley. Install water pump pulley but hand
Fig. 7: Removing Upper Timing Belt Cover tighten only. Install timing belt covers. Install crankshaft
pulley. Tighten water pump pulley bolts to specification.
See TORQUE SPECIFICATIONS.
Remove Crankshaft TDC Timing Peg (303-574). Install stud.
Install engine mount upper bracket and ground strap. Re-
move Engine Support Bar (303-F072). Install coolant tube,
catalytic converter and remove Camshaft Alignment Tool
(303-465).
Install valve cover and spark plugs. Reconnect accelerator
cable and cruise control actuator cable. Reinstall ignition
wires, air cleaner outlet pipe and accessory drive belt. Re-
connect negative battery cable.
Fig. 8: Installing Camshaft Alignment Tool (303-465)

386 MAZDA
2.0L 4-Cylinder DOHC, Tribute (Cont.)
Accessory Drive Belt Idler Pulley Bolt .......................... 35 (45)
Coolant Tube Attachments ............................................. 15 (20)
Engine Mount Lower Bracket Nuts ................................. 37 (50)
Engine Mount Upper Bracket Nuts ................................. 61 (83)
Engine Mount Upper Bracket Studs .............................. 25 (34)
Ground Strap .................................................................. 25 (34)
Spark Plugs ................................................................... 11 (15)
Stud (For Crankshaft TDC Timing Peg) ......................... 18 (24)
INCH Lbs. (N.m)
Fig. 11: Installing Timing Belt On Sprockets Upper Timing Belt Cover Bolt ....................................... 71 (8)
Valve Cover ...................................................................... 80 (9)

MAZDA 387
*2.0L & 2.2L 4-Cylinder SOHC

TIMING BELT APPLICATION *NOTE: These applications are interference en-
Belt gines. See page A-59 for interference engine cautions.
Application Time1 Kit No. No. REMOVAL & INSTALLATION
2.0L 4-Cyl. SOHC
B2000 TIMING BELT
1986 Removal:
Thru: Chassis No. Disconnect negative battery cable. Drain cooling system.
Remove cooling fan and shroud. Remove distributor from
568707 ......... 2.6 Hrs. ................................ T113 front housing. Remove cooling fan pulley and bracket. Re-
From: Chassis No. move secondary air pipe assembly (carbureted engines).
568708 ......... 2.6 Hrs. ................................ T117 Remove alternator drive belt and A/C and P/S drive belts (if
1987 ............... 1.6 Hrs. ................................ T117 equipped). Remove crankshaft pulley and baffle plate. Re-
626 move timing belt covers. Align camshaft pulley with front
1983 ............... 1.6 Hrs. ................................ T088 housing timing mark. See Fig. 1. Mark an arrow on timing
626 Coupe belt to indicate direction of travel. Remove tensioner lock
bolt, tensioner and spring. Remove timing belt. On 2.2L
1984-85 engines, measure free length of tensioner spring. Replace
Thru: VIN JM1GC221E spring if free length is not 2.48 inch (63 mm). See Fig. 2.
1617 ............. 1.6 Hrs. .............................. 2 T088
From:VIN JM1GC221E NOTE: Never twist, turn inside out, or bend timing belt.
16176 ........... 1.6 Hrs. .............................. 3 T113 Installation:
626 Hatchback Align camshaft pulley with front housing timing mark. Align
1984-85 crankshaft pulley with pointer on oil pump body. See Fig. 1.
Thru: VIN JM1GC Install tensioner, lock bolt and tensioner spring. Position
241E1 .......... 1.6 Hrs. .............................. 2 T088 timing belt tensioner to its limit of travel toward the intake
manifold side and partially tighten lock bolt.
From: VIN JM1GC
241E1 .......... 1.6 Hrs. .............................. 3 T113
626 Sedan
1984-85
Thru: VIN JM1GC221E163
5511 ............. 1.6 Hrs. .............................. 2 T088
From: VIN JM1GC221E163
5511 ............. 1.6 Hrs. .............................. 3 T113
1986-87 ........ 1.6 Hrs. .............................. T117
2.2L 4-Cyl. Non-Turbo & Turbo
B2200
1987-93 .......... 2.6 Hrs. ...... TCK134 .......... T134
MX-6
1988-92 .......... 2.3 Hrs. ...... TCK134 .......... T134
626
1988-92 .......... 1.6 Hrs. ...... TCK134 .......... T134
1
With Pwr. Strng. add .2 hours
2
With square tooth sprocket.
3
With round tooth sprocket.

kits.
The manufacturer recommends the belt be replaced every Fig. 1: Timing Belt Reference Marks & Deflection
60,000 miles.
388 MAZDA
*2.0L & 2.2L 4-Cylinder SOHC (Cont.)
TORQUE SPECIFICATIONS (2.0L)
Camshaft Pulley Bolt .......................................... 35-48 (47-65)
Torque Stopper Bolts ........................................ 45-56 (61-76)
INCH Lbs. (N.m)
Fig. 2: Measuring Free Length Of Tensioner Spring
Valve Cover ........................................................... 26-35 (3-4)
Install timing belt onto crankshaft pulley and then camshaft
TORQUE SPECIFICATIONS (2.2L & 2.2L Turbo)
pulley. Install timing belt from tension side (right side, as
viewed from engine front). If timing belt is being reused, Application Ft. Lbs. (N.m)
ensure that arrow is pointing in direction of travel. Coolant Inlet Pipe Bolt ...................................... 14-19 (19-26)
Loosen tensioner lock bolt to apply tension. To apply equal Crankshaft Sprocket Bolt .......................... 116-123 (157-167)
tension to each side of timing belt, turn crankshaft 2 revolu- Timing Belt Idler Pulley ..................................... 27-38 (37-52)
tions in direction of travel. Tighten tensioner lock bolt. Check Timing Belt Tensioner Lock Bolt ....................... 27-38 (37-52)
for proper alignment of timing marks. Water Pump Bolt .............................................. 14-19 (19-26)
Check for proper belt tension by measuring amount of de- INCH Lbs. (N.m)
flection midway between crankshaft and camshaft pulleys Crankshaft Pulley-To-Crankshaft
when force of 22 lbs. (10 kg) is applied. See Fig. 1. Deflec- Sprocket Bolt ................................................. 109-152 (13-7)
tion should be .43-.51" (11-13 mm). If tension is incorrect, Rocker Cover Bolt ................................................. 26-35 (3-4)
repeat timing belt tensioning procedure. Timing Belt Cover ............................................... 61-87 (7-10)
tension ranges.
MAZDA 389

TIMING BELT APPLICATION Remove torque bracket from right fender apron. If reusing
timing belt, mark an arrow on timing to indicate direction of
Belt Part No. travel, then remove timing belt. Check belt for premature wear,
2.0L 4-Cyl. Diesel missing teeth, or cracks. Check turning smoothness of belt
626 tensioner.
Camshaft ........... 1.9 Hours .................... T103 Ensure that timing mark on camshaft pulley is aligned with
mark on front seal plate. Make sure that notch on crank-
Injection Pump ... 1.0 Hours ..................... T102 shaft pulley is aligned with timing mark on oil pump hous-
1
- With Air Cond. add .2 hours. ing. See Fig. 1.
With Pwr. Strng. add .2 hours. If tensioner was removed, install tensioner, lock bolt, and
spring. Push tensioner as far left as it will go. Snug tensioner
MANUFACTURERS SUGGESTED lock bolt. Install timing belt. Release tensioner lock bolt
and allow tensioner to contact belt.
SCHEDULED MAINTENANCE Turn crankshaft in a clockwise direction (as viewed from
The manufacturer recommends the belt be replaced every front) for 2 complete revolutions. Tighten tensioner lock
100,000 miles. bolt. Check timing marks on front camshaft and crankshaft
pulleys.

TIMING BELT (FRONT)
Removal:
Disconnect negative battery cable. Remove right side
splash shield (if equipped). Remove drive belts and crank-
shaft pulley. Remove timing belt covers and rubber seals.
Turn crankshaft in a clockwise direction until mark on front
camshaft pulley and front seal plate timing mark align.
Loosen tensioner lock bolt, and push tensioner as far back
as it will go. Snug tensioner lock bolt.
Fig. 2: Rear Camshaft & Injection Pump Pulley Timing

Marks
Check timing belt deflection using 22 lbs. (10 kg) of force

between front camshaft and water pump pulleys. Deflection
should be .413-.472" (10.49-11.99 mm) Reverse removal pro-
cedure to complete installation. Adjust drive belts to proper
tension.
TIMING BELT (REAR)
Removal:
Remove rear timing belt cover. Turn crankshaft to align rear
camshaft pulley with rear seal plate timing mark. Loosen
belt tensioner lock nut. Rotate belt tensioner clockwise, us-
ing a screwdriver, as far as it will go. Snug tensioner lock nut.
If reusing timing belt, mark an arrow on timing belt to indi-
cate direction of travel. Remove rear timing belt. Check belt
for premature wear, missing teeth, or cracks. Check turn-
ing smoothness of belt tensioner.
Installation:
Check timing marks on rear camshaft and injection pump
pulleys. See Fig. 2. Secure injection pump pulley to engine
using two 8 x 1.5 x 45 mm bolts.
NOTE: DO NOT remove bolts securing injection pump pulley

at this time. Remove bolts after installing timing belt.
Fig. 1: Front Camshaft & Crankshaft Pulley Timing Marks
390 MAZDA
If tensioner was removed, install tensioner lock nut, and TORQUE SPECIFICATIONS
spring in fully released position. Rotate belt tensioner clock-
wise, using a screwdriver, as far as it will go. Snug tensioner
Camshaft Pulley Bolt ........................................ 41-48 (56-65)
lock nut.
Crankshaft Pulley Bolts .................................... 17-24 (23-33)
Install rear timing belt on injection pump pulley, around
Fuel Injection Pump Pulley Bolts ...................... 43-51 (58-69)
tensioner, and then on camshaft pulley. Remove bolts se-
Timing Belt (Front) Pulley Bolt .................. 116-123 (157-167)
curing injection pump pulley. Loosen tensioner lock nut
until tension is applied on belt. Turn crankshaft in a clock-
Front ............................................................... 23-34 (31-46)
wise direction for 2 complete revolutions.
Rear ............................................................... 15-20 (20-27)
Check timing marks on rear camshaft and injection pump
Water Pump Bolts ............................................ 23-34 (31-46)
pulleys. See Fig. 2. Tighten tensioner lock nut. Check tim-
INCH Lbs. (N.m)
ing belt deflection using 22 lbs. (10 kg) of force between
Rear Cover Bolts .................................................. 60-84 (7-9)
injection pump and camshaft pulleys. Deflection should be
0.375" (9.53 mm). Install rear timing belt cover. Adjust drive
ranges.
MAZDA 391
2.3L 4-Cylinder
2.3L 4-Cyl.
B2300
1994 ..................... 1 2.2 Hours .................... T210
1995-97 ................ 1 2.2 Hours .................... T276
1
60,000 miles.
TIMING BELT
Removal:
Disconnect negative battery cable. Ensure crankshaft is
set at TDC and camshaft sprocket timing mark is aligned
with cover pointer. See Fig. 2. Disconnect negative battery
cable.
Drain cooling system and remove upper radiator hose. Re-
move alternator. Loosen water pump pulley bolts. Remove
accessory drive belt(s). Remove spark plugs to ensure belt Fig. 1: Exploded View Of Timing Belt & Components
does not jump time during rotation.
Remove cooling fan and water pump pulley. Remove crank-
shaft pulley, hub and belt guide. Remove crankshaft posi-
tion sensor. Remove dipstick and pipe. Remove timing belt
cover retaining bolt. Release 8 cover interlocking tabs.
Remove timing belt cover. Loosen timing belt tensioner
pulley bolt. Pry tensioner away from timing belt and tighten
bolt to hold tensioner in place. Remove timing belt.
CAUTION: Always rotate engine in direction of normal rotation

(clockwise as viewed from front of engine).
Installation:
timing mark is aligned with cover pointer. See Fig. 1. Install
belt guide with flat side toward the camshaft sprocket. See
Fig. 2.
Install timing belt. Loosen tensioner bolt, allowing tensioner
to apply pressure on belt. Tighten tensioner bolt. Rotate
crankshaft clockwise 2 complete turns to remove slack from
belt.
Loosen tensioner bolt. Apply additional pressure to
tensioner as spring pressure is insufficient. Retighten
tensioner lock bolt. To complete installation, reverse re-
moval procedure. Fill and bleed cooling system. Adjust drive
ranges.
Crankshaft Damper Bolt ........................... 103-133 (140-180)
Water Pump Bolt 1 ............................................ 14-21 (19-29)
INCH Lbs. (N.m)
Engine Timing Belt Cover Bolt .......................... 71-106 (8-12)
Valve Cover Bolt .................................................. 62-97 (7-11)
1
- Apply sealant to bolt threads.
392 MAZDA
2.5L 4-Cylinder
TIMING BELT APPLICATION If reusing old timing belt, mark belt with arrow to indicate
2.5L 4-Cyl. CAUTION: Always rotate engine in direction of normal rotation
B2500 (clockwise as viewed from front of engine). Reverse rotation may
cause timing belt to jump time, causing engine damage.
1998-00 ................ 1 2.2 Hours .................... T276
1
- With Air Cond. add 1.0 hours. Installation:
timing mark and oil pump sprocket timing mark are aligned
with inner cover timing marks. See Fig. 1.
MANUFACTURERS SUGGESTED Install timing belt on crankshaft sprocket. Working clock-
SCHEDULED MAINTENANCE wise, install belt over oil pump sprocket, camshaft sprocket,
and tensioner pulley.
The manufacturer recommends the belt be inspected at Loosen tensioner bolt and allow tensioner to adjust itself.
120,000 miles and replaced if necessary. Rotate crankshaft clockwise 2 complete revolutions to re-
move slack from belt. Recheck timing mark alignment.
REMOVAL & INSTALLATION Readjust as necessary. Tighten timing belt tensioner bolts.
TIMING BELT Install timing belt cover. Install crankshaft pulley. Install A/C
compressor bracket with power steering pump. Install A/C
Removal: compressor and recharge system (if equipped).
Disconnect negative battery cable. Remove exhaust side To complete installation, reverse removal procedure. Ad-
spark plugs. Rotate crankshaft clockwise so No. 1 piston just drive belts to proper tension. See page A-60 for belt
is at TDC of compression stroke. tension ranges.
Remove fan shroud. Loosen fan clutch-to-pulley bolts. Re-
move accessory drive belt. Remove fan clutch and pulley. TORQUE SPECIFICATIONS
Remove crankshaft center bolt and remove crankshaft pul- Application Ft. Lbs. (N.m)
ley. A/C Compressor Bracket Mount Bolts
Using recycling equipment, recover refrigerant from air con- M8 Bolt ......................................................................... 18 (25)
ditioning system (if equipped). Disconnect A/C clutch con- M10 Bolt ....................................................................... 35 (48)
nector from A/C clutch. Remove A/C compressor from mount- A/C Compressor-To-Bracket Bolt ........................ 16-20 (21-28)
ing bracket. Remove A/C compressor mounting bracket Camshaft Sprocket Bolt .................................... 52-70 (70-95)
with hoses attached, and position out of way. Cooling Fan-To-Pulley Bolts ............................. 13-16 (17-23)
Remove timing belt outer cover retaining bolt. Release 7 Crankshaft Damper Bolt ............................ 92-122 (125-165)
cover interlocking tabs. Remove timing belt cover. Ensure Oil Pump Sprocket Bolt ..................................... 29-41 (40-55)
crankshaft and camshaft timing marks are aligned. See Timing Belt Tensioner Adjusting Bolt ................ 35-45 (26-33)
Fig. 1. Timing Belt Tensioner Pivot Bolt ....................... 29-41 (40-55)
Holding timing belt tensioner with Camshaft Belt Tension INCH Lbs. (N.m)
Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt Engine Timing Belt Cover Bolt .......................... 71-106 (8-12)
and slowly release tension. See Fig. 2. Pry tensioner away Spark Plug ........................................................ 80-115 (9-13)
from timing belt and tighten bolt to hold tensioner in place.

Fig. 1: Aligning Camshaft & Oil Pump Timing Marks Fig. 2: Exploded View Of Timing Belt & Components
MAZDA 393
1.8L V6
1.8L V6 Removal:
MX-3 Disconnect negative battery cable. Drain coolant. Raise and
1992-93 ............... 1 3.8 Hours ................... T214 support vehicle and remove right front wheel. Remove lower
MX-3 (Canadian) engine covers. Remove accessory drive belts. Remove water
1995 .................... 1 3.8 Hours ................... T214 pump pulley. Remove drive belt idler pulley bracket. See
Fig. 1. Disconnect necessary clamps and power steering
1
- With Air Cond. add .2 hours. pressure switch connector to remove power steering res-
With Pwr. Strng. add .2 hours. ervoir. Remove retaining bolts and power steering reser-
voir with hoses attached, and secure reservoir aside.
MANUFACTURERS SUGGESTED Remove retaining nut and power steering pump pulley. Re-
move retaining bolts and power steering pump with hoses
SCHEDULED MAINTENANCE attached, and secure pump aside. Remove crankshaft pul-
For 1992 model year, the manufacturer recommends the belt ley retaining bolt. Using puller, remove crankshaft pulley.
be replaced every 60,000 miles. For 1993-95 model years,
CAUTION: DO NOT damage crank angle sensor rotor on rear
the manufacturer recommends the belt be replaced at 60,000 of crankshaft pulley during crankshaft pulley removal.
mile intervals for vehicles sold outside of California. For ve-
hicles sold in California, inspect timing belt at 60,000 and
90,000 miles, and replace timing belt at 105,000 miles.

394 MAZDA
1.8L V6 (Cont.)
SPECIFICATIONS. Ensure all timing marks align. See Fig.

2. Install timing belt on sprockets. Ensure all slack is on
tensioner side. Ensure the timing belt fully engages all
sprockets.
CAUTION: If reusing timing belt, ensure timing belt is installed

Push outward at bottom of timing belt tensioner and install
lower retaining bolt in timing belt tensioner. Tighten both
timing belt tensioner retaining bolts to specification. Re-
move pin from timing belt tensioner, allowing tension to be
applied on timing belt. Rotate crankshaft 2 full revolutions
clockwise from TDC to TDC. Ensure timing marks on cam-
shaft sprockets and crankshaft sprockets are properly
Fig. 2: Aligning Camshaft & Crankshaft Timing Marks aligned. See Fig. 2. If timing marks are not aligned, repeat
entire timing belt installation procedure.
Unplug crank angle sensor and unclip wires from oil dip- Check timing belt deflection by applying 22 lbs (10 kg) of
stick tube. Remove oil dipstick and oil dipstick tube. Re- force at designated area on timing belt. Check timing belt
move crank angle sensor harness bracket. Remove en- deflection. See Fig. 6. Timing belt deflection should be .24-
gine wiring harness, located along top of timing belt cover. .31" (6.0-8.0 mm). If timing belt deflection is not within speci-
Support engine using hoist or floor jack. Remove right front fication, replace timing belt tensioner.
wheel. Remove through-bolt, retaining nuts and right (tim- Install timing belt covers using NEW gaskets. Tighten re-
ing belt side) engine mount. Remove retaining bolts, tim- taining bolts to specification. See TORQUE SPECIFICA-
ing belt covers and gaskets. See Fig. 1. TIONS. Install dipstick tube with new O ring. To install
Install crankshaft pulley retaining bolt in crankshaft. Rotate remaining components, reverse removal procedure.
crankshaft so No. 1 cylinder is at TDC on compression Tighten fasteners to specification. Adjust drive belts to proper
stroke. Ensure grove on crankshaft sprocket aligns with tension. See page A-60 for belt tension ranges.
indicator on oil pump body. See Fig. 2. TORQUE SPECIFICATIONS
If reusing timing belt, place reference mark on timing belt
to indicate direction of rotation. Hold timing belt tensioner Application Ft. Lbs. (N.m)
and remove lower retaining bolt first, then remove upper A/C Compressor Bolt ....................................... 27-38 (37-52)
bolt. Remove timing belt tensioner. Remove No. 2 timing Crankshaft Pulley Bolt .............................. 116-123 (157-166)
belt pulley and timing belt. Remove No. 1 idler pulley and No. 1 Idler Pulley Bolt ........................................ 28-38 (38-52)
tensioner pulley (if necessary). No. 2 Idler Pulley Bolt ........................................ 28-38 (38-52)
Inspection: Power Steering Pump Bracket Bolt ....................................... 1
Inspect timing belt for damaged teeth, cracking and oil con- Power Steering Pump Pulley Nut ...................... 49-69 (66-93)
tamination. Ensure idler pulleys No. 1 and No. 2 and Right (Timing Belt Side) Engine Mount
tensioner pulley rotate freely. Replace damaged compo- Nut ................................................................ 55-75 (74-102)
nents. Inspect timing belt tensioner for signs of oil leak- Through-Bolt .................................................... 50-68 (67-92)
age. Replace timing belt tensioner if oil leakage exists. Tensioner Pulley Bolt ........................................ 28-32 (38-44)
Measure timing belt tensioner rod protrusion from end of Timing Belt Tensioner Bolt ............................... 14-19 (19-26)
rod to edge of the housing. See Fig. 3. Replace timing belt Water Pump Bolt .............................................. 14-19 (19-26)
tensioner if distance is not .550-.630" (13.97-16.00 mm). INCH Lbs. (N.m)
Installation: Crank Angle Sensor Bracket Bolt ........................ 69-95 (8-11)
Place timing belt tensioner in a press using a flat washer Cylinder Block Valley Cover Bolt ......................... 69-95 (8-11)
to prevent damage to timing belt tensioner. See Fig. 4. Com- Timing Belt Cover Bolt ........................................ 69-95 (8-11)
press tensioner rod until holes in rod and housing are Valve Cover Bolt 2 .................................................. 43-78 (5-9)
aligned and install .06" (1.5 mm) diameter pin through holes Water Pump Pulley Bolt ...................................... 69-95 (8-11)
in housing and rod to hold rod in retracted position. See 1
- Tighten 2 upper bolts on front of bracket to 23-34 ft. lbs.
Fig. 4. (31-46 N.m.). Tighten lower bolt on front of bracket to 14-19
Install timing belt tensioner on cylinder block with the up- ft. lbs. (19-26 N.m). Tighten rear bracket-to-cylinder
per retaining bolt only, do not fully tighten upper bolt. Install block bolt to 24-33 ft. lbs. (32-45 N.m).
No. 2 idler pulley and tighten to specification. See TORQUE 2
- Tighten bolts to specification in sequence. See Fig. 5.
MAZDA 395
1.8L V6 (Cont.)
Fig. 5: Valve Cover Bolt Tightening Sequence

396 MAZDA
2.3L V6
2.3L V6 Removal:
Millenia Disconnect negative battery cable. Drain coolant. Raise
1995-00 ................ 1 4.5 Hours ................... T267 and support vehicle. Remove right front wheel. Remove
1
- With Air Cond. add .2 hours. lower engine covers. Remove accessory drive belts.
Remove crankshaft pulley retaining bolt. Using puller, re-
With Pwr. Strng. add .2 hours. move crankshaft pulley. Remove power steering pump pul-
ley. Remove water pump pulley. Remove generator drive
MANUFACTURERS SUGGESTED belt auto tensioner. See Fig. 1. Remove camshaft position
sensor from right hand camshaft.
SCHEDULED MAINTENANCE Remove engine oil dipstick and pipe. Remove vacuum pipe.
For 1996-95 vehicles, the manufacturer suggests the belt be Remove upper radiator hose. Support engine using hoist.
replaced at 60,000 mile intervals for vehicles sold outside of Remove No. 3 engine mount and brackets from timing belt
California. For vehicles sold in California, inspect timing belt end of engine. Remove retaining bolts, timing belt covers
at 60,000 and 90,000 miles, and replace timing belt at 105,000 and gaskets. Remove power steering belt auto tensioner.
miles. See Fig. 1.
For 1998-97 vehicles, the manufacturer suggests the belt be
replaced at 60,000 mile intervals for vehicles sold outside of CAUTION: DO NOT damage crank angle sensor rotor on rear
California and Massachusetts. For vehicles sold in California of crankshaft pulley during crankshaft pulley removal.
and Massachusetts, inspect timing belt at 60,000 and 90,000 Install crankshaft pulley retaining bolt in crankshaft. Rotate
miles, and replace timing belt at 105,000 miles. crankshaft so No. 1 cylinder is at TDC on compression
For 2000-99 vehicles, the replacement is 60,000 miles except stroke. The crankshaft and camshaft timing marks should
for vehicles registered in California, Connecticut, Delaware, align. See Fig. 2.
Maine, Maryland, Massachusetts, New Hampshire, New Jer- If reusing timing belt, place reference mark on timing belt
sey, New York, Pennsylvania, Rhode Island, Vermont, and to indicate direction of rotation. Hold timing belt tensioner
Washington D.C. For these states, inspect timing belt at 60,000 and remove lower retaining bolt first, then remove upper
and 90,000 miles, and replace timing belt at 105,000 miles. bolt. Remove timing belt tensioner. Remove timing belt.
For 2001 vehicles, the replacement is 60,000 miles.

MAZDA 397
2.3L V6 (Cont.)
Installation
Place timing belt auto tensioner in a press using a flat
washer to prevent damage to timing belt tensioner. See
Fig. 4. Using no more than 2200 lbs., compress tensioner
rod until holes in rod and housing are aligned. Install .063"
(1.6 mm) diameter pin through holes in housing and rod to
hold rod in retracted position. See Fig. 4.
Install timing belt on sprockets and around idler pulleys.
See Fig. 5. Ensure all slack is on tensioner pulley side.
Install timing belt auto tensioner. Tighten timing belt auto
tensioner bolts to specification. See TORQUE SPECIFI-
CATIONS. Ensure all timing marks align. See Fig. 2.


Inspection:
tamination. Inspect timing belt auto tensioner for signs of
oil leakage. Replace timing belt auto tensioner if oil leak- Fig. 4: Retracting Timing Belt Tensioner Rod
age exists. Measure timing belt auto tensioner rod protru-
sion from end of rod to edge of the housing. See Fig. 3.
Replace timing belt auto tensioner if distance is not .563-
.594" (14.3-15.1 mm).
NOTE: The following information on repairing the front engine

oil leaks is from Mazda technical service bulletin MT0596-07;
May, 1996.
Oil leaking from the front of the engine on 1995-96 models
may be caused by the No. 3 engine mount bracket stud.
See Fig. 6.
To repair the oil leak, remove No. 3 engine mount bracket.
Remove mounting stud from engine. Clean all threads thor-
oughly. Apply Loctite PST Pipe Sealant with Teflon (No. 565)
to stud threads. Install stud on engine block.

398 MAZDA
2.3L V6 (Cont.)
Camshaft Position Sensor Bolt ........................... 14-18 (19-25)
Crankshaft Pulley Center Bolt ................... 116-123 (157-166)
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)
Courtesy of Mazda Motors Corp. Timing Belt Auto Tensioner Bolt ........................ 14-19 (19-26)
Fig. 6: Locating Engine Mount Bracket Stud Water Pump Bolt .............................................. 14-19 (19-26)
Wheel Lug Nut ................................................. 66-94 (89-127)
Remove pin from timing belt tensioner, allowing tension to INCH Lbs. (N.m)
be applied on timing belt. Rotate crankshaft 2 full revolu- Timing Belt Cover Bolt ........................................ 69-95 (8-11)
tions clockwise from TDC to TDC. Ensure timing marks on Water Pump Pulley Bolt ...................................... 69-95 (8-11)
camshaft sprockets and crankshaft sprockets are properly
aligned. See Fig. 2. If timing marks are not aligned, remove
and repeat entire timing belt installation procedure.
Install timing belt covers using NEW gaskets. Tighten re-
taining bolts to specification. See TORQUE SPECIFICA-
TIONS. Install dipstick tube with new O ring.
dure. Tighten fasteners to specification. Check ignition tim-
ing. Adjust drive belts to proper tension. See page A-60 for
MAZDA 399
2.5L V6
TIMING BELT APPLICATION Remove oil dipstick and oil dipstick tube. Remove crank-
shaft position sensor from front of engine. See Fig. 2. Sup-
Application Labor Time Belt Part No. port engine using hoist or floor jack. Remove right (timing
2.5L V6 belt side) engine mount. Remove retaining bolts, timing
Millenia belt covers, and gaskets. See Fig. 2.
1995-01 ............... 1 3.4 Hours ................... T214 Install crankshaft pulley retaining bolt in crankshaft. Rotate
MX-6 crankshaft so No. 1 cylinder is at TDC on compression
stroke. Ensure grove on crankshaft sprocket aligns with
1993-97 ............... 1 4.0 Hours ................... T214 indicator on oil pump body. See Fig. 1. Ensure camshaft
626 sprocket timing marks are aligned with marks on rear cover.
1993-01 ............... 4.0 Hours ................... T214 If reusing timing belt, place reference mark on timing belt to
1
1
- With Air Cond. add .2 hours. indicate direction of rotation. Loosen the 2 timing belt
tensioner bolts. Hold timing belt tensioner and remove
With Pwr. Strng. add .2 hours. lower retaining bolt. Remove No. 1 idler pulley and timing
belt.
MANUFACTURERS SUGGESTED Inspection:
SCHEDULED MAINTENANCE Inspect timing belt for damaged teeth, cracking and oil con-
tamination. Ensure idler pulleys No. 1 and No. 2, and
For 1993 model year, the manufacturer recommends the belt tensioner pulley rotate freely. Replace damaged compo-
be replaced at 60,000 miles. nents.
For 1994-96 models years. the manufacturer recommends Inspect timing belt tensioner for signs of oil leakage. Re-
the belt be replaced at 60,000 mile intervals for vehicles sold place timing belt tensioner if oil leakage exists. Measure
outside of California. For vehicles sold in California, inspect timing belt tensioner rod protrusion from end of rod to edge
timing belt at 60,000 and 90,000 miles, and replace timing of housing. See Fig. 3. There are 2 types of tensioner used
belt at 105,000 miles. on this engine. See Fig. 4. Replace timing belt tensioner if
For 1997-98 model years, the manufacturer suggests the belt rod protrusion distance is not as specified. See TIMING
be replaced at 60,000 mile intervals for vehicles sold outside BELT TENSIONER ROD PROTRUSION table.
of California and Massachusettes. For vehicles sold in Cali- TIMING BELT TENSIONER ROD PROTRUSION
fornia and Massachusetts, inspect timing belt at 60,000 and
90,000 miles, and replace timing belt at 105,000 miles. Application In. (mm)
For 1999 626 models and 1999-00 Millenia models, the manu- Type A (2001) ................................... 0.511-0.551 (13.0-14.0)
facturer recommends the belt be replaced at 60,000 mile in- Type A (1993-00) .............................. 0.473-0.511 (12.0-13.0)
tervals except for vehicles registered in California, Connecti- Type B ............................................ 0.563-0.594 (14.3-15.1)
cut, Delaware, Maine, Maryland, Massachusetts, New Hamp- Installation:
shire, New Jersey, New York, Pennsylvania, Rhode Island, Place timing belt tensioner in a press using a flat washer to
Vermont, Virginia and Washington D.C. For these states, in- prevent damage to timing belt tensioner. See Fig. 5. Using
spect timing belt at 60,000 and 90,000 miles, and replace no more than 2200 lbs. pressure, SLOWLY compress
timing belt at 105,000 miles.
For 2000 626 models, the manufacturer recommends the belt
be replaced at 60,000 mile intervals except for vehicles regis-
tered in California, Maine, Massachusettes and Vermont. For
these states, inspect timing belt at 60,000 and 90,000 miles,
and replace timing belt at 105,000 miles.
For 2001 model year, replace timing belt at 105,000 miles,
UNLESS the vehicle is operated in temperatures that are un-
der 0F (-18C). In this case, replace timing belt at 60,000
miles.
TIMING BELT
Removal:
Disconnect negative battery cable. On Millenia, raise and
support vehicle. Remove right front wheel. Remove lower
engine covers.
On all models, remove accessory drive belts. Remove wa-
ter pump pulley. Remove drive belt idler pulley bracket. Re-
move retaining bolts and power steering pump with hoses
attached, and secure pump out of way.
Holding crankshaft stationary, remove the crankshaft pul-
ley retaining bolt. Using gear puller, remove crankshaft
pulley.
CAUTION: DO NOT damage crankshaft position sensor rotor

on rear of crankshaft pulley during crankshaft pulley removal.
400 MAZDA
2.5L V6 (Cont.)

Fig. 4: Identifying Timing Belt Tensioner Types
MAZDA 401
2.5L V6 (Cont.)
Rotate crankshaft 2 full revolutions clockwise (as viewed
from timing belt end of engine) from TDC to TDC. Ensure
timing marks on camshaft sprockets and crankshaft sprock-
ets are properly aligned. See Fig. 1. If timing marks are not
aligned, remove and repeat entire timing belt installation
procedure.
Install right (timing belt side) engine mount. Install timing
belt covers using NEW gaskets. Tighten retaining bolts to
Install dipstick tube with new O ring. To install remaining
components, reverse removal procedure. Tighten fasten-
ers to specification. Adjust drive belts to proper tension.
Check crankshaft position sensor air gap. Gap between
center of sensor and outer edge of rotor tooth should be
0.020-0.059 (0.5-1.5 mm). If not, check for damaged com-
ponents. Air gap is not adjustable.
Fig. 6: Installing Timing Belt TORQUE SPECIFICATIONS
tensioner rod until holes in rod and housing are aligned. Application Ft. Lbs. (N.m)
Install 0.055" (1.4 mm) diameter pin through holes in hous- Crankshaft Pulley Bolt .............................. 116-123 (157-166)
ing and rod to hold rod in retracted position. No. 1 & No. 2 Idler Pulley Bolt ........................... 28-38 (38-52)
Install timing belt tensioner on cylinder block with the up- Power Steering Pump Bracket Bolt ....................................... 1
per retaining bolt only, do not fully tighten upper bolt. Power Steering Pump Pulley Nut ...................... 37-43 (50-58)
Ensure crankshaft and camshaft timing marks align. See Right (Timing Belt Side) Engine Mount
Fig. 1. Install timing belt on sprockets in order. See Fig. 6. Nut (Millenia & 626) ....................................... 55-75 (74-102)
Ensure tension exists on belt between crankshaft pulley Through-Bolt
and camshaft pulleys. See Fig. 6. While applying pressure 626 ............................................................ 63-86 (86-116)
on timing belt, install No. 1 idler pulley. Tensioner Pulley Bolt ........................................ 28-32 (38-44)
CAUTION: If reusing timing belt, ensure timing belt is installed Water Pump Bolt .............................................. 14-18 (19-25)
in original direction of rotation. Wheel Lug Nut
Push outward at bottom of timing belt tensioner and install Millenia ........................................................... 66-94 (89-127)
lower retaining bolt in timing belt tensioner. Tighten both INCH Lbs. (N.m)
timing belt tensioner retaining bolts to specification. See Crankshaft Position Sensor Bracket Bolt ........... 69-95 (8-11)
TORQUE SPECIFICATIONS. Remove pin from timing belt Timing Belt Cover Bolt ........................................ 69-95 (8-11)
tensioner, allowing tension to be applied on timing belt. 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).
402 MAZDA
*3.0L V6 DOHC
TIMING BELT APPLICATION age sensor rotor. Remove coolant by-pass and upper ra-
diator hoses.
Application 1
Labor Time Belt Part No. Remove distributor. Remove timing belt covers and gas-
3.0L V6 DOHC ket. See Fig. 1. Turn crankshaft to align pulley match marks.
929 See Fig. 2. Remove timing belt upper idler pulley. If reusing
1990-95 ................. 3.9 Hours ..................... T183 timing belt, mark rotation direction. Remove timing belt and
Serenia (Canadian) timing belt automatic tensioner.
Inspection:
1992-95 ................. 3.9 Hours ..................... T183 Check automatic tensioner rod projection. Rod should
1
- With Air Cond. add .2 hours. project .47-.55" (12-14 mm) from tensioner body. Replace
With Pwr. Strng. add .2 hours. tensioner if projection is not within specification.
Installation:
MANUFACTURERS SUGGESTED Using flat washer to prevent damage to tensioner body
plug, place automatic tensioner in vise or arbor press. Com-
SCHEDULED MAINTENANCE press tensioner rod until a pin can be inserted into tensioner
The manufacturer recommends the belt be replaced every rod through hole in tensioner body. Install tensioner with
60,000 miles for Federal vehicles, and 105,000 miles on Cali- pin installed.
fornia vehicles.
CAUTION: DO NOT exceed 2200 lbs (1000 kg) pressure on tensioner
* NOTE: This application is an interference engine. rod.
See page A-59 for interference engine cautions. Ensure match marks on pulleys align with marks on heads.
See Fig. 2. With upper idler pulley removed, install timing
REMOVAL & INSTALLATION belt on pulleys. Keep slack toward automatic tensioner side.
Install upper idler pulley. Rotate crankshaft twice in direc-
TIMING BELT tion of rotation, and ensure match marks still align. Re-
Removal: move automatic tensioner pin, and repeat steps to confirm
Disconnect negative battery cable. Drain engine coolant. match marks are still in alignment.
Remove spark plug cables and spark plugs. Remove air Check timing belt deflection between right cam pulley and
intake hose. Remove cooling fan and fan shroud. lower idler. Deflection should be .20-.28" (5-7 mm) at 22
Remove drive belts. Remove A/C and P/S idler pulleys (if lbs. (10 kg). If deflection is not correct, repeat installation
equipped). Remove crankshaft pulley, baffle plate (if procedure. If deflection is still not correct, check for faulty
equipped), and sensor rotor (if equipped). DO NOT dam- automatic tensioner or stretched timing belt.

MAZDA 403

Tighten fasteners to specification. See TORQUE SPECIFI-
CATIONS. Adjust the drive belts to proper tension. See page
A/C Compressor-To-Bracket Bolt ..................... 21-29 (29-39)
Alternator-To-Bracket Bolt ................................. 27-38 (37-52)
Camshaft Pulley Bolt
Left Head ........................................................ 14-18 (19-25)
Right Head ..................................................... 52-59 (71-80)
Power Steering
Idler Bolt ......................................................... 14-18 (19-25)
Pulley Nut ....................................................... 29-43 (39-58)
Pump Mount Bolt .............................................. 23-34 (31-46)
Radiator Bolt ..................................................... 14-18 (19-25)
Courtesy of Mazda Motors Corp. Timing Belt Lower Idler Bolt ............................. 32-45 (43-61)
Fig. 2: Aligning Timing Belt Match Marks 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 1 ...................................... 71-97 (8-11)
Valve Cover Bolt .............................................. 30-39 (3.4-4.4)
1
- Exc. 3 top bolts on right side cover: 14-18 ft. Lbs. (19-25 N.m).
404 MAZDA
*3.0L V6 SOHC
TIMING BELT APPLICATION During the 60,000 mile inspection or timing belt replace-
ment on MPV models, inspect tensioner pulley pivot bush-
Belt ing for a bronze color (wear) on the Teflon coating. If the
Labor Component Part bushing is worn, the tensioner pulley and spacer must be
Application Time 1 Kit No. No. replaced with the timing belt. This is to prevent a torn or
3.0L V6 SOHC jumped timing belt.
929 Installation:
1988-91 .......... 3.1 Hrs. ...... TCK146 .......... T146 Install tensioner pulley and lower idler pulley (if removed).
Install retaining bolts, and tighten to specification. See
MPV TORQUE SPECIFICATIONS. Ensure all pulleys are clean
1989-98 .......... 3.0 Hrs. ...... TCK146 .......... T146 and rotate smoothly.
1
CAUTION: DO NOT apply more than 2200 lbs. (1000 kg) pressure
With Pwr. Strng. add .2 hours. on timing belt tensioner rod.

kits.
For 1988-93 models years, the manufacturer recommends
the belt be replaced at 60,000 miles.
For 1994-96 models 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 be replaced at 60,000 mile intervals for vehicles sold
outside of California and Massachusetts. For vehicles sold in
California and Massachusetts, inspect timing belt at 60,000
and 90,000 miles, and replace timing belt at 105,000 miles.


Removal:
Remove spark plug wires and spark plugs. Remove air
intake hose. Remove cooling fan and fan shroud. Remove
drive belts. Remove A/C compressor drive belt idler pulley. Courtesy of Mazda Motors Corp.
Remove retaining bolt and crankshaft pulley. Remove cool- Fig. 1: Exploded View Of Timing Belt & Components
ant bypass and upper radiator hoses. Remove timing belt
covers and gaskets. See Fig. 1. Rotate crankshaft and align
all timing marks. See Fig. 2.
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:
rod to edge of timing belt tensioner housing. Replace tim-
ing belt tensioner if distance is not .47-.55" (12.0-14.0 mm).
tamination. Ensure idler pulleys and tensioner pulley ro-
tate freely. Inspect timing belt tensioner for signs of oil leak-
age. Replace worn components.
NOTE: The following information on tensioner pulley inspection
is from Mazda technical service bulletin 002/00R; March 9,2000.
MAZDA 405
*3.0L V6 SOHC (Cont.)

Place timing belt tensioner in press with flat washer to
prevent damage to timing belt tensioner plug. Apply pres-
sure on rod of timing belt tensioner until rod is retracted
and holes in rod and housing are aligned. See Fig. 3. In-
stall pin through holes in housing and rod to hold rod in
retracted position. Release press and remove timing belt
tensioner.
Install timing belt tensioner on cylinder block with pin in-
stalled. Tighten retaining bolts to specification. See
TORQUE SPECIFICATIONS. Rotate camshafts and crank-
shaft to ensure all timing marks are aligned. See Fig. 2.
With upper idler pulley removed, install timing belt on crank-
shaft sprocket, lower idler pulley, left camshaft sprocket, Fig. 3: Retracting Timing Belt Tensioner Rod
right camshaft sprocket and tensioner pulley in sequence.
in original direction of rotation. Application Ft. Lbs. (N.m)
Install upper idler pulley. Tighten retaining bolt to specifica- A/C Compressor Bracket-To-Cylinder
tion. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 Block Bolt ........................................................ 27-38 (37-52)
full revolutions clockwise from TDC to TDC. Ensure all tim- Camshaft Sprocket Bolt .................................... 52-59 (71-80)
ing marks are aligned. See Fig. 2. If timing marks are not Crankshaft Pulley Bolt .............................. 116-123 (157-167)
aligned, remove timing belt and reinstall. Lower Idler Pulley Bolt ...................................... 27-38 (37-52)
Remove pin from timing belt tensioner, allowing pressure Power Steering Pump Bolt ................................ 23-34 (31-46)
to be applied to timing belt. Rotate crankshaft 2 full revolu- Power Steering Pump Pulley Nut ...................... 29-43 (39-58)
tions clockwise from TDC to TDC. Ensure all timing marks Tensioner Pulley Bolt ........................................ 17-22 (23-30)
are aligned. Check timing belt deflection by applying 22 lbs. Timing Belt Cover Bolt
(10 kg) of force at midpoint between right camshaft sprocket 6 mm Bolt ........................................................................... 1
and tensioner pulley. Timing belt deflection should be .20-.28" 10 mm Bolt ..................................................... 27-38 (37-52)
(5.0-7.0 mm). Timing Belt Tensioner Bolt ............................... 14-19 (19-26)
If timing belt deflection is not within specification, repeat Upper Idler Pulley Bolt ...................................... 27-38 (37-52)
installation procedure. To install remaining components, Water Pump Bolt/Nut ........................................ 14-19 (19-26)
reverse removal procedure. Tighten fasteners to specifica- INCH Lbs. (N.m)
tion. See TORQUE SPECIFICATIONS. Fill and bleed cool- Valve Cover Bolt .................................................... 30-39 (3-4)
ing system. Adjust drive belts to proper tension. See page
1
- Tighten to 69-95 INCH lbs. (8-11 N.m).
406 MITSUBISHI
Belt
1.5L 4-Cyl.
Mirage
1985-86 .......... 2.8 Hrs. ................................ T073
1987-90 .......... 2.8 Hrs. ...... TCK128 .......... T128
1991-96 .......... 2.4 Hrs. ...... TCK191 .......... T191
1997-01 .......... 2.4 Hrs. ................................ T289
Precis
1987-89 .......... 2.2 Hrs. ................................ T073
1990-93 .......... 2.2 Hrs. ...... TCK128 .......... T128
1

kits. Fig. 1: Aligning Timing Marks (1985-96)
be replaced at 60,000 miles.
cut, and Massachusetts. In California, Connecticut, and Mas-
sachusetts, timing belt replacement is recommended, but not
required, at 60,000 miles. In these states, replace timing belt
at 100,000 miles, unless previously changed.
For 2001 models, the manufacturer recommends the belt be
replaced every 60,000 miles except in California, Massachu-
setts and Vermont. In California, Massachusetts and Vermont,
timing belt replacement is recommended, but not required, at
60,000 miles. In these states, replace timing belt at 100,000 Fig. 2: Installing Timing Belt Tensioner (1985-96)
miles, unless previously changed. Remove timing belt covers and gaskets, noting bolt lengths
and locations as they are removed. Rotate engine clock-
*NOTE: This application is an interference engine. wise to align timing mark on camshaft sprocket with mark
See page A-59 for interference engine cautions. on cylinder head. Ensure all timing marks are aligned. See
Fig. 1.
REMOVAL & INSTALLATION Loosen timing belt tensioner bolts. Move tensioner inward
toward water pump. Temporarily tighten bolt in slot side of
TIMING BELT tensioner. Remove timing belt from camshaft sprocket. Re-
Removal (1985-96): move crankshaft pulley, and timing belt.
Disconnect negative battery cable. Remove air cleaner Inspection:
assembly, then disconnect accelerator cable and oxygen Inspect belt teeth for cracks, damage, or oil contamination.
lead sensor. Mark position of spark plug wires for installa- Inspect all sprockets for damage. Examine belt tensioner
tion, then remove wires from spark plugs. Support engine for grease leakage and roughness when pulley is rotated.
using a suitable engine support bar. Remove left engine Replace components if defective.
mount bracket. Remove all accessory drive belts and pul- Installation (1985-96):
leys. Ensure crankshaft and camshaft timing marks are aligned.
See Fig. 1. Install timing belt onto crankshaft and camshaft
CAUTION: DO NOT rotate engine counterclockwise (as viewed sprockets. Ensure tension side is tight and all timing marks
from timing belt end of engine). If reusing timing belt, place reference are aligned when camshaft sprocket is rotated. Install crank-
MITSUBISHI 407

Fig. 4: Checking Timing Belt Tension (1985-96)
shaft pulley. Loosen tensioner mounting bolts. See Fig. 2.

Ensure timing belt is not out of position and has not jumped
a sprocket tooth. Tighten tensioner bolts.
CAUTION: If pivot bolt is tightened before side bolt, belt tensioner

may rotate, causing belt to be over tightened.
Rotate crankshaft one full revolution clockwise, until crank- Fig. 6: Aligning Timing Marks
shaft sprocket timing mark aligns with TDC position. Re-
check belt tension. To check belt tension, hold belt tensioner engine mount bracket. On all vehicles, remove engine mount
and timing belt together. Apply slight thumb pressure at bracket-to-engine bolt and nut. Remove engine mount
center point of belt tensioner. See Fig. 3. A tension gauge bracket-to-body through bolt. Remove engine mount
can also be used to check belt tension. See Fig. 4. bracket.
To complete installation, reverse removal procedure. Ad- Remove water pump pulley. Remove power steering pump
just drive belts to proper tension. See page A-60 for belt and bracket with hoses attached and secure out of way.
tension ranges. Remove oil dipstick tube. Remove timing belt upper and
Removal (1997-01): lower covers.
Disconnect negative battery cable. Remove all accessory drive Rotate crankshaft clockwise to align timing mark on cam-
belts. Rotate crankshaft clockwise so that No. 1 cylinder is at shaft sprocket with mark on cylinder head. Ensure crank-
TDC of compression stroke. Holding crankshaft stationary, shaft sprocket timing marks are aligned. See Fig. 6.
remove crankshaft pulley. Loosen timing belt tensioner adjusting bolt. Move tensioner
toward water pump to relieve tension on timing belt. Tem-
CAUTION: DO NOT rotate engine counterclockwise (as viewed porarily tighten tensioner adjusting bolt. Remove timing
from timing belt end of engine). If reusing timing belt, place reference belt.
mark on timing belt to indicate direction of rotation before removing. Inspection:
Place jack under engine. Support engine so there is no Inspect belt teeth for cracks, damage, or oil contamination.
weight on engine mount bracket (timing belt end of en- Inspect all sprockets for damage. Examine belt tensioner
gine). On vehicles equipped with A/C, move A/C relay box for grease leakage and roughness when pulley is rotated.
and drier assembly (hoses attached) out of way to remove Replace components if defective.
408 MITSUBISHI
See Fig. 6. If timing belt tensioner and spring were removed,
install with tensioner spring in correct position. See Fig. 7.
Install timing belt onto crankshaft sprocket, camshaft
sprocket, and tensioner pulley. Ensure tension side is tight
and all timing marks are aligned. See Fig. 6.
After installing timing belt, ensure timing belt is tensioned
between crankshaft and camshaft sprockets. Check that
all timing marks are still aligned.
Loosen tensioner adjusting bolt. Rotate crankshaft one
full revolution clockwise, until crankshaft sprocket timing
mark aligns with TDC position. Tighten tensioner adjust-
ing bolt.
Ensure timing belt teeth are fully seated in camshaft
sprocket. Install timing belt covers. Install crankshaft pul-
ley. Tighten bolt to specification. See TORQUE SPECIFICA-
TIONS table.
tension ranges.
TORQUE SPECIFICATIONS (1985-96 MIRAGE)
1985-91 .......................................................... 47-54 (65-75)
1992-96 ........................................................ 52-74 (70-100) Courtesy of Mitsubishi Motor Sales of America
1991-96 .......................................................... 10-11 (14-15)
Crankshaft Sprocket Bolt TORQUE SPECIFICATIONS (1997-01)
1985 ............................................................... 37-43 (50-58)
1986-96 ...................................................... 52-74 (70-100)) Application Ft. Lbs. (N.m)
Front Cover Bolt Camshaft Sprocket Bolt ................................................ 64 (88)
1985-88 ............................................................ 9-10 (12-14) Crankshaft Pulley Center Bolt ................................... 1 93 (125)
Rocker Arm Adjuster Lock Nut Engine Mount Bracket-To-Engine ................................... 25 (35)
1989-96 .......................................................... 10-13 (14-18) Engine Mount
Timing Belt Tensioner Bolt Bracket-To-Engine Bracket Bolt/Nut ............................. 42 (57)
1985-96 .......................................................... 14-20 (19-27) Bracket-To-Body Through Bolt .................................... 2 72 (98)
INCH Lbs. (N.m) Power Steering Pump
Crankshaft Pulley Bolt ................................... 108-120 (12-14) Bracket-To-Engine Bolt ................................................ 16 (22)
Front Cover Bolt ................................................ 84-132 (9-15) Timing Belt Tensioner Adjusting Bolt .......................... 17 (24)
Fuel Rail Bolt INCH Lbs. (N.m)
1992-96 .......................................................... 84-108 (9-12) Timing Belt Cover Bolt ................................... 89-106 (10-12)
Rocker Cover Bolt ........................................... 13-17 (1.5-1.9) Water Pump Pulley Bolt ................................................ 80 (9)
Timing Belt Cover Bolt ........................................ 84-108 (9-12) 1
Apply engine oil to bolt thread before installation.
Water Pump Pulley Bolt 2
Final tighten with full weight of engine on bolt.
1988-85 ..................................................... 108-120 (12-14)
1996-89 .............................................................. 72-84 (8-9)
TORQUE SPECIFICATIONS (1991-94 PRECIS)

Camshaft Thrust Case Bolt .............................. 14-20 (19-27)
Crankshaft Sprocket Bolt ................................ 52-74 (70-100)
Front Cover Bolt ................................................ 10-11 (14-15)
INCH Lbs. (N.m)
Camshaft Rear Cover Bolts ................................. 70-86 (7-10)
Rocker Cover Bolt ........................................... 13-18 (1.5-2.0)
MITSUBISHI 409

TIMING BELT APPLICATION Loosen tensioner adjusting bolt and nut about 1 turn so
that timing belt tensioner contacts timing belt. Turn crank-
Application Labor Time Belt Part No. shaft clockwise by 2 teeth of the camshaft sprocket. See
1.6L 4-Cyl. SOHC Fig. 5. This is to give adequate tension to the timing belt.
Mirage DO NOT turn crankshaft counterclockwise.
1985-88 .............. 1 2.8 Hours ................... T093 Push timing belt tensioner to the right (as viewed from front
of engine) so that belt engages completely with camshaft
1
- With Air Cond. add .2 hours. sprocket without any slack. Tighten tensioner bolt first, and
With Pwr. Strng. add .3 hours. then the tensioner nut. See TORQUE SPECIFICATIONS.
Turn crankshaft one full revolution.
MANUFACTURERS SUGGESTED Ensure camshaft and crankshaft timing marks are still
aligned. To check timing belt final tension, hold timing belt
SCHEDULED MAINTENANCE between thumb and forefinger midway between camshaft
The manufacturer recommends the belt be replaced every sprocket and oil pump sprocket. See Fig. 6. Distance from
60,000 miles. back of timing belt to to edge of timing belt cover must be
.23 (6 mm). Readjust belt tension, if necessary.
REMOVAL & INSTALLATION Install timing belt covers. Ensure bolts are installed in cor-
rect position. See Fig. 7. Install crankshaft pulley. Tighten
TIMING BELT bolt to specification. See TORQUE SPECIFICATIONS.
Removal: To complete installation, reverse removal procedure. Ad-
Remove splash panel in left side wheel house. Remove just drive belts to proper tension. See page A-60 for belt
air intake duct to air cleaner housing. Noting installed posi- tension ranges.
tion for reassembly reference, remove spark plug cables TORQUE SPECIFICATIONS
from spark plugs.
Remove all accessory drive belts. Place jack under engine. Application Ft. Lbs. (N.m)
Support engine so there is no weight on engine mount Camshaft Sprocket Bolt .................................... 59-74 (80-100)
bracket (timing belt end of engine). Remove left side en- Crankshaft Pulley Center Bolt ....................... 1 80-96 (110-130)
gine mount. Engine Mount
Remove power steering pump pulley (if equipped). Re- To-Engine Bracket Bolt/Nut ............................... 37-50 (50-65)
move water pump pulley. See Fig. 1. Remove upper timing Bracket-To-Body Through Bolt ......................... 66-81 (90-110)
belt cover. Timing Belt Tensioner Adjusting Bolt/Nut ................... 17 (24)
Vibration Damper-To-Adapter Bolts ..................... 11-13 (15-18)
CAUTION: DO NOT rotate engine counterclockwise (as viewed INCH Lbs. (N.m)
from timing belt end of engine). If reusing timing belt, place reference Power Steering Pump Pulley Bolt ................................. 80 (9)
mark on timing belt to indicate direction of rotation before removing. Timing Belt Cover Bolt ................................... 89-106 (10-12)
Rotate crankshaft clockwise so that No. 1 cylinder is at 1
Apply engine oil to bolt thread before installation.
TDC of compression stroke. Ensure camshaft sprocket
timing mark aligns with mark on under upper cover. See
Fig. 2. Holding crankshaft stationary, remove crankshaft
pulley. Remove lower timing belt cover.
Loosen timing belt tensioner adjusting bolt and nut. Move
tensioner inward toward water pump. Temporarily tighten
tensioner adjusting bolt. Remove 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:
If crankshaft sprocket was removed, ensure flange and
spacer are correctly installed. See Fig. 3. If timing belt
tensioner was removed, ensure end of tensioner spring is
seated under water pump housing. See Fig. 4. Move
tensioner towards water pump and temporarily tighten
mounting bolt and nut.
See Fig. 2. Install timing belt onto crankshaft sprocket, and
keeping tension tight, install timing belt on camshaft Courtesy of Mitsubishi Motor Sales of America
sprocket.
After installing timing belt, ensure timing belt is tensioned
between crankshaft and camshaft sprockets. Check that
410 MITSUBISHI
Fig. 5: Camshaft Sprocket Position For Tension Adjustment


Fig. 6: Checking Timing Belt Tension Adjustment

Fig. 3: Crankshaft Sprocket, Flange & Spacer Installation

Fig. 7: Timing Belt Cover Bolt Length
Fig. 4: Installing Tensioner Spring

MITSUBISHI 411

Belt TIMING BELT
Labor Component Part Removal (1983-88):
Application Time Kit No. No. Disconnect negative battery cable. On models equipped
1.8L 4-Cyl. with A/C, remove upper radiator shroud and cooling fan/
Cordia & Tredia clutch assembly. On models equipped with power steer-
1983-84 ing, remove power steering pump and pulley. On all mod-
Balance Shaft ... 1 ..................................... T090 els, position No. 1 cylinder at TDC of compression stroke.
Loosen pulley bolts. Remove drive belts.
Camshaft .......... 2 3.2 Hrs. ....................... T089 Remove crankshaft, water pump and power steering pul-
1985-86 leys. Remove upper and lower front timing belt covers. Re-
Balance Shaft ... 1 ..................................... T159 lieve camshaft timing belt tensioner pressure and secure
Camshaft .......... 2 3.2 Hrs. ....................... T089 tensioner toward water pump. If camshaft timing belt is to be
1987-88 reused, mark belt with an arrow indicating direction of rotation
Balance Shaft ... 1 ..................................... T159 and remove belt. Remove camshaft and crankshaft sprocket
Camshaft ............ 2 3.2 Hrs. . TCK158....... T158 bolts. Remove camshaft sprocket, crankshaft sprocket and
crankshaft flange.
2.0L 4-Cyl. Remove plug on left side of cylinder block. Insert a screw-
Cordia & Tredia driver to keep left silent shaft in position. See Fig. 3. Re-
1984, move oil pump sprocket. Loosen right silent shaft sprocket
Balance Shaft ... 1 ..................................... T090 mounting bolt until it can be turned by hand. Remove belt
Camshaft .......... 2 3.2 Hrs. ....................... T089 tensioner B and timing belt B.
1985-86 Inspection (1983-88):
Balance Shaft ... 1 ..................................... T159 Inspect back of belt for hardness, non-elasticity and glossy
surface. If no mark is produced when fingernail is forced
Camshaft .......... 2 3.2 Hrs. ....................... T089 into it, replace belt. Check for rounded sides on belt, flak-
1987-88, ing, peeling, cracking and separating rubber. Cracks are
Balance Shaft ... 1 ..................................... T159 most evident at base of tooth.
Camshaft .......... 2 3.2 Hrs. ....................... T158 Installation (1983-88):
Galant Install timing belt B ensuring tension side has no slack.
1989-92 Install tensioner B so only light pressure is on belt. En-
sure flange on tensioner is mounted away from engine
Balance Shaft ... 1 ..................................... T159 and finger-tighten bolt. Lift tensioner with finger tip until slack
Camshaft .......... 2 2.4 Hrs. . TCK155....... T155 is removed from tension side of belt. Tighten tensioner bolt,
1993, being careful to prevent turning shaft. Ensure timing marks
Balance Shaft ... 1 ..................................... T168 are in alignment. Tighten right silent shaft bolt.
Camshaft .......... 2 2.4 Hrs. . TCK232....... T232 Check belt tension by pressing center of tension side in-
Pickup ward, using index finger and measuring belt deflection.
1983-86 Deflection should be .20-.30" (5.0-7.0 mm). Readjust if not
within specification. Align camshaft timing belt sprockets
Balance Shaft ... 1 ..................................... T090 with corresponding timing marks. See Fig. 1 or Fig. 2. To
Camshaft .......... 2 2.3 Hrs. ....................... T089 ensure oil pump sprocket is in correct alignment, insert
1987-89 screwdriver shaft in hole on left side of block. See Fig. 3.
Balance Shaft ... 1 ..................................... T159 If screwdriver cannot be inserted at least 2.4" (60.0 mm),
Camshaft .......... 2 2.3 Hrs. . TCK158A..... T158 turn oil pump sprocket one revolution and realign marks.
Insert screwdriver. Leave screwdriver inserted until timing
1
- Balance Shaft Belt labor time included in belt installation is complete. With tensioner secured fully
Camshaft Belt labor time. toward water pump, install timing belt in order of crank-
2
- With Air Cond. add .7 hours. shaft sprocket, oil pump sprocket and camshaft sprocket.
With Pwr. Strng. add .3 hours. Ensure tension side of belt has no slack. Loosen tensioner
mounting bolt and nut to allow only tensioner spring pres-
NOTE: A timing belt component kit is available for sure to tighten belt.
this application. See page I for information on component Check belt to ensure each tooth is in proper mesh with
camshaft sprocket. Tighten slot-side bolt before tightening
kits. nut. Otherwise, tension bracket will turn and belt will be too
tight. Ensure all timing marks are in correct alignment. Re-
MANUFACTURERS SUGGESTED move screwdriver and install plug in block. Turn crankshaft,
SCHEDULED MAINTENANCE clockwise only, one revolution. Loosen mounting nut and
bolt to allow tensioner to readjust and tighten slot-side bolt,
The manufacturer recommends the belt be replaced every then tighten nut.
60,000 miles. Hold belt and seal line of undercover, between thumb and
forefinger, at center of tension side. Measure clearance
between belt and seal line. Clearance should be .55" (14.0
mm). Reverse removal procedure to complete reassembly.
tension ranges.
412
MITSUBISHI
Removal (1989-93): sprocket. Belt deflection should be .55" (14 mm). To com-
Disconnect negative battery cable. Remove A/C and power plete installation, reverse removal procedure. Adjust drive
steering hose mounting bracket or oxygen sensor connec- belts to proper tension. See page A-60 for belt tension
tor bracket from upper engine mount at timing belt cover. ranges.
Support engine, and remove upper engine mount. Remove TORQUE SPECIFICATIONS
all drive belts and drive pulleys from crankshaft and water
pump. Application Ft. Lbs. (N.m)
Remove drive belt tensioner. Remove upper and lower tim- A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27)
ing belt covers. Note bolt lengths and locations. Longer (2) Automatic Tensioner Bolt .................................. 14-20 (19-27)
bolts are located above crankshaft seal. Remove crank- Camshaft Sprocket Bolt .................................... 58-72 (79-98)
shaft sprocket bolt access cover, crankshaft sprocket bolt Crankshaft Pulley Bolt
and washer. If necessary, remove rocker arm cover for clear- 1983-85 .......................................................... 11-15 (15-20)
ance. 1986-93 .......................................................... 15-21 (20-29)
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed Damper Pulley Bolt ........................................... 11-13 (15-18)
from timing belt end of engine). If timing belt is to be reused, Front Cover Bolts
mark direction of rotation before removing. M8 X 30 Bolt .................................................... 20-26 (27-35)
Except M8 X 30 Bolt ........................................ 14-20 (19-27)
Rotate crankshaft clockwise (as viewed from timing belt
end of engine) until cylinder No. 1 is at TDC of compres-
Rear Timing Belt Tensioner ............................. 11-16 (15-22)
sion stroke. Align timing mark on camshaft sprocket with
Silent Shaft Sprocket Bolt
timing mark on cylinder head. See Fig. 1 or Fig. 2. Loosen
.08" (2.0 mm) Washer .................................... 25-29 (34-39)
timing belt tensioner adjustment bolt, and move tensioner
.10" (2.5 mm) Washer .................................... 31-35 (42-47)
toward water pump. Tighten bolt to secure tensioner. Re-
move front timing belt and camshaft sprocket.
If oil pump sprocket removal is necessary, remove left si- Timing Belt Cover Bolt
lent shaft access plug from cylinder block. Insert .31" (8.0
Left Lower Rear Cover .................................... 22-30 (30-41)
mm) diameter Phillips screwdriver to block left silent shaft.
All Others ............................................................................ 1
Remove oil pump sprocket nut and sprocket. Remove front
Timing Belt Tensioner Nut
crankshaft sprocket and flange. Note direction and order of
1983-85 .......................................................... 16-21 (22-28)
installation. Remove rear timing belt tensioner assembly.
1986-93 .......................................................... 32-39 (42-53)
Remove rear timing belt.
Water Pump Bolt
Inspection (1989-93):
Except 8 X 65 mm ............................................ 9-11 (12-15)
Check belt teeth for cracks, damage and contamination. 8 X 65 mm ...................................................... 15-19 (20-26)
Inspect sprockets for damage. Check belt tensioner for
INCH Lbs. (N.m)
leakage or roughness in rotation. Replace components as
necessary.
All Except Left Lower Rear Cover Bolt ............. 84-108 (9-12)
If reusing rear timing belt, install in original direction of rotation.
Ensure timing marks are aligned. See Fig. 4. Install rear timing 1
- All except Left Lower Rear Cover Bolt tighten to 84-108
belt tensioner. Hold tensioner tightly against belt while tightening INCH Lbs. (9-12 N.m).
bolts. Depress belt between sprockets to ensure deflection is
.20-28" (5-7 mm). Adjust as necessary.
Install crankshaft front sprocket. Install oil pump sprocket.
Hold left silent shaft using a .31 (8.0 mm) diameter Phillips
screwdriver through access hole. Ensure screwdriver can
be inserted at least 2.36 (59.9 mm). Remove screwdriver
if it cannot be inserted at least 2.36" (59.9 mm), and rotate
oil pump sprocket one revolution. Align timing mark. Insert
screwdriver, and ensure it can be inserted at least 2.36"
(59.9 mm).
DO NOT remove screwdriver until timing belt is installed.
Install camshaft sprocket. Tighten bolts to specification.
See TORQUE SPECIFICATIONS. Install front timing belt
tensioner, tension spring and spacer(s). Ensure spring is
properly engaged against water pump case. Rotate
tensioner toward water pump, and temporarily tighten bolts.
Ensure timing marks are aligned. See Fig. 1 or Fig. 2.
If reused, install timing belt in original direction of rotation.
Apply pressure on tension side of belt while installing belt
on camshaft sprocket. Loosen timing belt tensioner to ap-
ply spring pressure to timing belt. Ensure timing marks are
still aligned. To apply tension on belt, rotate crankshaft clock-
wise until camshaft sprocket timing mark is offset by 2
teeth. Tighten tensioner bolt. Tighten tensioner nut.
To check belt tension, apply slight thumb pressure and Fig. 1: Aligning Camshaft Sprocket Timing Marks
measure deflection between camshaft and oil pump (8-Valve Engine)
MITSUBISHI 413
Fig. 3: Aligning Oil Pump Sprocket
Courtesy of Chrysler Corp.

(16-Valve Engine)

414 MITSUBISHI
*2.0L 4-Cylinder DOHC, Eclipse & Galant
Labor Component Part For 1989-94 vehicles, the manufacturer recommends the belt
Application Time Kit No. No. be replaced every 60,000 miles.
2.0L 4-Cyl. DOHC (4G6) For 1995-97 vehicles, the manufacturer recommends the belt
Eclipse Turbo & Non-Turbo be replaced every 60,000 miles, except in California. In Cali-
fornia, timing belt replacement is recommended but not re-
1990-94 ...... 1 & 2 3.6 Hrs. .... TCK167 ........ 3 T167 quired at 60,000 miles. In California, replace belt at 100,000
1990-94 ...... 1 & 2 3.6 Hrs. ............................ 4 T168 miles, unless previously changed.
Eclipse Turbo For 1998-99 vehicles, the manufacturer recommends the belt
1995-99 ...... 1 & 2 3.6 Hrs. .... TCK167 ........ 3 T167 be replaced every 60,000 miles, except in California, Con-
1995-99 ...... 1 & 2 3.6 Hrs. ............................ 4 T168 necticut and Massachusetts. In California, Connecticut and
Galant Massachusetts, timing belt replacement is recommended but
1989-92 ...... 1 & 2 3.6 Hrs. .... TCK167 ........ 3 T167 not required at 60,000 miles. In California, replace belt at
100,000 miles, unless previously changed.
1989-92 ...... 1 & 2 3.6 Hrs. ............................ 4 T168
1993 ........... 1 & 2 3.6 Hrs. .... TCK232 ........ 3 T232 *NOTE: This application is an interference engine.
1993 ........... 1 & 2 3.6 Hrs. ............................ 4 T168 See page A-59 for interference engine cautions.
1
- Balance shaft labor time included in camshaft
labor time. REMOVAL & INSTALLATION
2
With Pwr. Strng. add .2 hours. TIMING BELT & BALANCE SHAFT BELT
3
Camshaft timing belt. Removal:
4
Balance shaft belt.
Disconnect negative battery cable. Remove engine under-
cover. Place wooden block between jack and oil pan and
raise engine slightly. Remove engine mount assembly near
NOTE: A timing belt component kit is available for timing belt cover.
this application. See page I for information on component Remove clamp for power steering return hose near timing
belt cover. Remove all drive belts and tensioner pulley
kits. bracket. See Fig. 1. Remove power steering and water
pump pulleys. Rotate crankshaft clockwise so that No. 1
cylinder is at TDC of compression stroke. Remove crank-
shaft pulley.
Fig. 1: Exploded View Of Timing Belts & Components

MITSUBISHI 415
*2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)

Fig. 4: Timing Belt B (Balance Shaft Belt) Components

416 MITSUBISHI
2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)
CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure
timing marks are aligned. If reusing timing belts, mark timing
belts for direction of rotation.
Remove upper timing belt cover and gasket. Remove stub
bolt of engine support bracket and remove center timing
belt cover. Remove lower timing belt cover.
NOTE: Camshaft sprocket dowel pins will be in 12 oclock position

when timing marks are correctly aligned.
Ensure camshaft, crankshaft and oil pump sprocket timing
marks are aligned. See Figs. 2 and 3. Loosen tensioner
pulley center bolt. Move tensioner to relieve timing belt ten-
sion. Remove timing belt. Remove timing belt auto
tensioner. See Fig. 1.
Fig. 5: Holding Balance Shaft Stationary
Remove plug from left side of cylinder block. Install a .31"
(8.0 mm) diameter Phillips screwdriver into the hole against
balance shaft. See Fig. 5. Screwdriver must go in at least
2.36 (60 mm) or more. If screwdriver will only go in about
.79-.98
(20-25 mm) before striking balance shaft, turn sprocket
one revolution and align timing mark. Keep screwdriver in
place until timing belt is installed. This ensures balance
shaft driven by oil pump sprocket remains in correct posi-
tion.
To remove timing belt B (balance shaft belt), hold crank-
shaft sprocket stationary with a spanner wrench. Remove
crankshaft sprocket bolt. Using gear puller, remove outer
crankshaft sprocket.
Remove crankshaft sensing blade (if equipped). See Fig.
4. Loosen timing belt B tensioner bolt. If reusing timing
belt B, mark direction of belt rotation for reassembly refer-
ence. Remove timing belt B.
Inspection:
Inspect timing belts for damaged teeth and cracking. En-
sure belts are not contaminated with oil. Check tensioners
for free rotation and grease leakage. Replace components
if damaged or if grease leakage exists.
NOTE: The following revised information for timing belt tensioner

inspection is from Mitsubishi technical service bulletin 96-11-
006; June, 1996.
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.
Installation:
Courtesy of Mitsubishi Motor Sales of America Retract rod into auto tensioner housing by placing auto
Fig. 7: Aligning Timing Belt B (1990-92 Models) tensioner assembly in a soft-jawed vise. Close vise
SLOWLY to push rod back into auto tensioner housing.
When pin hole in cylinder aligns with pin hole in rod, insert
set pin. Replace tensioner assembly if rod can be retracted
easily into housing. Install auto tensioner on engine with
set pin in place.
Align balance shaft and crankshaft timing marks with rear
cover. See Figs. 7 and 8. Install timing belt B on sprock-
ets. If using old belt, install belt in original direction of rota-
tion. Ensure there is no slack in tension side of belt.
CAUTION: Ensure tensioner pulley shaft does not rotate when

bolt is tightened or excessive pressure will be applied to tim-
ing belt.
MITSUBISHI 417
*2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)

Install timing belt B tensioner so center of tensioner pul- Attach Adapter (MD998767) to tensioner pulley eccentric.
ley is to the left and above of retaining bolt center. See Fig. Attach torque wrench to adapter and apply 24 INCH lbs.
9. Rotate tensioner inward toward timing belt until belt is (2.7 N.m) of torque in a clockwise direction. See Fig. 15.
tight. Tighten tensioner retaining bolt without letting With torque applied to eccentric, tighten tensioner pulley
tensioner pulley rotate out of position. Check belt deflec- center bolt to 32-40 ft. lbs. (43-55 N.m).
tion at designated area. Belt deflection should be .20-.28" Insert Set Screw (MD998738) through inner timing belt cover
(5.0-7.0 mm). Readjust timing belt if belt deflection is not until it contacts tensioner arm. See Fig. 12. Slowly rotate
within specification. set screw until set pin can be removed. Remove set screw
from engine.
CAUTION: Install crankshaft sensing blade and crankshaft sprockets Rotate crankshaft 6 complete turns clockwise. Wait 15 min-
in correct positions or timing belt may be damaged. utes without turning crankshaft. Measure distance between
Install crankshaft sensing blade (if equipped) in front of top of auto tensioner body and tensioner arm. See Fig. 16,
crankshaft sprocket B, with offset in proper direction. See Dimension A. The distance should be .15-.18 (3.8-4.5
Fig. 10. Install crankshaft sprocket A. Apply light coat of mm). If distance is not correct, timing belt tension will have
engine oil to crankshaft sprocket bolt threads, and tighten to be readjusted. Go to FINAL ASSEMBLY.
bolt to specification. See TORQUE SPECIFICATIONS. In- Timing Belt Tension Adjustment (1993-98):
stall idler pulley (if removed). Lift tensioner pulley upward to apply tension on timing belt.
Ensure camshaft, crankshaft and oil pump timing marks The 2 pin holes in the center of the tensioner must face
are still aligned. See Figs. 2 and 3. Do not remove screw- down. See Fig. 12. Screw the Set Screw (MD998738) into
driver from side of engine block until timing belt is installed. engine support bracket until it makes contact with tensioner
arm. At that point, screw the set screw in a few more threads
NOTE: Intake and exhaust camshafts use same camshaft sprocket. and remove the set pin from the auto tensioner. Remove
Camshaft sprockets are provided with 2 timing marks. For exhaust the set screw. Tighten timing belt tensioner pulley center
camshaft sprocket, use timing mark on right with dowel pin facing bolt to 35 ft. lbs (48 N.m).
up. On intake camshaft, sprocket, use timing mark on the left, Remove screwdriver from side of engine block and install
with dowel pin hole on top. plug. To tension timing belt, rotate crankshaft about 1/4
turn counterclockwise, then 1/4 turn clockwise until all tim-
Rotate camshaft sprocket so dowel pins are upward and ing marks align.
away from cylinder head and timing marks are aligned with Loosen tensioner pulley center bolt. Install Adapter
cylinder head surface. Timing marks should face each other. (MD998767) or equivalent to tensioner eccentric. Install
See Figs. 2 and 3. torque wrench on adapter. See Fig 13. Starting with eccen-
Install timing belt on intake camshaft sprocket. Install spring tric pin holes still facing down, apply 31 INCH Ibs. (3.5 N.m)
clip to retain timing belt on sprocket. See Fig. 11. Place a of torque counterclockwise on tensioner pulley.
wrench on each camshaft sprocket retaining bolt. Rotate Hold tensioner pulley at specified torque, and tighten
camshafts so timing marks align with each other. tensioner center bolt to specification. DO NOT let tensioner
Install timing belt over exhaust camshaft. Install spring clip pulley turn with bolt. See TORQUE SPECIFICATIONS.
to retain timing belt. Install timing belt over idler pulley, oil Rotate crankshaft 2 full revolutions clockwise so that tim-
pump sprocket, crankshaft sprocket and tensioner pulley. ing marks are aligned. Allow engine to stand for 15 min-
Remove spring clips from camshaft sprockets. utes without turning crankshaft. Distance between top of
Timing Belt Tension Adjustment (1990-92) auto tensioner housing and tensioner arm should be .15-
Position timing belt tensioner pulley so that the 2 pin holes .18" (3.8-4.5 mm). If distance is incorrect, repeat tensioning
in the center eccentric are facing to the left (as viewed from procedure until distance is correct. Go to FINAL ASSEMBLY.
timing belt end of engine) of the center bolt. Finger tighten Final Assembly:
center bolt. To install remaining components, reverse removal proce-
Remove screwdriver from balance shaft hole in side of dure. Ensure proper length bolts are installed in timing belt
engine block. Install plug. covers. See Fig. 14. See TIMING COVER BOLT LENGTH &
Rotate crankshaft 1/4 turn counterclockwise, then rotate TORQUE. Adjust the drive belts to proper tension. See page
crankshaft 1/4 clockwise until timing marks are aligned A-60 for belt tension ranges.
again. No. 1 cylinder should be at TDC of compression
stroke.
Fig. 10: Installing Crankshaft Sprocket & Crankshaft

Sensing Blade
418 MITSUBISHI
2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)

Fig. 11: Installing Timing Belt On Intake Sprockets


Balance Shaft Sprocket Bolt ......................................... 33 (46)
Courtesy of Mitsubishi Motor Sales of America Crankshaft Sprocket Bolt ............................. 80-94 (108-127)
Fig. 13: Adjusting Timing Belt Tension (1993-98) Drive Belt Tensioner Pulley Bracket ..................... 17-20 (23-26)
Bolt/Nut (1993-98) ..................................................... 49 (67)
TIMING COVER BOLT LENGTH & TORQUE Engine Mount-To-Engine
Bolt Length INCH Lbs. (N.m) Bolt/Nut (1990-92) ........................................... 36-47 (50-65)
A : 6 x 16 mm Flange Bolt ............................. 89-106 (10-12) Engine Mount-To-Body
B : 6 x 18 Flange Bolt .................................... 89-106 (10-12) Through-Bolt (1993-98) ..................................... 72-87 (98-118)
C: 6 x 25 Loose Washer Bolt .................................. 58 (6.5) Engine Mount-To-Body
D: 6 x 25 Flange Bolt .................................... 89-106 (10-12) Through-Bolt (1990-92) ...................................... 43-58 (60-80)
E : 6 x 45 Flange Bolt .................................... 89-106 (10-12) 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)

MITSUBISHI 419

TIMING BELT APPLICATION To remove camshaft sprockets, hold camshaft hexagon
(between camshaft journals No. 2 and 3) while removing
Belt camshaft sprocket bolt. Remove camshaft sprockets. Remove
Labor Component Part silent shaft access plug from cylinder block. Insert .31" (8.0 mm)
Application Time 1& 2 Kit No. No. diameter Phillips screwdriver to block left silent shaft. See Fig. 3.
2.4L 4-Cyl. DOHC Remove oil pump sprocket nut and sprocket.
Galant Remove bolt, washer, crankshaft sprocket and flange. Note
direction of flange installation. Remove rear timing belt
1994 tensioner assembly. Remove rear timing belt.
Balance Shaft .............. 1 ............................ T168 Inspection:
Camshaft Check belt teeth for damage and oil contamination. Inspect
Thru 5/94 ..... 3.6 Hrs. ...... TCK256 .......... T256 belt for glossy, hardened or non-elastic surface. Ensure
From 6/94 .... 3.6 Hrs. ................................ T230 belt is not cracked, separated or showing canvas fiber. In-
1995-96 spect all sprockets fordamage. Check tensioner pulley and
Balance Shaft 1 ......................................... T168 idler pulley for grease leakage and roughness in rotation.
Replace components if damaged.
Camshaft ....... 3.6 Hrs. ................................ T230 Inspect automatic tensioner for leaks. Check rod end of auto-
1
-Balance Shaft included in Camshaft labor time. matic tensioner for wear. Measure distance from tensioner
2
- With Air Cond. add .7 hours. rod end to tensioner housing. Distance should be .47" (11.9
With Pwr. Strng. add .3 hours. mm).
Retract rod into tensioner housing by placing automatic
NOTE: A timing belt component kit is available for tensioner assembly in a soft-jawed vise. Close vise to push
rod back into tensioner. Replace automatic tensioner as-
this application. See page I for information on component sembly if rod can be easily pushed into automatic tensioner.
kits.
NOTE: lf plug at bottom of tensioner protrudes past tensioner
housing, place a washer over plug to prevent it from contacting
MANUFACTURERS SUGGESTED vise when pushing rod into tensioner housing.
For 1994-96 models, the manufacturer recommends the belt Align timing marks on silent shaft rear crankshaft sprock-
be replaced every 60,000 miles except in California. In Califor- ets with timing marks on engine case.
nia, timing belt replacement is recommended, but not required, Install rear timing belt and tensioner. Hold tensioner tightly
at 60,000 miles. In California, replace timing belt at 100,000 against belt while tightening bolts. To check tension, de-
miles, unless previously changed. press belt with finger midway between sprockets. Deflec-
tion should be .20-.28" (5.0-7.1 mm). Install crankshaft
* NOTE: This application is an interference engine. sprocket, oil pump sprocket and camshaft sprocket. Tighten
See page A-59 for interference engine cautions. camshaft sprocket bolts to specification while holding hexa-
gon area of camshaft. See TORQUE SPECIFICATIONS.
REMOVAL & INSTALLATION Install idler pulley.
Retract automatic tensioner rod into tensioner housing by
TIMING BELT placing tensioner assembly in a soft-jawed vise. Push rod
back into automatic tensioner in small increments until
CAUTION: To prevent engine damage, DO NOT rotate crankshaft both rod and housing holes are aligned. See Fig. 6. Install
counterclockwise (as viewed from timing belt end of engine). a .055" (1.39 mm) diameter wire into holes. Remove auto-
matic tensioner from vise with wire attached.
Removal: Install tensioner and arm. Install tensioner pulley on
Disconnect negative battery cable. Remove protective cover tensioner arm. Ensure pin holes of tensioner pulley shaft
from below engine. Remove A/C and power steering hose are left of pulley center bolt. Tighten center bolt. Rotate
mounting bracket. Support engine. Remove upper engine camshaft sprockets so dowel pins face upward and timing
mount located near timing belt cover. Remove all drive belts. marks on sprockets align. See Fig. 1. Outer marks on
Remove tensioner pulley bracket. Remove pulleys from sprockets should be aligned with cylinder head surface.
crankshaft, water pump and power steering. When exhaust camshaft sprocket is released, camshaft
Remove drive belt tensioner. Remove upper and lower tim- will rotate one tooth in counterclockwise direction. Ensure
ing belt cover with gasket. Note bolt lengths and locations. this rotation is compensated for when installing timing belt.
Remove breather hose, PCV hose and center shield from Rotate crankshaft and oil pump sprockets to align timing
valve cover. Disconnect spark plug wires from spark plugs. marks.
Remove rocker cover and semi-circular packing (located at If reusing old timing belt, ensure belt is installed in original
rear of rocker cover). Remove rubber plug. Rotate crank- direction of rotation. Remove silent shaft access plug from
shaft clockwise (as viewed from timing belt end of engine) cylinder block. Insert .31" (8.0 mm) diameter Phillips screw-
until all timing marks align and cylinder No. 1 is at TDC of driver. See Fig. 3. If screwdriver can be inserted 2.36" (59.9
compression stroke. See Fig. 1. mm) or more, timing mark alignment is okay.
Remove automatic tensioner. See Fig. 2. If timing belt is to be
reused, mark timing belt to indicate original direction of rota-
tion. Remove timing belt. Remove tensioner pulley, tensioner
arm and idler pulley (if necessary). Inspect sprockets for dam-
age.
420 MITSUBISHI
If screwdriver cannot be inserted at least 2.36" (59.9 mm), To adjust belt tension, rotate crankshaft 1/4 turn counter-
remove screwdriver and rotate oil pump sprocket one full clockwise, and then rotate clockwise until cylinder No. 1 is
turn. Reinsert screwdriver. Leave screwdriver in place until at TDC. Ensure timing marks are aligned. Loosen center
timing belt is installed. Install timing belt on intake cam- bolt on tensioner pulley. Note location of pin holes in
shaft sprocket. Use spring clip to hold belt on sprocket. tensioner pulley. Using INCH-lb. torque wrench and Socket
See Fig. 7. Wrench (MD998767) or equivalent, apply 22 INCH Ibs. (2.6
Install wrench on both camshaft sprocket bolts. Install tim- N.m) on tensioner pulley. See Fig. 5. With torque applied to
ing belt around exhaust camshaft sprocket while holding tensioner pulley, tighten tensioner pulley center bolt to 35 ft.
camshaft sprocket bolt so timing mark on camshaft sprocket Ibs. (48 N.m).
is aligned with timing mark. Install another spring clip on Install set screw in support bracket until set screw end
timing belt and camshaft sprocket to hold belt on sprocket. contacts tensioner arm. See Fig. 8. Rotate set screw fur-
Install timing belt in following sequence: around idler pul- ther until wire can be removed from automatic tensioner.
ley, oil pump sprocket, crankshaft sprocket and tensioner Remove set screw. Rotate crankshaft clockwise 2 com-
pulley. plete revolutions, and allow to remain in this position for
Remove both spring clips. Rotate tensioner pulley inward to- about 15 minutes. Measure distance between tensioner
ward timing belt until belt does not sag. Temporarily tighten arm and automatic tensioner body. Distance should be
center bolt on tensioner pulley. Ensure all timing marks are .15-.18" (3.8-4.5 mm). See Fig. 9, Dimension A.
aligned. Remove Phillips screwdriver from silent shaft ac- If distance cannot be measured due to lack of clearance,
cess hole. Install plug. Remove wrench from camshaft use alternate method. Install set screw until it contacts
sprocket bolts. 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.
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

Fig. 4: Installing Crankshaft Sprockets

MITSUBISHI 421
Fig. 5: Adjusting Timing Belt Tensioner Pulley

Fig. 8: Measuring Timing Belt Adjustment
Auto Tensioner Bolt .......................................... 14-20 (19-27)
Front ............................................................... 36-51 (49-69)
Left .................................................................. 22-30 (30-41)
Front Cover Bolt ................................................ 14-16 (19-22)
Front Tensioner Pulley Bolt ............................... 31-40 (42-54)
Rear Tensioner Retaining Bolt ......................... 11-16 (15-22)
Water Pump Bolt
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Crankshaft Position Sensor Nut ....................... 84-108 (9-12)
Valve Cover Bolt .................................................... 24-36 (3-4)
Fig. 7: Installing Timing Belt On Camshaft Sprockets

Fig. 9: Measuring Automatic Tensioner Protrusion
422 MITSUBISHI
2.4L 4-Cylinder 1985-90 Galant & Van
TIMING BELT APPLICATION TIMING BELT INSTALLATION
Installation:
Belt
Lightly oil right silent shaft spacer and insert spacer with
Labor Component Part chamfered end toward seal. Install right silent shaft
Application Time Kit No. No. sprocket (if removed) and finger-tighten bolt. Align crank-
2.4L 4-Cyl. SOHC shaft sprocket and silent shaft sprocket timing marks with
Galant corresponding marks on front case. See Figs. 2 and 7.
1985-87 ........ 1 & 2 2.4 Hrs. .. TCK124 ........ 3 T124 Install timing belt B, ensuring tension side has no slack.
1985-87 ........ 1 & 2 2.4 Hrs. .......................... 4 T159 Install tensioner B so only light pressure is on belt. En-
sure flange on tensioner is mounted away from engine
Van and finger-tighten bolt.
1990-87 ........ 1 & 2 3.2 Hrs. .. TCK124 ........ 3 T124 Lift tensioner with finger tip until slack is removed from
1990-87 ........ 1 & 2 3.2 Hrs ........................... 4 T159 tension side of belt. Tighten tensioner bolt, being careful to
1
- Balance shaft belt labor time included in prevent turning shaft. Ensure timing marks are in align-
ment. Tighten right silent shaft bolt.
camshaft belt labor time. Check belt tension by pressing center of tension side in-
2
- With Air Cond. add .7 hours. ward, using index finger and measuring belt deflection.
With Pwr. Strng. add .3 hours. Deflection should be .20-.30" (5.0-7.0 mm). Readjust if not
3
Camshaft timing belt. within specification.
4
Balance shaft belt. 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
NOTE: A timing belt component kit is available for side of block. See Figs. 4 and 5.
this application. See page I for information on component If screwdriver cannot be inserted at least 2.4" (60.0 mm),
kits. turn oil pump sprocket one revolution and realign marks.
Insert screwdriver. Leave screwdriver inserted until timing
belt installation is complete. Install crankshaft sprocket.
MANUFACTURERS SUGGESTED See Figs. 1 and 8.
60,000 miles.

TIMING BELT REMOVAL
Removal:
Disconnect negative battery cable. Position No. 1 cylinder
at TDC of compression stroke. Remove crankshaft and
water pump pulleys. Remove upper and lower front timing
belt covers Relieve camshaft timing belt tensioner pres-
sure and secure tensioner toward water pump.
If camshaft timing belt is to be reused, mark belt with an
arrow indicating direction of rotation and remove belt. Re-
move camshaft and crankshaft sprocket bolts. Remove cam-
shaft sprocket, crankshaft sprocket and crankshaft flange.
Remove plug on left side of cylinder block. Insert a screw- Fig. 1: Installing Crankshaft Sprockets (Galant)
driver to keep left silent shaft in position. See Figs. 4 and 5.
Remove oil pump sprocket. Loosen right silent shaft
sprocket mounting bolt until it can be turned by hand. Re-
move belt tensioner B and timing belt B.
Inspect back of belt for hardness, non-elastic and having a
glossy surface. If no mark is produced when fingernail is
forced into it, replace belt. Check for rounded sides on belt.
Sides of belt should be straight and clear-cut. Flaking, peel-
ing, cracking and rubber from canvas also indicates belt
warrants replacement. Cracks are most evident at base of
tooth.
Abnormal wear most often occurs on load side of tooth.
Fluffy canvas, unclear canvas texture, belt color changed to
White from rubber missing, reduced tooth width or a miss-
ing tooth warrant belt replacement.
Fig. 2: Aligning Timing Marks For Timing Belt B

MITSUBISHI 423
2.4L 4-Cylinder 1985-90 Galant & Van (Cont.)

With tensioner secured fully toward water pump, install tim-
ing belt in order of crankshaft sprocket, oil pump sprocket
and camshaft sprocket. Ensure tension side of belt has no
slack. Loosen tensioner mounting bolt and nut to allow
only tensioner spring pressure to tighten belt. Check belt to
ensure each tooth is in proper mesh with camshaft
sprocket.
Tighten slot-side bolt before tightening nut. Otherwise, ten-
sion bracket will turn and belt will be over tensioned. En-
sure all timing marks are in correct alignment. Remove
screwdriver and install plug in block. Turn crankshaft, clock-
wise only, one revolution. Loosen mounting nut and bolt to Fig. 4: Aligning Oil Pump Sprocket
allow tensioner to readjust and tighten slot-side bolt, then
tighten nut.
Hold belt and seal line of undercover, between thumb and
forefinger, at center of tension side. Measure clearance
between belt and seal line. Clearance should be .55" (14.0
mm). See Fig. 9. Reverse removal procedure to complete
reassembly. Adjust drive belts to proper tension. See page

424 MITSUBISHI
2.4L 4-Cylinder 1985-90 Galant & Van (Cont.)
Fig. 8: Installing Crankshaft Sprockets (Van)

Fig. 9: Checking Timing Belt A Tension

Crankshaft Pulley Bolt ........................................ 14-22 (19-30)
Front ............................................................... 36-51 (49-69)
Left .................................................................. 22-30 (30-41)
Engine Support Bracket Bolts .......................... 29-36 (39-49)
Front Cover Bolts .............................................. 15-19 (20-26)
Fig. 6: Aligning Camshaft Timing Marks (8-Valve Engine) Front Roll Stopper Bracket Nuts ....................... 22-36 (30-49)
Front Roll Stopper Insulator Nut ....................... 36-41 (49-56)
Left Mounting Bracket-To-Engine
Bolts & Nuts ................................................... 36-47 (49-64)
Rear Roll Stopper Bracket-To-Rear
Roll Stopper Insulator Nut .............................. 22-29 (30-39)
Roll Stopper Stay Bolt ..................................... 11-15 (15-20)
Rear Roll Stopper-To-No. 2
Crossmember Nuts ....................................... 43-58 (58-79)
Rear Tensioner Retaining Bolt ....................... 11-16 (15-22)
Silent Shaft Sprocket Bolt
1985-87 .......................................................... 25-28 (34-38)
Timing Belt Tensioner Nut
1986-85 .......................................................... 16-21 (22-28)
1987-90 .......................................................... 32-39 (42-53)
Water Pump Bolt
Except 8 X 65 mm .................................................... 10 (14)
8 X 65 mm ...................................................... 15-19 (20-26)
INCH Lbs. (N.m)
Valve Cover Bolt ................................................ 84-108 (9-12)
MITSUBISHI 425
*2.4L 4-Cylinder SOHC, VIN G

Application Labor Time Belt Part No. SCHEDULED MAINTENANCE
2.4L 4-Cyl. SOHC For 1994-96 models, the manufacturer recommends the belt
Eclipse be replaced every 60,000 miles except in California. In Califor-
2000-01 ............... 1 & 2 2.4 Hours ................ 3 T232 nia, timing belt replacement is recommended, but not required,
1996-98 ............... 1 & 2 2.4 Hours ................ 3 T230 at 60,000 miles. In California, replace timing belt at 100,000
1996-01 ............... 1 & 2 2.4 Hours ................ 4 T168 For 1997-00 models, the manufacturer recommends the belt
Galant be replaced every 60,000 miles except in California, Connecti-
1999-01 ............... 1 & 2 2.4 Hours ................ 3 T232 cut, and Massachusetts. In California, Connecticut, and Mas-
1994-98 ............... 1 & 2 2.4 Hours ................ 3 T230 sachusetts, timing belt replacement is recommended, but not
1994-01 ............... 1 & 2 2.4 Hours ................ 4 T168 required, at 60,000 miles. In these states, replace timing belt
Montero Sport at 100,000 miles.
1997-99 ............... 1 & 2 1.8 Hours ................ 3 T230 For 2001 models, the manufacturer recommends the belt be
1997-99 ............... 1 & 2 1.8 Hours ................ 4 T168 setts and Vermont. In California, Massachusetts and Vermont,
1 -
Balance shaft belt labor time included in timing belt replacement is recommended, but not required, at
camshaft belt labor time. 60,000 miles. In these states, replace timing belt at 100,000
2 -
With Air Cond. add .7 hours for Galant. miles.
With Air Cond. add .2 hours for Eclipse. *NOTE: This application is an interference engine.
With Pwr. Strng. add .3 hours. See page A-59 for interference engine cautions.
3
Camshaft timing belt.
4
Balance shaft belt. REMOVAL & INSTALLATION
NOTE: Engine VIN is eight character of vehicle VIN. TIMING BELT REMOVAL
Eclipse & Galant:
Raise and support vehicle. Remove engine splash shield
from right side wheelwell.
Fig. 1: Exploded View Of Drive Belts & Timing Belt Components (Except Montero Sport)
426 MITSUBISHI
*2.4L 4-Cylinder SOHC, VIN G (Cont.)
To remove balance shaft belt, remove left balance shaft
access plug from cylinder block. Insert .31" (8.0 mm) diam-
eter Phillips screwdriver to block left silent shaft. See Fig. 3.
Ensure screwdriver can be inserted at least 2.36 (59.9
mm). Remove screwdriver if it cannot be inserted at least
2.36" (59.9 mm). Rotate balance shaft one revolution and
realign timing mark.
If reusing old balance shaft timing belt, mark belt with ar-
row to indicate rotation direction. Holding crankshaft sta-
tionary, remove front crankshaft sprocket bolt. Use gear
puller to remove crankshaft sprocket from crankshaft.
Noting direction of installation, remove crankshaft sensing
blade. Loosen balance shaft tensioner pulley center bolt.
Remove balance shaft timing belt.

Fig. 2: Aligning Front Timing Belt Marks

(Montero Sport)
Fig. 3: Locking Balance Shaft
Lower vehicle. Support weight of engine with floor jack.

Remove upper engine mount located near timing belt cover.
Remove all drive belts. On all except 1999 Galant, remove
drive belt tensioner pulley bracket and power steering pump
pulley. See Fig. 1. On all models, remove water pump pul-
ley.
Remove crankshaft pulley. Noting bolt lengths and loca-
tions, remove upper and lower timing belt cover with gas-
ket.
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.
Rotate crankshaft clockwise (as viewed from timing belt Courtesy of Mitsubishi Motor Sales of America
end of engine) until cylinder No. 1 is at TDC of compres- Fig. 5: Aligning Balance Shaft Timing Marks
sion stroke. Align timing mark on camshaft sprocket with
timing mark on cylinder head. See Fig. 2.
Loosen timing belt tensioner center bolt, and move
tensioner toward water pump. Tighten center bolt to secure
tensioner. Remove front timing belt. Remove timing belt
auto tensioner.
MITSUBISHI 427

Montero Sport:
Drain engine coolant. Remove upper radiator hose. Loosen
the cooling fan clutch-to-pulley nuts. Remove accessory
drive belts. Remove fan shroud and cooling fan clutch with
pulley.
CAUTION: Never rotate crankshaft counterclockwise.

Rotate crankshaft clockwise so that No. 1 piston is at TDC
of compression stroke. Leaving secondary wires attached,
remove distributor cap and set aside.
Note installed position of distributor and distributor rotor.
Unplug distributor electrical connector. Remove distbutor
housing and set aside. Courtesy of Mitsubishi Motor Sales of America
Disconnect ignition power transistor and ignition coil con- Fig. 7: Adjusting Balance Shaft Timing Belt Tensioner
nector. Remove ignition coil. Remove timing belt upper
cover.
Holding crankshaft stationary, remove crankshaft pulley bolt.
Remove crankshaft pulley. Remove distributor bracket. See
Fig. 4.
Remove timing belt lower cover. Align timing mark on cam-
shaft sprocket with timing mark on cylinder head. See Fig.
2.
Loosen timing belt tensioner center bolt, and remove
tensioner toward water pump. Tighten center bolt to secure
tensioner. If reusing old timing belt, mark belt with arrow to
indicate original direction of rotation. Remove timing belt.
Remove timing belt auto tensioner.
To remove balance shaft timing belt, remove left balance
shaft access plug from cylinder block. Insert .31" (8.0 mm)
diameter Phillips screwdriver to block left silent shaft. See Fig. 8: Installing Crankshaft Sensing Blade
Fig. 3. Ensure screwdriver can be inserted at least 2.36 (Eclipse & Galant)
(59.9 mm). Remove screwdriver if it cannot be inserted at
least 2.36" (59.9 mm). Rotate balance shaft one revolution Check timing belt and balance shaft belt tensioner pulleys
and realign timing mark. for worn bearings. Replace as necessary.
If reusing old balance shaft timing belt, mark belt with ar- Check timing belt auto tensioner for leaks. Hold timing belt
row to indicate rotation direction. Loosen balance shaft auto tensioner upright. Measure rod protrusion above edge
tensioner pulley center bolt. Remove balance shaft timing of housing. See Fig. 6. Length should be .47 (12 mm).
belt. 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
TIMING BELT INSPECTION auto tensioner.
Inspect back of belt for being hard, non-elastic and having
a glossy surface. Check for rounded sides on belt. Sides of
belt should be straight and clear-cut. Flaking, peeling, crack- Eclipse & Galant:
ing rubber from canvas also indicates belt warrants re- Align crankshaft rear sprocket and balance shaft sprocket
placement. Cracks are most evident at base of tooth. timing marks. See Fig. 5. Install balance shaft timing belt. If
Abnormal wear most often occurs on load side of tooth. reusing old belt, install in original direction of rotation.
Fluffy canvas, unclear canvas texture, belt color changed to
White from rubber missing, reduced tooth width or a miss-
ing tooth warrant belt replacement.

428 MITSUBISHI
Move the balance shaft tensioner pulley so that the center
of the tensioner pulley is above and to the left of the
centerline of the tensioner center bolt. See Fig. 7. The
tensioner pulley flange should face toward the front of the
engine.
Using your hand, place pressure on balance shaft tensioner
pulley in direction of balance shaft timing belt. Loosen bal-
ance shaft tensioner pulley center bolt. Ensure balance
shaft timing belt is taut (no slack), and tighten balance shaft
tensioner pulley center bolt.
NOTE: When tightening balance shaft tensioner pulley center

bolt, ensure tensioner pulley shaft does not rotate with bolt. This
will place excessive tension on belt.
Press balance shaft belt on side opposite tensioner to check
belt deflection. See Fig. 5. Balance shaft belt deflection
should be .20-.28" (5.0-7.0 mm). Adjust as necessary.
Install crankshaft sensing blade in correct direction. See
Fig. 8. Install crankshaft sprocket. Apply engine oil to threads
of crankshaft sprocket bolt. Install and tighten bolt to speci- Courtesy of Mitsubishi Motor Sales of America
fication. See TORQUE SPECIFICATIONS. Fig. 11: Timing Belt Cover Bolt Installation Guide
NOTE: DO NOT remove Phillips screwdriver from side of engine Remove locking pin from auto tensioner. Remove set screw.
block until camshaft timing belt is installed. Turn crankshaft 2 revolutions clockwise. Align all timing
Using a soft-jawed vise, SLOWLY compress the timing belt marks. Let vehicle sit for 15 minutes. Measure auto
auto tensioner push rod until rod pin hole aligns with pin tensioner rod protrusion between auto tensioner housing
hole in tensioner body. Insert a locking pin through tensioner and point where it contacts tensioner arm. Protrusion
body and tensioner push rod pin holes to lock auto tensioner should be .150-.177 (3.8-4.5 mm). If protrusion is not as
in position. Install auto tensioner on engine with locking specified, repeat timing belt tensioning procedure.
pin in place. Install timing belt covers. Ensure bolts are installed in origi-
Ensure all timing marks are still aligned. See Fig. 2. Install nal locations. See Fig. 11. Continue installation in reverse
timing belt on engine. If reusing old timing belt, ensure belt order of removal procedure. Adjust drive belts to proper
is installed in original direction of rotation. Make sure there tension. See page A-60 for belt tension ranges.
is no slack in timing belt between sprockets. Montero Sport:
Set the timing belt tensioner pulley so that pin holes are at Align crankshaft sprocket and balance shaft sprocket tim-
the bottom of the pulley. See Fig. 9. Press tensioner pulley ing marks. See Fig. 5. Install balance shaft timing belt. If
lightly against the timing belt. Temporarily tighten tensioner reusing old belt, install in original direction of rotation.
pulley center bolt. Move the balance shaft tensioner pulley so that the center
of the tensioner pulley is above and to the left of the
CAUTION: To prevent breaking auto tensioner push rod, turn centerline of the tensioner center bolt. See Fig. 7. The
Set Screw (MD998738) by hand only. tensioner pulley flange should face toward the front of the
engine.
Install Set Screw (MD998738) into rear timing belt cover. Using your hand, place pressure on balance shaft tensioner
See Fig. 9. Screw in set screw until tensioner bracket arm pulley in direction of balance shaft timing belt. Loosen bal-
makes contact with auto tensioner push rod end. ance shaft tensioner pulley center bolt. Ensure balance
Remove Phillips screwdriver from engine block and install shaft timing belt is taut (no slack), and tighten balance shaft
plug. To adjust timing belt tension, turn crankshaft 1/4 revo- tensioner pulley center bolt.
lution counterclockwise. Turn crankshaft clockwise until all
timing marks are aligned. NOTE: When tightening balance shaft tensioner pulley center
Loosen the tensioner pulley center bolt. Install Adapter bolt, ensure tensioner pulley shaft does not rotate with bolt. This
(MD998767) and torque wrench on tensioner pulley. See will place excessive tension on belt.
Fig. 10. Apply 31 INCH lbs. (3.5 N.m) of torque while tight-
ening tensioner pulley center bolt to specification. See
Press balance shaft belt on side opposite tensioner to check
belt deflection. See Fig. 5. Balance shaft belt deflection
TORQUE SPECIFICATIONS. DO NOT let tensioner pulley
should be .20-.28" (5.0-7.0 mm). Adjust as necessary.
turn while tightening center bolt.
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.
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.
MITSUBISHI 429

TORQUE SPECIFICATIONS (ECLIPSE & GALANT)
NOTE: DO NOT remove Phillips screwdriver from side of engine
block until camshaft timing belt is installed. Application Ft. Lbs. (N.m)
Set the timing belt tensioner pulley so that pin holes are at Camshaft Sprocket Bolt .............................................. 65 (90)
the bottom of the pulley. See Fig. 9. Press tensioner pulley
Crankshaft Drive Belt Pulley Bolt ................................ 18 (25)
lightly against the timing belt. Temporarily tighten tensioner Crankshaft Sprocket Bolt ............................ 1 80-94 (108-127)
pulley center bolt. Drive Belt Tensioner Pulley Bracket Bolt .............. 17-20 (23-26)
CAUTION: To prevent breaking auto tensioner push rod, turn Engine Upper Mount
Set Screw (MD998738) by hand only. Mount-To-Engine Bracket Nut/Bolt ................................ 49 (67)
Mount-To-Body Through Bolt ............................ 71-85 (98-118)
Install Set Screw (MD998738) into rear timing belt cover. Power Steering Pump Pulley Bolt .................................. 45 (61)
See Fig. 9. Screw in set screw until tensioner bracket arm Tensioner Pulley Center Bolt
makes contact with auto tensioner push rod end. Balance Shaft Belt Pulley ............................................ 14 (19)
Remove Phillips screwdriver from engine block and install Camshaft Belt Pulley ................................................... 35 (48)
plug. To adjust timing belt tension, turn crankshaft 1/4 revo- Water Pump Bolt ........................................................ 10 (14)
lution counterclockwise. Turn crankshaft clockwise until all INCH Lbs. (N.m)
timing marks are aligned. Timing Belt Cover Bolt
Loosen the tensioner pulley center bolt. Install Adapter 6 mm (Except Flange Bolts) .................................... 78 (8.8)
(MD998767) and torque wrench on tensioner pulley. See 6 mm (Flanged Bolt) ...................................... 89-106 (10-12)
Fig. 10. Apply 31 INCH lbs. (3.5 N.m) of torque while tight- 8 mm Bolt .................................................................. 120 (14)
ening tensioner pulley center bolt to specification. See Water Pump Pulley Bolt ........................................ 71-80 (8-9)
TORQUE SPECIFICATIONS. DO NOT let tensioner pulley 1
Apply engine oil to bolt threads.
turn while tightening center bolt.
Remove locking pin from auto tensioner. Remove set screw.
TORQUE SPECIFICATIONS (MONTERO SPORT)
Turn crankshaft 2 revolutions clockwise. Align all timing
marks. Let vehicle sit for 15 minutes. Measure auto Application Ft. Lbs. (N.m)
tensioner rod protrusion between auto tensioner housing Auto Tensioner Bolt .................................................... 18 (24)
and point where it contacts tensioner arm. See Fig. 12, Camshaft Sprocket Bolt .............................................. 65 (90)
Dimension A. Protrusion should be .150-.177 (3.8-4.5 Crankshaft Drive Belt Pulley Bolt ................................ 18 (25)
mm). If protrusion is not as specified, repeat timing belt Distributor Bracket Bolt (M6 x 18 mm) ......................... 17 (24)
tensioning procedure. Tensioner Pulley Center Bolt
Install timing belt lower cover, distributor bracket, and tim- Balance Shaft Belt Pulley ............................................ 14 (19)
ing belt upper cover. Install distributor, distributor cap, and Camshaft Belt Pulley ................................................... 35 (48)
ignition coil. Water Pump Bolt ........................................................ 10 (14)
Install cooling fan clutch, pulley, fan shroud, and upper INCH Lbs. (N.m)
radiator hose. Continue installation in reverse order of re- Cooling Fan Clutch-To-Stud Nut ....................... 89-106 (10-12)
moval procedure. Fill and bleed cooling system. Adjust ig- Distributor Bracket Bolt
nition timing. Except M6 x 18 mm ..................................................... 97 (11)
Distributor Housing Hold-Down Bolt ........................... 115 (13)
Timing Belt Cover
Lower Cover Bolt ..................................................... 78 (8.8)
Upper Cover Bolt ......................................................... 97 (11)
Water Pump Pulley Bolt ............................................ 117 (13)

430 MITSUBISHI
3.0L V6 SOHC, 12-Valve Engine
TIMING BELT APPLICATION On all models, remove engine support bracket. Remove
crankshaft pulley. Remove timing belt covers. Remove
Belt flange from crankshaft. See Fig. 3. Rotate crankshaft to
Labor Component Part align all timing marks. See Fig. 4. Loosen belt tensioner
Application Time 1 Kit No. No. bolt, and rotate belt tensioner counterclockwise to release
3.0L V6 SOHC belt tension.
Diamante If reusing timing belt, mark belt to indicate direction of belt
rotation. Loosen tensioner bolt. Pry tensioner counterclock-
1992-96 .......... 3.8 Hours ... TCK139 .......... T139 wise to relieve belt tension. While holding tensioner, tighten
Galant tensioner bolt. Remove timing belt.
1988 ............... 3.8 Hrs. ...... TCK139 .......... T139 Galant:
Montero (12-Valve Engine) Disconnect negative battery cable. Remove all accessory
1989-94 .......... 3.5 Hrs. ...... TCK139 .......... T139 drive belts. Disconnect connector and pressure hoses at
Pickup (4WD) power steering pump. Remove power steering pump with
1990-94 .......... 3.5 Hrs. ...... TCK139 .......... T139 return hose connected. Remove through-bolt from front
engine mount.
Sigma
1989-90 .......... 3.8 Hrs. ...... TCK139 .......... T139 CAUTION: Apply spray lubricant on reamer bolt during removal
3000GT as bolt is sometimes seized in engine support.
1997-98 .......... 3.4 Hours ... TCK139 .......... T139 Support engine and remove front engine mount. Remove
1
- With Air Cond. add .2 hours. engine mount bracket bolts in sequence. Lubricate reamer
With Pwr. Strng. add .2 hours. bolt with penetrating oil before and during removal. See
Fig. 2.
Remove A/C tensioner pulley and mounting bracket. Re-
NOTE: A timing belt component kit is available for move No. 1 upper outer cover and gaskets. See Fig. 3.
this application. See page I for information on component Remove engine support bracket bolts in proper sequence.
kits. See Fig. 2. Remove engine support bracket.
be replaced at 60,000 miles.

TIMING BELT REMOVAL
Diamante: Fig. 1: Locating Timing Belt & Sprocket
Disconnect negative battery cable. Remove left front and
left side splash shields. Using engine hoist, lift engine just Remove cover cap and No. 2 upper outer cover and gas-
enough to remove weight from engine mounts. Remove kets. Remove under cover. Using Holder (MB990767-01)
drive belts. Remove A/C tensioner pulley and bracket. and Adapter Bolts (MD998719) or equivalent, remove crank-
shaft pulley.
CAUTION: Apply spray lubricant on reamer bolt during removal Remove lower outer cover, gaskets and flange. See Fig. 3.
as bolt is sometimes seized in engine support. Rotate crankshaft and align all timing marks. See Fig. 4.
Loosen belt tensioner bolt and rotate belt tensioner coun-
Remove engine mount bracket bolts in sequence. Lubri- terclockwise to release belt tension.
cate reamer bolt with penetrating oil before and during re- If timing belt is to be reused, place arrow on belt to indicate
moval. See Fig. 2. Remove power steering pump, leaving direction of belt rotation. Remove timing belt and belt
hoses attached. On 1996 models, remove crankshaft po- tensioner.
sition sensor and right oxygen sensor. Remove crankshaft
pulley. On vehicles with ABS, remove overflow tank and
bracket.
MITSUBISHI 431
3.0L V6 SOHC, 12-Valve Engine (Cont.)
Montero & Pickup:

Disconnect upper radiator hose. Remove upper radiator
shroud. Remove cooling fan and fan clutch assembly. Re-
move cooling fan pulley. Remove all accessory drive belts.
Remove power steering pump with pressure and return
hoses connected and set aside.
Remove power steering pump brackets. Remove A/C
tensioner pulley and mounting bracket. Remove A/C com-
pressor with hoses connected and mounting bracket. Re-
Courtesy of Mitsubishi Motor Sales of America move cooling fan bracket assembly. Remove timing belt
Fig. 2: Removal & Installation Of Engine Support Bracket No. 1 upper outer cover and gaskets. See Fig. 3.
Remove timing belt No. 2 upper outer cover and gaskets.
Remove timing belt lower outer cover and gaskets. Using
Holder (MB998747) or equivalent, and a used V belt, re-
move crankshaft pulley bolt. Remove crankshaft pulley.
NOTE: V belt will be damaged by tool. DO NOT use engine

V belt to hold crankshaft pulley unless belt is to be replaced.
Remove flange. See Fig. 3. Rotate crankshaft and align all
timing marks. See Fig. 4. Loosen belt tensioner bolt and
rotate belt tensioner counterclockwise to release belt ten-
sion.
direction of belt rotation. Remove timing belt and belt
tensioner.
Sigma:
drive belts. Disconnect connector and pressure hose at
power steering pump. Remove power steering pump with
return hose connected. Support engine. Remove through-
bolt from front engine mount. Remove front engine mount.
NOTE: Apply spray lubricant on reamer bolt during removal

as bolt is sometimes seized in engine support bracket.
Remove A/C tensioner pulley and mounting bracket. Re-
move timing belt No. 1 upper outer cover and gaskets. See
Fig. 3. Remove engine support bracket bolts in proper se-
quence. See Fig. 2. Remove engine support bracket.
Remove cover cap and timing belt No. 2 upper outer cover
and gaskets. Remove under cover. Using Holder
(MB990767-01) and Adapter Bolts (MD998719) or equiva-
Fig. 3: Exploded View Of Timing Belt Components lent, remove crankshaft pulley.
Remove lower outer cover, gaskets and flange. See Fig. 3.
Rotate crankshaft and align all timing marks. See Fig. 4.
Loosen belt tensioner bolt and rotate belt tensioner coun-
terclockwise to release belt tension. If timing belt is to be
reused, place arrow on belt to indicate rotation direction.
432 MITSUBISHI
3000GT: Install flange onto crankshaft. Loosen belt tensioner bolts
Remove engine lower splash shields. Remove cruise con- slightly, and allow tensioner to apply belt tension. Using
trol actuator (if equipped) from right side fenderwell. Crankshaft Socket (MD998716-01) or equivalent, rotate
Remove all drive belts. Remove A/C drive belt tensioner crankshaft 2 revolutions clockwise. DO NOT rotate coun-
pulley assembly. Remove power steering and generator terclockwise. Realign all timing marks. Tighten belt
drive belt tensioner pulley bracket. tensioner bolts to specification. Using belt tension gauge,
Place floor jack under engine to support weight of engine. measure belt tension halfway between crankshaft sprocket
Remove engine-to-body mount from timing belt end of en- and camshaft sprocket on side opposite belt tensioner.
gine. Belt tension should be 44-66 Ibs. (20-30 kg).
Unplug power steering pump pressure switch electrical Install proper length bolts in timing belt covers. See Fig. 6.
connector. Remove power steering pump with hoses at- Tighten all bolts and nuts to specification. See TORQUE
tached and set out of way. SPECIFICATIONS.
Remove engine support bracket bolts, in specified se-
quence, from front of engine. Fig. 2. Note position of reamer NOTE: Engine support bracket reamer bolt must be tightened
bolt for reassembly reference. slowly while spraying lubricant on bolt.
CAUTION: Reamer bolt may be heat-seized to engine support

Install engine support bracket and tighten bolts in sequence.
bracket. Reamer bolt has R marking on bolt head.
See Fig. 2. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. To install remaining components, re-
Holding crankshaft stationary, remove crankshaft pulley verse removal procedure. Adjust drive belts to proper ten-
bolt. Remove crankshaft pulley. sion. See page A-60 for belt tension ranges.
Remove all timing belt covers. See Fig. 6. Noting position Galant:
for reassembly reference, remove front flange from crank- Install belt tensioner and spring. Ensure spring is secured
shaft. See Fig. 7. on pin of water pump and engaged in hole of belt tensioner
Rotate crankshaft to align all timing marks. See Fig. 4. with hook of spring pointing away from cylinder block.
Loosen belt tensioner bolt. Rotate belt tensioner pulley Rotate belt tensioner counterclockwise as far as possible
counterclockwise to relieve belt tension. Tighten tensioner and temporarily tighten bolt. Align all timing marks with No.
pulley bolt. 1 cylinder at TDC of compression stroke. See Fig. 4.
If reusing timing belt, place arrow on belt to indicate belt Install timing belt. Ensure belt is installed in original direc-
running direction. Remove timing belt. tion of rotation and all timing marks are aligned. Install
TIMING BELT INSPECTION flange on crankshaft. Loosen belt tensioner bolts slightly
All Models: Using Crankshaft Socket (MD998716) or equivalent, rotate
Inspect timing belt for wear on edges of drive teeth. Inspect crankshaft 2 revolutions clockwise. DO NOT rotate coun-
belt for signs of oil contamination, cracks, separation, worn terclockwise. Realign all timing marks. Tighten belt
or missing teeth, or hardened black surface. Replace belt tensioner bolts to specification. Using belt tension gauge,
if worn, damaged or contaminated. Inspect belt tensioner measure belt tension half way between crankshaft sprocket
for smooth rotation. Replace parts, if defective. and camshaft sprocket on side opposite belt tensioner.
Diamante: CAUTION: Engine support bracket reamer bolt must be tightened
slowly while spraying lubricant on bolt.
Install timing belt onto crankshaft sprocket, then around
left camshaft sprocket, with all slack removed from tension Belt tension should be 57.3-83.8 Ibs. (26-38 kg). To install
side of belt. Route timing belt onto water pump pulley, right remaining components, reverse removal procedure. Install
camshaft sprocket, and tensioner. Apply torque to rear cam- proper length bolts in timing belt covers and engine sup-
shaft pulley to tighten belt. Ensure all timing marks are port bracket. See Figs. 2 and 6. Tighten bolts to specifica-
aligned. tion. See TORQUE SPECIFICATIONS. Adjust drive belts to
Montero & Pickup:
on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing away from cylinder block.
Rotate belt tensioner counterclockwise as far as possible
and temporarily tighten bolt. Align all timing marks with No.
1 cylinder at TDC of compression stroke. See Fig. 4.
Install timing belt on crankshaft sprocket and then left cam-
shaft sprocket with all slack removed from tension side of
belt. Route timing belt onto water pump pulley, right cam-
shaft sprocket and tensioner. Remove any slack from belt
by rotating left and then right camshaft sprockets counter-
clockwise. Ensure all timing marks are aligned. Install
flange on crankshaft. Loosen belt tensioner bolts slightly
Using Crankshaft Socket (MD998716), rotate crankshaft 2
revolutions clockwise. DO NOT rotate counterclockwise.
Fig. 5: Identifying Timing Belt Cover Bolt Lengths (Pickup) Realign all timing marks. Tighten belt tensioner bolts to
specification. Using belt tension gauge, measure belt ten-
sion halfway between crankshaft sprocket and camshaft
sprocket on side opposite belt tensioner.
MITSUBISHI 433

Belt tension should be 57.3-83.8 Ibs. (26-38 kg). To install Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install
remaining components, reverse removal procedure. Install remaining components, reverse removal procedure. Install
proper length bolts in timing belt covers. See Fig. 5. Tighten proper length bolts in timing belt covers. See Fig. 6.
just drive belts to proper tension. See page ...........for belt NOTE: Engine support bracket reamer bolt must be tightened
tension ranges. slowly while spraying lubricant on bolt.
CAUTION: The sealing washer under the cooling system air bleed
Install engine support bracket . Tighten bolts in sequence
bolt was reduced to .85mm from 2.0mm. The .85 mm washer CANNOT
to specification. See Fig. 2. See TORQUE SPECIFICATIONS.
be reused. Replace washer if bolt is loosened or removed. This Adjust drive belts to proper tension. See page A-60 for belt
information is from Mitsubishi technical service bulletin 96- tension ranges.
00-003; February, 1996. 3000GT:
Ensure all timing belt marks are aligned. See Fig. 4. If not
Before refilling cooling system, remove air bleed bolt on already done, loosen tensioner center bolt. Turn tensioner
top of thermostat housing. Refill cooling system with 50/50 counterclockwise. Temporarily tighten tensioner center bolt.
mix of water and coolant until it overflows from air bleed Install timing belt on crankshaft sprocket, left hand cam-
bolt hole. Install air bleed bolt with new .85 mm washer (if shaft sprocket (side away from tensioner pulley), water
equipped). pump pulley, right hand camshaft sprocket, and timing belt
Start engine and run to normal operating temperature. Race tensioner. Apply counterclockwise force to right hand cam-
engine to 3000 RPM several times. Stop engine. After en-
gine cools, refill radiator.
Sigma:
on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing away from cylinder block.
Rotate belt tensioner counterclockwise as far as possible
and temporarily tighten bolt. Align all timing marks with No.1
cylinder at TDC of compression stroke. See Fig. 4.
Install timing belt on crankshaft sprocket, rear head cam-
shaft sprocket, water pump pulley, front head sprocket and
timing belt tensioner. Ensure belt is installed in original
direction of rotation and all timing marks are aligned on
crankshaft. Loosen belt tensioner bolts slightly and allow
tensioner to apply belt tension.
Using Crankshaft Socket (MD998716) or equivalent, rotate
crankshaft 2 revolutions clockwise. DO NOT rotate coun-
terclockwise. Realign all timing marks. Tighten belt
tensioner bolts to specification. Using belt tension gauge,
measure belt tension halfway between crankshaft sprocket
and camshaft sprocket on side opposite belt tensioner.

(3000GT SOHC)
Fig. 8: Identifying Timing Belt Cover Bolts (3000GT)
Fig. 6: Timing Belt Cover Bolt Length Identification

(Diamante, Galant & Sigma)
434 MITSUBISHI
shaft sprocket (camshaft closest to firewall) to remove any TORQUE SPECIFICATIONS (MONTERO & PICKUP)
belt slack. Ensure all timing marks are still aligned.
Install front flange on crankshaft. Loosen timing belt
tensioner pulley center bolt. Allow the tensioner spring
force to tension timing belt. Turn crankshaft 2 revolutions
Montero .................................................. 108-116 (146-157)
clockwise. DO NOT turn counterclockwise.
Pickup .................................................... 130-137 (176-186)
Align all timing belt marks. Final tighten tensioner pulley
Left Engine Support Bracket Bolt ...................... 15-21 (20-30)
center bolt. Using a belt tension gauge, measure timing
Rear Engine Support Bracket Bolt .................... 13-18 (18-25)
belt tension midway between crankshaft sprocket and left
Right Engine Support Bracket Bolt
hand camshaft sprocket (side opposite belt tensioner pul-
10 X 22 mm .................................................... 25-36 (34-49)
ley). Belt tension should be 46.3-68.3 lbs. (21-31 kg).
10 X 40 mm .................................................... 25-36 (34-49)
Install flange onto crankshaft. Loosen belt tensioner bolts
12 X 22 mm .................................................... 47-61 (64-83)
slightly, and allow tensioner to apply belt tension.
12 X 32 mm .................................................... 47-61 (64-83)
Install timing belt covers. Install timing belt cover bolts in
correct locations. See Fig. 8.
Water Pump Bolt .............................................. 14-20 (19-27)
NOTE: When installing engine support bracket reamer bolt, tighten INCH Lbs. (N.m)
it slowly while spraying lubricant on reamer bolt. Reamer bolt Timing Belt Cover Bolt ...................................... 84-108 (9-12)
has R marking on bolt head. Timing Belt Cover Cap Bolt .............................. 84-108 (9-12)
Install crankshaft pulley. Tighten crankshaft pulley bolt to TORQUE SPECIFICATIONS (SIGMA)
specification. See TORQUE SPECIFICATIONS. Install en-
gine support bracket on engine block. Install bolts in cor-
rect location, and tighten in sequence. See Fig. 2.
To install remaining components, reverse removal proce- Engine Mount Bracket Nut ................................ 44-57 (60-77)
10 X 40 mm .................................................... 25-36 (34-49)
TORQUE SPECIFICATIONS (DIAMANTE) 10 X 53 mm .................................................... 47-54 (64-73)
Application Ft. Lbs. (N.m) 12 X 56 mm
Automatic Tensioner Bolt ............................................ 17 (23) 1989 ........................................................ 76-83 (103-113)
Camshaft Sprocket Bolt .............................................. 66 (90) 1990 ............................................................ 47-61 (65-85)
Crankshaft Pulley Bolt Timing Belt Tensioner Bolt ............................... 16-21 (22-29)
1991 ....................................................... 108-116 (146-157) Water Pump Bolt .............................................. 14-20 (19-27)
1994-92 ................................................................ 136 (185) INCH Lbs. (N.m)
Engine Support Bracket Bolt Timing Belt Cover Bolt .................................... 90-102 (10-12)
10 X 40 mm .................................................... 47-54 (64-73)
Except 10 X 40 mm ..................................... 76-83 (103-113) TORQUE SPECIFICATIONS (3000GT)
Timing Belt Tensioner Arm Bolt .................................. 31 (42) Application Ft. Lbs. (N.m)
Timing Belt Tensioner Pulley Nut ............................... 36 (49) Camshaft Sprocket Bolt .............................................. 66 (90)
Water Pump Bolt ........................................................ 17 (23) Crankshaft Pulley Bolt .............................. 108-116 (150-160)
INCH Lbs. (N.m) Engine Mount
Timing Belt Cover Bolt ...................................... 84-108 (9-12) To-Body Through-Bolt ................................................. 51 (70)
To-Engine Support Bracket ......................... 72-87 (100-120)
TORQUE SPECIFICATIONS (GALANT) Engine Support Bracket-To-Engine Bolt 1
Application Ft. Lbs. (N.m) M10 Bolt ..................................................................... 51 (70)
Camshaft Sprocket Bolt .................................... 58-72 (79-98) M12 Bolt ................................................................... 80 (110)
Crankshaft Pulley Bolt .............................. 108-116 (146-157) Generator/Power Steering Tensioner Pulley
Engine Support Bracket Bolt Bracket Bolt ................................................................. 30 (42)
10 X 40 mm .................................................... 25-36 (34-49) Power Steering Pump Mount Bolt
10 X 53 mm .................................................... 47-54 (64-73) Short Bolt ................................................................... 29 (40)
12 X 56 mm ................................................ 76-83 (103-113) Long, Shoulder Bolt .................................................... 16 (22)
Timing Belt Tensioner Bolt ............................... 16-21 (22-29) Timing Belt Tensioner Pulley Center Bolt ......... 16-22 (22-30)
Water Pump Bolt .............................................. 14-19 (19-26) Water Pump Bolt ........................................................ 17 (23)
INCH Lbs. (N.m) INCH Lbs. (N.m)
Timing Belt Cover Bolt ...................................... 84-108 (9-12) Timing Belt Cover Bolt .................................... 89-106 (10-12)
Timing Belt Cover Cap Bolt .............................. 84-108 (9-12) 1
Spray lubricant on reamer bolt while tightening.
MITSUBISHI 435
*3.0L V6 SOHC, 24 Valve Engine

3.0L V6 SOHC
Eclipse
2000-01 ................ 1 3.0 Hours .................... T259
Galant
1999-01 ................ 1 2.4 Hours .................... T259
Montero (24-Valve Engine)
1995-96 ................ 1 3.5 Hours .................... T259
Montero Sport
1997-01 ................ 1 3.5 Hours .................... T259
1
- With Air Cond. add .2 hours for Eclipse, and .6
hours for Galant and Montero Sport.
be replaced every 60,000 miles except in California. In Califor- Courtesy of Mitsubishi Motor Sales of America
nia, timing belt replacement is recommended, but not required, Fig. 2: Aligning Timing Marks (Hydraulic Auto-Tensioner)
miles, unless previously changed. *NOTE: This application is an interference engine.
be replaced every 60,000 miles except in California, Connecti- See page A-59 for interference engine cautions.
sachusetts, timing belt replacement is recommended, but not REMOVAL & INSTALLATION
at 100,000 miles, unless previously changed. TIMING BELT REMOVAL
For 2001 models, the manufacturer recommends the belt be Eclipse & Galant:
replaced every 60,000 miles except in California, Massachu- Disconnect negative battery cable. Raise and support ve-
setts and Vermont. In California, Massachusetts and Vermont, hicle. Remove engine splash shield from right wheelwell.
timing belt replacement is recommended, but not required, at Remove generator and A/C compressor drive belt. Remove
60,000 miles. In these states, replace timing belt at 100,000 dipstick tube from front of engine. Remove generator with
miles, unless previously changed. wires attached and secure out of way. Remove power steer-
ing pump drive belt.
Lower vehicle. Support weight of engine with jack. Remove
engine mount from timing belt end of engine. Holding crank-
shaft pulley stationary, remove crankshaft pulley bolt. Re-
move crankshaft pulley.
Remove engine support bracket from front of engine.
CAUTION: Always turn crankshaft in clockwise direction (as viewed

from front of engine).
direction of belt rotation. Turn crankshaft clockwise to align
camshaft and crankshaft timing marks. See Fig. 2. Loosen
center bolt of timing belt tensioner pulley, and remove tim-
ing belt. Remove timing belt auto-tensioner from engine
block.
Montero & Montero Sport:
Disconnect upper radiator hose from engine. Remove up-
per radiator shroud. Loosen cooling fan clutch-to-pulley
nuts. Relieve tension on accessory drive belts.
Remove cooling fan and fan clutch assembly. Remove cool-
ing fan pulley. Remove all accessory drive belts. Remove
generator with wires attached and secure out of way.
Remove power steering pump with hoses connected, and
set aside. Remove A/C compressor with hoses connected,
Fig. 1: Exploded View Of Timing Belt Components (Galant) and set aside. Remove A/C compressor bracket. Remove
accessory mount assembly. See Fig. 4.
436 MITSUBISHI
*3.0L V6 SOHC, 24 Valve Engine (Cont.)
direction of belt rotation. Remove timing belt. Remove tim-
ing belt auto-tensioner.
All Models:
belt for signs of oil contamination, cracks, separation, worn
or missing teeth, or hardened black surface. Replace belt
if worn, damaged or contaminated. Inspect belt tensioner
pulley for smooth rotation. Replace if defective.
Check timing belt auto -tensioner for leaks. Hold timing
belt auto-tensioner upright. Measure rod protrusion above
edge of housing. See Fig. 5. Length should be .47 (12
mm). Apply 22-44 lbs. (98-196 N) of force to end of rod. If
auto tensioner rod moves more than 0.39 (1 mm), replace
the auto-tensioner.
Eclipse & Galant:
Place auto-tensioner in soft-jawed vise to SLOWLY com-
press the push rod. If there is a plug at the base of the auto-
tensioner body, place flat washer around plug so it will not
contact vise jaw.
CAUTION: Never compress the auto-tensioner too fast or the push

rod will be damaged.
Courtesy of Mitsubishi Motor Sales of America Slowly compress auto-tensioner push rod until holes in
Fig. 3: Exploded View Of Timing Belt Components push rod and auto-tensioner housing are aligned. Insert a
(Montero Sport) locking pin into the alignment holes. Install auto-tensioner
on engine.
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.
Loosen the tensioner pulley center bolt. Rotate tensioner
pulley against timing belt. Temporarily tighten tensioner
pulley center bolt. Turn crankshaft 1/4 turn counterclock-
wise. Turn crankshaft 1/4 turn clockwise. Ensure all timing
belt marks are still aligned.
For 1999-00 models, loosen tensioner pulley center bolt.
Position tensioner pin holes at BOTTOM of tensioner. In-
stall Adapter (MD998767) on tensioner pulley. See Fig. 6. U
se a torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque
(counterclockwise direction) to tensioner pulley. Tighten
tensioner center bolt to specification while holding tensioner
stationary.
For 2001 models, loosen tensioner pulley center bolt. Po-
sition tensioner pin holes at TOP of tensioner. Install
Adapter (MD998767) on tensioner pulley. See Fig. 8. Us e
a torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque
(clockwise direction) to tensioner pulley. Tighten tensioner
Courtesy of Mitsubishi Motor Sales of America center bolt to specification while holding tensioner station-
Fig. 4: Exploded View Of Accessory Mount Assembly ary.
(Montero & Montero Sport) On all models, remove locking pin from auto-tensioner.
Turn crankshaft 2 revolutions clockwise and align all tim-
Remove upper timing belt upper cover. See Fig. 3. Holding ing marks. DO NOT rotate counterclockwise.
crankshaft pulley stationary, remove crankshaft pulley bolt. Wait for at least 5 minutes, then check auto-tensioner push
Remove crankshaft pulley. rod protrusion. To check push rod protrusion, measure
clearance between body of auto-tensioner and bottom of
CAUTION: Always turn crankshaft in clockwise direction (as viewed tensioner pulley bracket arm. Clearance should be 0.15-
from front of engine). 0.20 (3.8-5.0 mm). If protrusion is not correct, repeat tim-
ing belt tensioning procedure.
Remove lower timing belt cover. Turn crankshaft clockwise
to align camshaft and crankshaft timing marks. See Fig. 2.
Loosen belt tensioner pulley center bolt.
MITSUBISHI 437

Install power steering pump. Install A/C compresor bracket
and A/C compressor. Install water pump pulley and cooling
fan. To install remaining components, reverse removal pro-
cedure. Adjust drive belts to proper tension. See page A-60
CAUTION: The sealing washer under the cooling system air bleed
bolt was reduced to .85mm from 2.0mm. The .85 mm washer CANNOT
be reused. Replace washer if bolt is loosened or removed. This
information is from Mitsubishi technical service bulletin 96-
00-003; February, 1996.
Before refilling cooling system, remove air bleed bolt on
Courtesy of Mitsubishi Motor Sales of America top of thermostat housing. Refill cooling system with 50/50
Fig. 5: Checking Timing Belt Auto-Tensioner Movement mix of water and coolant until it overflows from air bleed
bolt hole. Install air bleed bolt with new .85 mm washer (if
Install engine support bracket on engine block. Tighten top equipped).
bolt first, then working in a counterclockwise direction, Start engine and run to normal operating temperature. Race
tighten the remaining bolts. See Fig. 7. Install timing belt engine to 3000 RPM several times. Stop engine. After en-
covers. Install crankshaft pulley. Apply engine oil to crank- gine cools, refill radiator.
shaft pulley bolt, then tighten bolt to specification. See
TORQUE SPECIFICATIONS (ECLIPSE & GALANT)
To install remaining components, reverse removal proce- Application Ft. Lbs. (N.m)
dure. Adjust drive belts to proper tension. See page A-60 Auto-Tensioner-To-Engine Block Bolt ............................ 18 (24)
for belt tension ranges. Camshaft Sprocket Bolt .............................................. 65 (88)
Montero & Montero Sport: Crankshaft Pulley Bolt ............................. 1 131-137 (177-186)
Place auto-tensioner in soft-jawed vise to SLOWLY com- Dipstick Tube Bolt ......................................................... 10 (14)
press the push rod. If there is a plug at the base of the auto- Engine Mount
tensioner body, place flat washer around plug so it will not To-Engine Support Bracket Nut/Bolt ......................... 63 (86)
contact vise jaw. To-Body Through Bolt ................................................ 2 61 (83)
Engine Support Bracket-to-Engine Bolt ......................... 32 (44)
CAUTION: Never compress the auto-tensioner too fast or the push Generator Pivot Bolt ....................................................... 32 (44)
rod will be damaged. Generator Top Bolt ........................................................ 15 (21)
SLOWLY compress auto-tensioner push rod until holes in Power Steering Pump Belt Tensioner Bolt .................... 32 (44)
push rod and auto-tensioner housing are aligned. Insert a Timing Belt Tensioner Center Bolt .............................. 35 (48)
locking pin into the alignment holes. Install auto-tensioner Timing Belt Tensioner Arm Pivot Bolt ............................ 32 (44)
on engine. Water Pump Bolt
Ensure all timing marks are still aligned. See Fig. 2. Install M8 Bolt .......................................................................... 17 (23)
timing belt on crankshaft sprocket, idler pulley, left bank M10 Bolt ....................................................................... 30 (41)
camshaft sprocket, water pump pulley, right bank camshaft INCH Lbs. (N.m)
sprocket, and tensioner pulley. Take all slack out of timing Timing Belt Cover Bolt .............................................. 106 (12)
belt. 1
Apply engine oil to bolt threads before installation.
Loosen the tensioner pulley center bolt. Rotate tensioner 2
Final tighten bolt with full weight of engine on mount.
pulley against timing belt. Temporarily tighten tensioner
pulley center bolt. Turn crankshaft 1/4 turn counterclock-
wise. Turn crankshaft 1/4 turn clockwise. Ensure all timing
belt marks are still aligned.
Loosen tensioner pulley center bolt. Position tensioner pin
holes at bottom of tensioner. Install Adapter (MD998767)
on tensioner pulley. See Fig. 6. Using torque wrench, apply
39 INCH lbs. (4.4 N.m) of torque (counterclockwise direc-
tion) to tensioner pulley. Tighten tensioner center bolt to
specification while holding tensioner stationary.
Remove locking pin from auto-tensioner. Turn crankshaft 2
revolutions clockwise and align all timing marks. DO NOT
rotate counterclockwise.
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 Courtesy of Mitsubishi Motor Sales of America
tensioner pulley bracket arm. Clearance should be 0.15- Fig. 6: Adjusting Timing Belt Tension (1999-00 Eclipse &
0.20 (3.8-5.0 mm). If protrusion is not correct, repeat tim- (Galant; 1997-01 Montero & Montero Sport)
ing belt tensioning procedure.
Install timing belt covers. Install crankshaft pulley. Install
accessory mount assembly on front of engine.
438 MITSUBISHI

(2001 Eclipse & Galant)
Fig. 7: Engine Support Bracket Tightening Sequence
(Eclipse & Galant)
TORQUE SPECIFICATIONS (MONTERO & MONTERO

SPORT)
Accessory Mount Assembly Bolt .................................... 33 (44)
Auto-Tensioner-To-Engine Block Bolt ............................ 18 (24)
Crankshaft Pulley Bolt ............................................ 1 134 (181)
Generator Pivot (Upper) Bolt ......................................... 38 (52)
Generator Bottom Bolt ................................................... 16 (22)
Power Steering Pump Bolt .................................. 29-33 (39-44)
Timing Belt Tensioner Arm Pivot Bolt ............................ 32 (44)
Water Pump Bolt ............................................................ 18 (24)
INCH Lbs. (N.m)
Cooling Fan Clutch-to-Pulley Nut ..................... 89-106 (10-12)
M6 Bolt ......................................................................... 97 (11)
M8 Bolt ....................................................................... 117 (13)
1
MITSUBISHI 439
*3.5L V6 DOHC
Application LaborTime Belt Part No.
3.5L V6
Montero
1994-96 ................ 1 4.5 Hours .................... T253
1
The manufacturer requires the belt be replaced every 60,000
miles, except in California. In California, belt replacement is
recommended, but not required. In California, replace belt at
100,000 miles, unless previously changed.

REMOVAL & INSTALLATION Courtesy of Mitsubishi Motor Sales of America, Inc.

TIMING BELT
NOTE: Ensure timing marks are aligned. Mark timing belt direction
of rotation
Removal:
Disconnect negative battery cable. Drain engine coolant.
Remove engine coolant reservoir tank, fan shroud and ra-
diator.
Remove generator with wires attached and secure out of
way. Remove battery and battery tray. Remove engine lower
splash shields.
Remove accessory drive belts. Remove cooling fan clutch
assembly. See Fig. 2. Remove cooling fan pulley. Remove
A/C compressor with hoses attached and secure out of
way. Remove A/C compressor bracket.
Remove power steering pump mount cover. Remove power
steering pump with hoses attached and secure out of way.
Remove accessory mount. See Fig. 2.
Remove timing belt upper cover. Disconnect crankshaft po-
sition sensor connector. Using Holder (MB990767) and
Bolts (MB998754) or equivalents, hold crankshaft station-
ary while remove crankshaft pulley center bolt.
If reusing timing belt, place arrow on belt to indicate run-
ning direction. Rotate crankshaft to align all timing marks. Courtesy of Mitsubishi Motor Sales of America, Inc.
See Fig. 3. Loosen timing belt tensioner center bolt. Re- Fig. 2: Exploded View Of Accessory Mount Components
move timing belt and timing belt automatic tensioner.
Installation:
NOTE: Revised auto-tensioner procedure is from Mitsubishi technical Place automatic tensioner assembly in a soft-jawed vise.
service bulletin 96-11-006; June, 1996. SLOWLY close vise to press rod back into tensioner until
both rod and housing holes are aligned. Install a .055"
Inspection:
(1.40 mm) diameter wire or drill bit through both holes.
Inspect timing belt for wear on edges of drive teeth. Inspect Remove automatic tensioner from vise, and install assem-
bly on engine with wire in place. Install crankshaft sprocket
(if removed). Align timing marks on crankshaft and cam-
shaft sprockets. See Fig. 3.
pulley for smooth rotation.
Check timing belt automatic tensioner for leaks. Hold tim- CAUTION: Turning camshaft sprockets while No. 1 piston is at
ing belt auto-tensioner upright. Measure rod protrusion TDC may damage valve and piston. Use care when aligning timing
above edge of housing. Length should be .461-.484 (11.7- marks.
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), To lower No. 1 piston from TDC and prevent valve and pis-
replace the automatic tensioner. ton contact, turn crankshaft back 3 sprocket teeth (mea-
sured at timing mark). See Fig. 4.
440 MITSUBISHI
Courtesy of Mitsubishi Motor Sales of America, Inc.

Fig. 5: Securing Timing Belt With Spring Clips
Courtesy of Mitsubishi Motor Sales of America, Inc.

Install timing belt on the idler pulley. Realign the crankshaft
sprocket timing mark with mark on oil pump housing. Turn
Fig. 3: Aligning Timing Marks crankshaft ONE turn counterclockwise (as viewed from front
of engine). Set timing belt on crankshaft sprocket, then onto
tensioner pulley.
Rotate timing belt tensioner pulley until pin holes are lo-
cated above center bolt. See Fig. 6. Push tensioner pulley
against belt, and temporarily tighten center bolt. Ensure all
timing marks are still aligned, and remove spring clips.
Rotate crankshaft 1/4 revolution counterclockwise. Rotate
crankshaft clockwise until timing marks are realigned.
Loosen tensioner center bolt.
Using Tensioner Pulley Socket (MD998767) or equivalent,
apply approximately 83 INCH Ibs. (9.4 N.m) torque to
tensioner pulley in a clockwise direction. Holding tensioner
pulley to prevent it from turning, final tighten center bolt to
35 ft. lbs. (48 N.m). Ensure tensioner pulley does not rotate
while tightening center bolt.
Remove set pin or drill bit from automatic tensioner. Rotate
crankshaft 2 revolutions clockwise. Wait 5 minutes. Verify
Courtesy of Mitsubishi Motor Sales of America, Inc. wire or drill bit can still be easily removed and installed.
Fig. 4: Positioning Crankshaft For Timing Belt Installation
Even if set pin or drill bit cannot be easily installed, the
automatic tensioner is normal if its push rod protrusion is
Starting with left (drivers side) bank of cylinders, verify in- within .15-.18" (3.8-4.5 mm). Measure push rod protrusion
take and exhaust camshaft timing marks are correctly between top of tensioner body and lever arm of tensioner
aligned with marks on rear timing belt cover. See Fig. 3. pulley lever. See Fig. 7.
Rotate either camshaft sprocket clockwise to align timing If push rod protrusion is out of specification, timing belt
marks. tension adjustment will have to be repeated.
Install timing belt covers. Install crankshaft pulley. Tighten
WARNING: Use care when aligning timing marks. Camshaft is crankshaft pulley bolt to specification. See TORQUE SPECI-
under valve spring pressure and may rotate suddenly, pinching FICATIONS.
hand between sprockets. Install generator. Install accessory mount. Install power
steering pump and A/C compressor. Install cooling fan.
Align camshaft timing marks on right (passengers side) Install accessory drive belts.
camshaft sprockets. See Fig. 3. Using box end wrenches,
hold camshaft sprocket center bolts to prevent sprockets CAUTION: On later model years, the sealing washer under the
from turning. With right bank camshaft sprocket timing cooling system air bleed bolt was reduced to .85 mm from 2.0
marks aligned with marks on rear timing belt cover, install mm. The .85 mm washer CANNOT be reused. Replace washer if
timing belt on right bank camshaft sprockets. Hold cam- bolt is loosened or removed. This information is from Mitsubishi
shaft sprockets in place with spring clips. See Fig. 5. technical service bulletin 96-00-003; February, 1996.
Install timing belt around water pump pulley. With left bank
camshaft sprockets correctly aligned, install timing belt on Install radiator. Before refilling cooling system, remove air
left hand camshaft sprocket. Secure timing belt onto sprock- bleed bolt on top of thermostat housing. Refill cooling sys-
ets with spring clips. tem with 50/50 mix of water and coolant until it overflows
from air bleed bolt hole. Install air bleed bolt with new .85
mm washer (if equipped).
MITSUBISHI 441
Start engine and run to normal operating temperature. Race Courtesy of Mitsubishi Motor Sales of America, Inc.
engine to 3000 RPM several times. Stop engine. After en- Fig. 7: Measuring Push Rod Protrusion
gine cools, refill radiator.
Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS.
tension ranges.
Application Ft. Lbs. (N,m)
Automatic Tensioner Bolt ............................................... 17 (24)
Accessory Mount Bolts
10 x 80 mm ..................................................... 28-30 (38-41)
10 x 100 mm ................................................... 32-34 (43-46)
12 x 100 mm ................................................... 53-55 (72-75)
Crankshaft Pulley Center Bolt ................... 130-137 (177-186)
Timing Belt Tensioner Arm Pivot Bolt ............................. 33 (44)
INCH Lbs. (N.m)
Coolant Air Bleed Bolt ............................................. 80-97 (9-11)
Cooling Fan-To-Pulley Bolt ............................. 89-106 (10-12)
Crankshaft Position Sensor ........................................... 80 (9)
Radiator Mounting Bolt/Nut .............................................. 62 (7)
442 MITSUBISHI
*3.5L V6 SOHC
TIMING BELT APPLICATION Disconnect negative battery cable. Drain cooling system.
Remove upper radiator hose. Remove radiator shroud.
Application Labor Time Belt Part No. Loosen cooling fan clutch-to-pulley nuts. Relieve tension
3.0L V6 SOHC on accessory drive belts.
Diamante Remove cooling fan and fan clutch assembly. Remove cool-
1997-01 ................ 1 3.4 Hours .................... T287 ing fan pulley. Remove all accessory drive belts. Remove
Montero generator with wires attached and secure out of way.
1997-00 ................ 1 3.5 Hours .................... T287 Remove power steering pump with hoses connected, and
set aside. Remove A/C compressor from bracket ( hoses
Montero Sport connected), and set aside. Remove A/C compressor
2000-01 ................ 1 3.5 Hours ................... T287 bracket. On Montero Sport, remove timing mark indicator
1
- With Air Cond. add .6 hours for Montero and plate from front of engine. On Montero and Montero sport,
remove accessory mount assembly. See Fig. 4.
Montero Sport. Remove upper timing belt upper cover. See Fig. 3. Holding
With Pwr. Strng. add .3 hours. crankshaft pulley stationary, remove crankshaft pulley bolt.
For 2001 models, the manufacturer recommends the belt be
setts and Vermont. In California, Massachusetts and Vermont,
timing belt replacement is recommended, but not required, at
60,000 miles. In these states, replace timing belt at 100,000


NOTE: Replacement procedure for Diamante includes revised
information from Mitsubishi technical service bulletin No. 00-
11-005; April, 2000.
TIMING BELT REMOVAL

Diamante:
belts. Remove generator with wires attached and secure
out of way.
Holding crankshaft pulley stationary, remove crankshaft
pulley bolt. Remove crankshaft pulley.
Remove timing belt covers. See Fig. 1. Support weight of
engine with floor jack. Remove engine mount from front
(timing belt end) of engine. Remove engine support bracket
from front of engine.

If timing belt is to be reused, place arrow on belt to indicate Courtesy of Mitsubishi Motor Sales of America
direction of belt rotation. Turn crankshaft clockwise to align Fig. 1: Exploded View Of Timing Belt Components
camshaft and crankshaft timing marks. See Fig. 2. Loosen (Diamante Shown; Others Similar)
center bolt of timing belt tensioner pulley, and remove tim-
ing belt. Remove timing belt auto-tensioner from engine
block.
Montero & Montero Sport:
MITSUBISHI 443

Remove lower timing belt cover. Turn crankshaft clockwise
to align camshaft and crankshaft timing marks. See Fig. 2.
Loosen belt tensioner pulley center bolt.
direction of belt rotation. Remove timing belt. Remove tim-
ing belt auto-tensioner.
All Models:
pulley for smooth rotation. Replace if defective.
Check timing belt auto-tensioner for leaks. Hold timing belt
auto-tensioner upright. Measure rod protrusion above edge
of housing. See Fig. 5. Length should be .461-.484 (11.7-
12.3 mm). Apply 22-44 lbs. (98-196 N) of force to end of rod.
If auto tensioner rod moves more than 0.39 (1 mm), re-
place the auto-tensioner.
Diamante:
Fig. 2: Aligning Timing Marks Place auto-tensioner in soft-jawed vise to SLOWLY com-
press the push rod. If there is a plug at the base of the auto-
tensioner body, place flat washer around plug so it will not
contact vise jaw.

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 valve spring
pressure. Be careful not to pinch fingers when installing timing
belt.

(Montero & Montero Sport)
Fig. 4: Exploded View Of Accessory Mount Assembly

(Montero & Montero Sport)
444 MITSUBISHI
Ensure all timing marks are still aligned. See Fig. 2. Install Ensure all timing marks are still aligned. See Fig. 2. Install
timing belt on crankshaft sprocket, idler pulley, left bank timing belt on crankshaft sprocket, idler pulley, left bank
camshaft sprocket, water pump pulley, right bank camshaft camshaft sprocket, water pump pulley, right bank camshaft
sprocket, and tensioner pulley. Take all slack out of timing sprocket, and tensioner pulley. Take all slack out of timing
belt. belt.
Loosen the tensioner pulley center bolt. Rotate tensioner Loosen the tensioner pulley center bolt. Rotate tensioner
pulley against timing belt. Temporarily tighten tensioner pulley against timing belt. Temporarily tighten tensioner
pulley center bolt. Turn crankshaft 1/4 turn counterclock- pulley center bolt. Turn crankshaft 1/4 turn counterclock-
wise. Turn crankshaft 1/4 turn clockwise. Ensure all timing wise. Turn crankshaft 1/4 turn clockwise. Ensure all timing
belt marks are still aligned. belt marks are still aligned.
Loosen tensioner pulley center bolt. Position tensioner pin Loosen tensioner pulley center bolt. Position tensioner pin
holes at bottom of tensioner. Install Adapter (MD998767) holes at bottom of tensioner. Install Adapter (MD998767)
on tensioner pulley. See Fig. 5. Using torque wrench, apply on tensioner pulley. See Fig. 6. Using torque wrench, apply
39 INCH lbs. (4.4 N.m) of torque (counterclockwise direc- 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direc-
tion) to tensioner pulley. Tighten tensioner center bolt to tion) to tensioner pulley. Tighten tensioner center bolt to
specification while holding tensioner pulley stationary. specification while holding tensioner pulley stationary.
Remove locking pin from auto-tensioner. Turn crankshaft 2 Remove locking pin from auto-tensioner. Turn crankshaft 2
revolutions clockwise and align all timing marks. DO NOT revolutions clockwise and align all timing marks. DO NOT
rotate counterclockwise. rotate counterclockwise.
Wait for at least 5 minutes, then check auto-tensioner push Wait for at least 5 minutes, then check auto-tensioner push
rod protrusion. To check push rod protrusion, measure rod protrusion. To check push rod protrusion, measure
clearance between body of auto-tensioner and bottom of clearance between body of auto-tensioner and bottom of
tensioner pulley bracket arm. Clearance should be 0.15- tensioner pulley bracket arm. Clearance should be 0.15-
0.20 (3.8-5.0 mm). If protrusion is not correct, repeat tim- 0.20 (3.8-5.0 mm). If protrusion is not correct, repeat tim-
ing belt tensioning procedure. ing belt tensioning procedure.
Install engine support bracket on engine block. Tighten top Install timing belt covers. Install crankshaft pulley. Tighten
bolt first, then working in a counterclockwise direction, crankshaft pulley bolt to specification. See TORQUE SPECI-
tighten the remaining bolts. See Fig. 7. Install timing belt FICATIONS table. Install accessory mount assembly on
covers. Install crankshaft pulley. Apply engine oil to crank- front of engine.
shaft pulley bolt, then tighten bolt to specification. See Install A/C compressor. Install generator. Install upper ra-
TORQUE SPECIFICATIONS table. diator hose. Adjust drive belts to proper tension. See page
To install remaining components, reverse removal proce- A-60 for belt tension ranges.
dure. Adjust drive belts to proper tension. See page A-60 To install remaining components, reverse removal proce-
for belt tension ranges. dure. When filling cooling system, use 50/50 mix of coolant
Montero & Montero Sport: and water. Open bleed screw on top of thermostat housing.
Place auto-tensioner in soft-jawed vise to SLOWLY com- Slowly fill cooling system until coolant flows out of bleed
press the push rod. If there is a plug at the base of the auto- hole. Install bleed screw. Start engine and run to normal
tensioner body, place flat washer around plug so it will not operating temperature. Race engine to 3000 RPM several
contact vise jaw. times. Stop engine. After engine cools, refill radiator and
coolant reservoir tank.
TORQUE SPECIFICATIONS (DIAMANTE)
Slowly compress auto-tensioner push rod until holes in
Auto-Tensioner Bolt ....................................................... 17 (23)
push rod and auto-tensioner housing are aligned. Insert a Camshaft Sprocket Bolt .............................................. 65 (88)
locking pin into the alignment holes. Install auto-tensioner Crankshaft Pulley Bolt ............................................ 1 134 (181)
on engine.
Engine Mount
To-Engine Support Bracket Nut/Bolt ............. 73-87 (98-118)
To-Body Through Bolt 2 ..................................... 73-87 (98-118)
Engine Support Bracket-to-Engine Bolt ......................... 32 (44)
Generator Pivot Bolt ....................................................... 32 (44)
Generator Top Bolt ........................................................ 15 (21)
Power Steering Pump Belt Tensioner Bolt .................... 32 (44)
Water Pump Bolt
M8 Bolt .......................................................................... 17 (23)
M10 Bolt ....................................................................... 30 (41)
INCH Lbs. (N.m)
Courtesy of Mitsubishi Motor Sales of America Timing Belt Cover Bolt ................................................ 97 (11)
Fig. 5: Checking Timing Belt Auto-Tensioner Movement Timing Mark Indicator Plate Bolt ..................................... 97 (11)
1
2
Arrow on engine mount plates must face toward front
of vehicle.
MITSUBISHI 445

(MONTERO & MONTERO SPORT)
Accessory Mount Assembly Bolt .................................... 33 (44)
Auto-Tensioner Bolt ....................................................... 18 (24)
Crankshaft Pulley Bolt ............................................ 1 134 (181)
Generator Pivot (Upper) Bolt ......................................... 38 (52)
Generator Bottom Bolt ................................................... 16 (22)
Power Steering Pump Bolt ............................................ 17 (24)
Water Pump Bolt ............................................................ 17 (23)
INCH Lbs. (N.m)
Cooling Fan Clutch-to-Pulley Nut ..................... 89-106 (10-12) Fig. 6: Adjusting Timing Belt Tension
1
Fig. : Engine Support Bracket Tightening Sequence

(Diamante)
446 NISSAN
*1.5L & *1.6L 4-Cylinder SOHC
TIMING BELT APPLICATION * NOTE: This application is an interference engine.
Belt See page A-59 for interference engine cautions.
Application Time 1 Kit No. No. REMOVAL & INSTALLATION
1.5L 4-Cyl. SOHC
Sentra TIMING BELT
1982-83 .......... 2.8 Hrs. ...... TCK077 .......... T077
CAUTION: DO NOT rotate crankshaft or camshaft separately
Pulsar NX with timing belt removed. Valves will contact piston and may
1983-84 .......... 3.0 Hrs. ...... TCK077 .......... T077 cause damage.
310
Removal:
1982 ............... 5.8 Hrs. ...... TCK077 .......... T077 Disconnect negative battery cable. Place crankshaft on TDC
1.6L 4-Cyl. SOHC of compression stroke. Remove spark plugs. Remove right
Pulsar & Pulsar NX front under engine cover and splash cover. Remove acces-
1983-88 .......... 2.3 Hrs. ...... TCK077 .......... T077 sory drive belts. Remove water pump pulley and crankshaft
Sentra pulley. On 1988 models, support engine with a jack under
1983-88 .......... 2.8 Hrs. ...... TCK077 .......... T077 oil pan and remove right side engine mount.
On all models remove upper and lower timing belt cover.
1
- With Air Cond. add .3 hours. Check timing mark alignment. See Fig. 2. Mark timing belt
With Pwr. Strng. add .3 hours. rotation direction for installation reference. Loosen timing
belt tensioner and retain tensioner away from timing belt.
NOTE: A timing belt component kit is available for Remove timing belt. Remove tensioner and spring (if nec-
this application. See page I for information on component essary). See Fig. 1.
kits. CAUTION: Camshaft sprockets have 2 marks on them. Ensure
the correct mark is aligned. See Fig. 2.
MANUFACTURERS SUGGESTED Installation:
SCHEDULED MAINTENANCE Ensure camshaft and crankshaft sprocket timing marks
are aligned at TDC on compression stroke. See Fig. 2.
On 1982-85 models, although the manufacturer does not rec-
Install timing belt tensioner so no tension will be applied to
ommend a specific scheduled maintenance interval, belt
belt during installation (if removed). If installing removed
belt, properly position rotation direction mark made at re-
intervals. On 1986 and later models, the manufacturer recom-
moval.
Install timing belt, keeping belt tight on jackshaft and cam-
shaft sprockets side. Loosen tensioner and allow tension
to be applied to timing belt. Rotate camshaft sprocket 20
degrees (2 cogs) clockwise.
Fig. 1: Exploded View Of Timing Belt Components Fig. 2: Timing Mark Alignment
NISSAN 447
*1.5L & *1.6L 4-Cylinder SOHC (Cont.)

Using a screwdriver, prevent tensioner from turning and TORQUE SPECIFICATIONS (1.6L)
tighten tensioner lock nut. Recheck timing mark alignment.
Ensure ignition rotor is firing No. 1 cylinder. To complete
installation, reverse removal procedure. Adjust drive belts
Timing Belt Tensioner Lock Nut ...................... 12-15 (16-21)
INCH Lbs. (N.m)
TORQUE SPECIFICATIONS (1.5L) Camshaft Sprocket Bolt .............................. 78-104 (8.8-11.8)
Application Ft. Lbs. (N.m) Jackshaft Sprocket Bolt ............................... 78-104 (8.8-11.8)
Camshaft Sprocket Bolt ................................... 29-35 (39-48) Valve Cover Bolt
Crankshaft Pulley Bolt .............................. 108-145 (147-197) 1st Step ....................................................... 17-35 (1.9-4.0)
Crankshaft Pulley Damper Bolt .................... 90-98 (123-132) 2nd Step ...................................................... 35-52 (4.0-5.9)
INCH Lbs. (N.m) Timing Belt Cover .......................................... 46-58 (5.2-6.6)
Camshaft Lockplate ............................................. 35-43 (4-5) Water Pump Pulley Bolt ............................... 74-96 (8.4-10.9)
Timing Belt Tensioner ......................................... 52-70 (6-8) Water Pump Bolt ........................................... 46-58 (5.2-6.6)
448 NISSAN
*1.6L & *1.8L 4-Cylinder DOHC
TIMING BELT APPLICATION Ensure No. 1 cylinder is at TDC of compression stroke.
Align camshaft and crankshaft sprockets. See Fig. 2. In-
Belt Part No. stall timing belt. Ensure 39 teeth exist between marks on
1.6L 4-Cyl. DOHC camshaft sprockets and 48 teeth between crankshaft and
Pulsar camshaft sprockets. See Fig. 2.
1987 ...................... 3.8 Hours ..................... T137 Loosen tensioner pulley nut. Install crankshaft bolt and a
1.8L 4-Cyl. DOHC spacer. Rotate crankshaft 2 revolutions. Tighten tensioner
pulley nut to specification. Ensure all marks are aligned.
Pulsar NX Install timing belt covers.
1988-89 ................. 3.8 Hours ..................... T137 Install crankshaft pulley and washer. Install engine mount.
1
- With Air Cond. add .3 hours. Install crank angle sensor and water pump pulley. Ensure
With Pwr. Strng. add .3 hours. reference marks on crank angle sensor are aligned. Tighten
bolts to specification.
MANUFACTURERS SUGGESTED Install accessory drive belts. Adjust drive belts to proper
tension. See page A-60 for belt tension ranges. Install up-
SCHEDULED MAINTENANCE per radiator hose and refill cooling system.
The manufacturer recommends the belt be replaced every TORQUE SPECIFICATIONS
60,000 miles.
* NOTE: This application is an interference engine. Camshaft Pulley Bolt ........................................ 10-14 (14-19)
See page A-59 for interference engine cautions. Engine Mount Bolt ............................................ 29-40 (39-54)
Idler Nut ............................................................ 23-31 (31-42)
REMOVAL & INSTALLATION Tensioner Pulley Nut ........................................ 16-22 (22-30)
Timing Belt Tensioner Pulley Nut ..................... 16-22 (22-30)
TIMING BELT Water Pump Bolt .............................................. 12-14 (16-19)
Removal: INCH Lbs. (N.m)
Disconnect negative battery cable. Drain cooling system. Crank Angle Sensor Bolt ....................................... 61-70 (7-8)
Remove upper radiator hose. Remove undertray from right Rear Timing Belt Cover Bolt ................................. 61-70 (7-8)
side. Remove accessory drive belts. Remove water pump
pulley.
Place reference mark on crank angle sensor and timing
belt cover for reassembly reference. See Fig. 1. Remove
crank angle sensor. Support engine and remove front engine
mount support.
Remove upper timing belt cover. See Fig. 1. Align timing
marks on camshaft sprockets. See Fig. 2. Remove right
side inner fender panel. Remove crankshaft pulley and lower
timing belt cover. Loosen tensioner pulley nut and release
tension. Remove timing belt.
Using dial indicator, check camshaft sprocket runout. Re-
place sprocket if runout exceeds .004" (.10 mm). To re-
move camshaft sprocket, remove camshaft cover and hold
hex area of camshaft. Remove sprocket retaining bolts.
See Fig. 3.
Remove camshaft sprocket. If crankshaft sprocket requires
removal, note direction of sprocket plates prior to removal.
See Fig. 1. Remove plates and sprocket.
Inspection:
Inspect belt for signs of oil contamination. Replace belt if
damaged or contaminated.
Check tensioner and idler pulleys for smooth rotation. In-
spect tensioner pulley return spring for distortion or corro-
sion. Fig. 1: Exploded View Of Timing Belt & Components
Installation:
Install crankshaft sprocket and sprocket plates. Sprocket
plates must be installed with flat side against crankshaft
sprocket.
NISSAN 449
*1.6L & *1.8L 4-Cylinder DOHC
Fig. 3: Removing Camshaft Sprocket

450 NISSAN
1.7L 4-Cyl. Diesel
Sentra
1983-87
Camshaft ............ 4.0 Hours ..................... T096
1
ommend a specific scheduled maintenance interval, belt
intervals. On 1986-87 models, the manufacturer recommends

REMOVAL & INSTALLATION 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:
Install timing belt ensuring timing marks are aligned. See
Fig. 1. Ensure reference marks are 39 cogs apart.
Rotate crankshaft 2 revolutions in normal direction of rota-
tion. Tighten tensioner bolt while holding it to keep it from
rotating. To complete installation, reverse removal proce-
dure.
tension ranges.
INJECTION PUMP BELT
Removal:
Disconnect negative battery cable. Remove timing belt cover
from rear of engine. Loosen injection timing belt tensioner.
Remove injection timing belt. Fig. 2: Installing Injection Timing Belt
Installation:
Install injection timing belt. Ensure reference marks are 23 TORQUE SPECIFICATIONS
cogs apart. See Fig. 2. Rotate crankshaft 2 revolutions in
normal direction of rotation. Tighten tensioner bolt while Application Ft. Lbs. (N.m)
holding it to keep it from rotating. To complete installation, Camshaft Pulley Bolt ........................................ 68-75 (18-22)
reverse removal procedure. 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 451
1.8L & *2.0L 4-Cylinder

1.8L 4-Cyl. Turbo
200SX (Includes Canadian)
1984-87 ................ 1 2.0 Hours .................... T100
2.0L 4-Cyl.
Stanza & Stanza Wagon
1982-89 ................ 1 4.4 Hours .................... T078
200SX
1984-88 ................ 1 2.0 Hours .................... T078
1
On 1985-82 models, the manufacturer does not recommend a
specific scheduled maintenance interval, belt manufacturers
suggest the belt be replaced at 60,000 mile intervals. On 1986 plugs. Turn crankshaft until No. 1 cylinder is at TDC on
and later models, the manufacturer recommends the belt be compression stroke. Remove dust cover and undercovers.
replaced every 60,000 miles. Remove belts.
Support engine with a chain hoist. Remove right side en-
*NOTE: The 2.0L is an interference engine. See page gine mount and bracket. Remove upper and lower timing
A-59 for interference engine cautions. belt covers and gaskets. Remove timing belt tensioner,
bracket and timing belt.
REMOVAL & INSTALLATION Installation (All Models):
Do not tighten tensioner bolts to final specification before
TIMING BELT drive belt is installed. Install timing belt. Align belt mark to
camshaft and crankshaft sprocket marks. See Fig. 1.
Removal (1982-88):
Disconnect negative battery cable. Turn crankshaft until No. Tighten belt tensioner and assemble spring. To set spring,
hook one end on bolt B side and hook the other end on
1 cylinder is at TDC on compression stroke. Remove cool-
tensioner bracket pawl. Tighten bolt B and then bolt A.
ing fan, radiator shroud and accessory drive belts.
See Fig. 2.
NOTE: After timing belt is removed, do not rotate crankshaft Belt tension will automatically be at the specified value.
or camshaft. Install lower front cover with gaskets and tighten mount
bolts. Install plate and front pulley damper. Complete in-
Remove upper and lower dust cover mount bolts. Remove stallation by reversing removal procedure. Adjust drive belts
upper and lower covers and gaskets. Remove timing belt to proper tension. See page A-60 for belt tension ranges.
tensioner, bracket, and timing belt. TORQUE SPECIFICATIONS (1982-88)
Removal (1989):
Disconnect negative battery cable. Raise and support ve- Application Ft. Lbs. (N.m)
hicle. Remove right front wheel. Remove exhaust side spark Camshaft Pulley Bolt ........................................ 10-14 (14-19)
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)

Camshaft Lock Plate Bolt ................................. 58-65 (78-88)
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)
Fig. 1: Timing Belt Alignment Procedure
Rear Timing Belt Cover Bolt ................................. 61-70 (7-8)
452 NISSAN
*3.0L V6 DOHC
TIMING BELT APPLICATION Loosen tensioner nut and bolts 1/2 turn. Move tensioner as
far pack as possible. Using Push/Pull Gauge (J-38387) or
Belt Part No. equivalent, apply 15.2-18.3 lbs. (6.9-8.3 kg) pressure to
3.0L V6 DOHC end of pusher. See Fig. 2. Tighten tensioner nut and bolts.
300ZX Turn crankshaft 120 degrees clockwise, then turn it 120 de-
1990-93 ................. 4.6 Hours ..................... T180 grees counterclockwise to TDC. Fabricate a small steel plate.
1994-96 ................. 4.6 Hours ..................... T251 See Fig. 3. Set plate at each position shown (A, B, C and
D).
1
- With Air Cond. add .3 hours. Using push/pull gauge, apply 11 lbs. (5 kg) pressure. Mea-
With Pwr. Strng. add .3 hours. sure and record timing belt deflection in each position. Divide
sum of measurements (A + B + C + D) by 4 to obtain
MANUFACTURERS SUGGESTED average.
SCHEDULED MAINTENANCE Average timing belt deflection should be .24-.28" (6-7 mm).
If deflection is not as specified, repeat last five (5) steps. If
The manufacturer recommends the belt be replaced every timing belt deflection is excessive, change amount of push-
60,000 miles. ing force applied in third step back.
Remove tensioner stopper bolt. After 5 minutes, ensure
* NOTE: This application is an interference engine. clearance between pusher rod and tensioner arm is .138-
See page A-59 for interference engine cautions. .205" (3.5-5.2 mm). Check for slippage or misplacement of
timing belt at each sprocket. Install timing belt covers. To
REMOVAL & INSTALLATION drive belts to proper tension. See page A-60 for belt tension
TIMING BELT ranges.
Removal: TORQUE SPECIFICATIONS
Disconnect negative battery cable. Remove engine under- Application Ft. Lbs. (N.m)
cover. Drain coolant from radiator and cylinder block. Re- Camshaft Sprocket Bolts
move radiator. Remove accessory drive belts. Remove cool- Exhaust .......................................................... 10-14 (14-19)
ing fan and coupling. Remove starter. Intake ......................................................... 90-98 (122-133)
Lock flywheel/flexplate to prevent crankshaft from rotating. Crankshaft Pulley Bolt .............................. 159-174 (216-236)
Remove crankshaft pulley bolt and pulley. Remove water Timing Belt Idler Pulley Nut .............................. 32-43 (43-58)
inlet and outlet hoses. Remove timing belt front covers. Timing Belt Tensioner Lock Nut ....................... 12-15 (16-20)
Remove spark plugs. Water Pump Bolt .............................................. 12-15 (16-20)
Install a stopper bolt (M6 x 16) into timing belt tensioner INCH Lbs. (N.m)
arm to maintain tensioner position. See Fig. 1. Set cylinder Timing Belt Cover ................................................. 27-43 (3-5)
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:
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
after next. If clearance is not .16" (.4 mm), go to next step.
Remove tensioner. Remove stopper bolt. Using a vise, ad-
just clearance until it is as specified. Install stopper bolt in
tensioner to maintain clearance. Install tensioner. Hand-
tighten tensioner nut and bolts.
shaft sprockets and crankshaft sprocket. White lines ensure
correct number of teeth exist between timing marks on sprock-
ets.
Push tensioner gently toward timing belt to prevent belt
from slipping (excessive pressure will overtighten belt). Main-
tain light pressure on tensioner.
Fig. 1: Installing Timing Belt & Tensioner
Turn crankshaft clockwise 10 degrees. Tighten tensioner
bolts and nut. See TORQUE SPECIFICATIONS. Turn crank-
shaft counterclockwise 120 degrees. Turn crankshaft clock-
wise until cylinder No. 1 is at TDC of compression stroke.
NISSAN 453
Fig. 3: Checking Timing Belt Deflection

454 NISSAN
*3.0L V6 SOHC
TIMING BELT APPLICATION Remove front upper and lower belt covers. Remove drive
belts and set No. 1 cylinder at TDC of compression stroke.
Belt Remove idler bracket of compressor drive belt and crank-
Labor Component Part shaft pulley. Remove timing belt by removing timing belt
Application Time 1 Kit No. No. tensioner and return spring.
3.0L V6 SOHC Inspection:
Maxima Visually inspect condition of timing belt. Inspect for cracks,
wear, breaks, and oil/coolant saturation.
1985-88 .............. 6.0 Hrs. .... TCK104 ........ T104 Installation:
1989-91 .............. 5.7 Hrs. .... TCK104 ........ T104 Ensure that piston No. 1 is at TDC of compression stroke.
1992-94 Remove valve covers and loosen all rocker shaft bolts. Do not
With Square Tooth bend timing belt. Install tensioner and return spring.
Sprocket ........ 5.7 Hrs. .... TCK104 ........ T104 Turn tensioner clockwise and temporarily tighten lock nut.
With Round Tooth Install timing belt. Align White lines on timing belt with punch
Sprocket ........ 5.7 Hrs. ............................ T249 mark on camshaft pulleys and crankshaft pulley. Arrow on
timing belt must be pointing toward front belt covers.
Pathfinder & Pickup Using Allen wrench, slowly turn tensioner clockwise and
1986-92 .............. 4.5 Hrs. .... TCK104 ........ T104 counterclockwise 2 or 3 times. When camshafts and crank-
1993-94 shaft marks are aligned, tighten tensioner lock nut. See
With Square Tooth Fig. 3. Ensure that camshaft lobes are correctly positioned.
Sprocket ........ 4.5 Hrs. .... TCK104 ........ T104 Tighten rocker shaft bolts in 2 stages.
With Round Tooth Refill and bleed air from from cooling system. To complete
installation, reverse removal procedures. Adjust drive belts
Sprocket ........ 4.5 Hrs. ............................ T249
to proper tension. See page ...... for belt tension ranges.
1995-96 .............. 4.5 Hrs. ............................ T249 Removal (Maxima & Quest):
Quest Disconnect negative battery cable. Raise and support ve-
1993-94 hicle. Remove covers from below engine. Drain cooling
With Square Tooth system. Remove right front wheel and engine side cover.
Sprocket ....... 3.5 Hrs. .... TCK104 ........ T104 Remove accessory drive belts. Remove crankshaft pulley
With Round Tooth bolt and pulley.
Sprocket ....... 3.5 Hrs. ............................ T249 Remove upper radiator hose and water inlet hose. Re-
move A/C compressor idler pulley and bracket. Remove
1995-98 .............. 3.5 Hrs. ............................ T249 water pump pulley. Remove upper and lower timing belt
200SX front covers.
1987-88 .............. 4.8 Hrs. .... TCK104 ........ T104 Temporarily install crankshaft pulley bolt so crankshaft can
300ZX be rotated. Set cylinder No. 1 at TDC of compression stroke
1984-89 .............. 6.0 Hrs. .... TCK104 ........ T104 by rotating crankshaft until marks on camshaft sprockets
align with marks on timing belt upper rear cover, and mark
1
- With Air Cond. add .3 hours. on crankshaft sprocket aligns with mark on front cover hous-
With Pwr. Strng. add .3 hours. ing. See Fig. 2.

kits.
ommend a specific scheduled maintenance interval, belt manu-
facturers suggest the belt be replaced at 60,000 mile inter-
vals. On 1986 and later models, the manufacturer recom-


TIMING BELT
Removal (200SX, 300ZX): Fig. 1: Exploded View Of Timing Belt & Related omponents
Disconnect negative battery cable. Release fuel pressure
from system. Raise and support vehicle. Remove right wheel
and engine side cover (if necessary). Drain cooling sys-
tem. Remove cooling fan duct. Remove engine coolant res-
ervoir. Remove actuator and remove radiator hoses. Do not
allow coolant to contact drive belts.
NISSAN 455

Loosen timing belt tensioner nut. Release tension on belt.
Remove timing belt. Check timing belt tensioner, spring
and timing belt.
Removal (Pathfinder & Pickup):
Disconnect negative battery cable. Remove covers from be-
low engine. Drain and remove radiator. Remove cooling fan
and water pump pulley. Remove accessory drive belts. Re-
move spark plugs. Remove distributor protector. Remove A/C
compressor idler pulley and bracket.
Remove fresh air tube from cylinder head cover. Remove
thermostat housing coolant hose. Remove crankshaft pul-
ley bolt and pulley. Remove upper and lower timing belt front
covers. Temporarily install crankshaft pulley bolt to rotate crank-
shaft.
Set cylinder No. 1 at TDC of compression stroke by align-
ing marks on camshaft sprockets with marks on timing
belt upper rear cover and mark on crankshaft sprocket with
mark on front cover housing. See Fig. 1. Loosen timing
belt tensioner. Remove timing belt. Check timing belt
tensioner, spring and timing belt.
Installation:
Ensure cylinder No. 1 is at TDC of compression stroke. Fig. 2: Installing Timing Belt & Sprocket
See Fig. 2. Install tensioner and return spring if removed. If
return spring stud was removed, apply thread lock sealant
to threads before installing stud. Insert an Allen wrench
into hole in tensioner, turn tensioner fully clockwise, and
temporarily tighten lock nut.
shaft sprockets and crankshaft sprocket. White lines en-
sure correct number of teeth exist between timing marks on
sprockets.
Loosen tensioner lock nut. Using Allen wrench, rotate
tensioner by turning Allen wrench clockwise 70-80 degrees.
Temporarily tighten lock nut. Rotate crankshaft clockwise
at least 2 revolutions.
Return cylinder No. 1 to TDC of compression stroke. Using
Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs. TORQUE SPECIFICATIONS
(10.0 kg) pressure to timing belt between right camshaft
sprocket and tensioner. Hold tensioner in position with Allen Application Ft. Lbs. (N.m)
wrench, and loosen tensioner lock nut. Camshaft Sprocket Bolt .................................... 58-65 (79-88)
Place a .0138" (.351 mm) feeler gauge at tensioner pulley Crankshaft Pulley Bolt ................................. 90-98 (122-133)
and timing belt, and rotate crankshaft until feeler gauge is Rocker Shaft Bolts ............................................ 13-16 (16-20)
centered between tensioner pulley and timing belt. See Timing Belt Tensioner Lock Nut/Bolt ................ 32-43 (43-58)
Fig. 3. Tighten tensioner lock nut to specification. See Water Pump Bolt .............................................. 13-16 (16-20)
TORQUE SPECIFICATIONS. INCH Lbs. (N.m)
Rotate crankshaft to remove feeler gauge. Rotate crank- Timing Belt Cover ................................................. 27-43 (3-5)
shaft clockwise at least 2 revolutions until cylinder No. 1 is
at TDC of compression stroke. Measure timing belt deflec-
tion halfway between camshaft sprockets. If deflection is
not .51-.59" (13-15 mm), repeat procedure. To complete
installation, reverse removal procedure.
Refill and bleed air from cooling system. Adjust drive belts
456 NISSAN
3.3L V6 SOHC
TIMING BELT APPLICATION Turn tensioner clockwise fully outward with hexagon wrench
and temporarily tighten lock nut. Align White lines on timing
Application Labor Time Belt Part No. belt with punch marks on camshaft sprockets and crank-
3.3L V6 VG33E shaft sprocket. See Fig. 6. Point arrow on timing belt to-
Frontier ward front belt cover. There should be 40 teeth between left
1999-01 ................ 1 3.1 Hours .................... T249 and right camshaft sprockets and 43 teeth between left
Pathfinder camshaft sprocket and crankshaft sprocket.
1996-00 ................ 1 2.8 Hours .................... T249 Loosen tensioner lock nut. Using hex wrench, turn
tensioner clockwise and counterclockwise at least 2 times.
QX4 Tighten tensioner lock nut. Turn crankshaft clockwise at
1997-00 ................. 3.9 Hours ..................... T249 least 2 revolutions, then slowly set No. 1 cylinder at TDC on
Quest compression stroke. Apply 22 lbs. (10 kg) of force to belt
1999-01 ................ 1 2.6 Hours .................... T249 (downward direction) midway between camshaft sprock-
Xterra ets. Belt deflection should be 0.51-0.59 (13-15 mm). If not,
2000-01 ................ 1 3.1 Hours .................... T249 readjust belt tension.
Install lower and upper belt covers. Install crankshaft pul-
1
- With Air Cond. add .3 hours. ley. Tighten bolt to specfication. See TORQUE SPECIFICA-
With Pwr. Strng. add .3 hours. TIONS. To complete installation, reverse removal proce-
With Supercharger add .2 hours. dures. Fill and bleed cooling system.
*NOTE: The 1996-00 3.3L engine used in the Pathfinder

is an interference engine. See page A-59 for interference
engine cautions.

TIMING BELT
Removal (Frontier, Pathfinder, QX4 & Xterra):
Disconnect negative battery cable. Remove the engine un-
der cover. Drain coolant and remove the radiator. Remove
engine cooling fan and water pump pulley. Remove acces-
sory drive belts. Remove spark plugs.
Remove distributor protector. Remove A/C compressor drive
belt idler bracket. Remove fresh air intake tube from rocker
cover. Remove thermostat housing hose.
Rotate crankshaft to set No. 1 cylinder at TDC on compres-
sion stroke. See Fig. 2. Remove crankshaft pulley bolt and 96B14499 Courtesy of Nissan Motor Co., U.S.A.
remove crankshaft pulley. Remove front upper and lower Fig. 1: Exploded View Of Timing Belt Components
belt covers.
Align punch mark on left camshaft sprocket with punch
mark on timing belt upper rear cover. Align punch mark on
crankshaft sprocket with notch on oil pump housing. See
Fig. 3. Install crankshaft pulley bolt so that crankshaft can
be rotated.
Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner,
and remove timing belt.
Inspection (Frontier, Pathfinder, QX4 & Xterra):
Check timing belt for cracks and broken or worn teeth.
Check belt tensioner for smooth turning. Check condition
of tensioner spring. Replace parts as necessary.
Installation (Frontier, Pathfinder, QX4 & Xterra):
Install timing belt when engine is cold. Ensure No. 1 cylin-
der is at TDC on compression stroke. Crankshaft sprocket
mark should align with mark on rear cover. See Fig. 5. If
removed, install timing belt tensioner and tensioner spring.
NOTE: If stud for tensioner spring is removed, apply thread sealant

to stud threads before installing. 96E14500 Courtesy of Nissan Motor Co., U.S.A.
Fig. 2: Setting Crankshaft To TDC

NISSAN 457
96G14502 Courtesy of Nissan Motor Co., U.S.A.

Fig. 4: Loosening Timing Belt Tensioner Nut
96F14501 Courtesy of Nissan Motor Co., U.S.A.

Fig. 3: Aligning Camshaft & Crankshaft Punch Marks
If vehicle is equipped with manual A/C, move temperature

control lever to full HOT position. If vehicle is equipped with
automatic A/C, turn ignition on. Remove air relief plug on
intake manifold collector. See Fig. 7. Remove heater hose
from heater core inlet. See Fig. 8. Fill radiator slowly until 96H14503 Courtesy of Nissan Motor Co., U.S.A.
coolant starts to drip from air relief plug. Tighten air relief Fig. 5: Positioning Camshaft & Crankshaft Sprockets
plug to 61-69 INCH lbs. (7-8 N.m).
Fill radiator and coolant reservoir tank to MAX mark. Install Remove upper radiator hose and water inlet hose from
and tighten radiator cap. Start and run engine until warm. timing belt end of engine. Remove A/C compressor drive
Run engine at 3000 RPM for at least 10 seconds (repeat 2- belt idler bracket. Remove water pump pulley. Remove
3 times). Stop engine and allow it to cool. Refill radiator and breather pipe from timing belt front upper cover. Remove
coolant reservoir as necessary. front upper and lower belt covers.
Repeat previous step at least 3 times with temperature Align punch mark on left camshaft sprocket with punch
control lever at several different positions between full COLD mark on timing belt upper rear cover. Align punch mark on
and full HOT positions. System is full when water noise is crankshaft sprocket with notch on oil pump housing. See
no longer heard at heater core and coolant level no longer Fig. 3. Install crankshaft pulley bolt so that crankshaft can
drops. Adjust drive belts to proper tension. See page A-60 be rotated.
for belt tension ranges. Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner,
Removal (Quest): and remove timing belt.
Raise and support vehicle. Remove the engine under cover.
Remove right side wheel and engine side cover. Drain cool- NOTE: After removing timing belt, DO NOT turn crankshaft or
ant from radiator. Remove accessory drive belts. camshaft separately or valves will strike pistons.
Rotate crankshaft to set No. 1 cylinder at TDC on compres- Inspection (Quest):
sion stroke. See Fig. 2. Remove crankshaft pulley bolt and Check timing belt for cracks and broken or worn teeth.
remove crankshaft pulley using a gear puller. Check belt tensioner for smooth turning. Check condition
of tensioner spring. Replace parts as necessary.
458 NISSAN
Slowly add coolant through radiator filler neck allowing
several minutes for air to escape. When coolant starts to
drip from radiator air relief plug, close plug. Tighten radia-
tor air relief plug to 15-19 ft. lbs. (20-26 N.m).
Continue adding coolant while gently moving upper radia-
tor hose up and down until coolant no longer lowers in filler
neck. Place wire under radiator filler cap negative pressure
relief valve. See Fig. 10. DO NOT install cap at this time. If
vehicle is equipped with rear heater, ensure rear fan is ON
and rear temperature control lever is in full HOT position.
Start and run engine at 2000 RPM for 10-15 minutes or until
lower radiator hose becomes hot. If coolant comes out of
engine air relief plug, close plug. Tighten plug to 15-19 ft.
lbs. (20-26 N.m). If coolant in radiator neck lowers, add
coolant. If coolant overflows filler neck, install radiator cap
(with wire installed).
NOTE: Ensure coolant level in reservoir tank is maintained at

Courtesy of Nissan Motor Co., U.S.A. MAX mark for the following steps.
Fig. 6: Installing Timing Belt On vehicles without rear heater, ensure temperature con-
Installation (Quest): trol lever is in full HOT position. Select any fan speed and
Install timing belt when engine is cold. Ensure No. 1 cylin- mode except OFF. Ensure A/C control unit is in ON position.
der is at TDC on compression stroke. Crankshaft sprocket Run engine at 3000 RPM for 5 minutes or until outlet air is
mark should align with mark on rear cover. See Fig. 5. If hot. Repeat this step at least 3 times. Ensure no water
removed, install timing belt tensioner and tensioner spring. noise is present in heater core.
On vehicles with rear heater, run engine at 3000 RPM with
NOTE: If stud for tensioner spring is removed, apply thread sealant front temperature control lever in full COLD position. Move
to stud threads before installing. rear temperature control lever to full HOT position. Select
any fan speed except OFF. Ensure A/C control unit is in ON
Turn tensioner clockwise fully outward with hexagon wrench position. Start and run engine for 5 minutes or until rear
and temporarily tighten lock nut. Align white lines on timing outlet air is hot.
belt with punch marks on camshaft sprockets and crank- Move rear temperature control lever to full COLD position.
shaft sprocket. See Fig. 6. Point arrow on timing belt to- Move front temperature control lever to full HOT position.
ward front belt cover. There should be 40 teeth between left Select any fan speed and mode except OFF. Start and run
and right camshaft sprockets and 43 teeth between left engine for 5 minutes or until front outlet air is hot. Repeat
camshaft sprocket and crankshaft sprocket. previous step and this step at least 3 times. Ensure no
Loosen tensioner lock nut. Using hex wrench, turn water noise is present in front or rear heater core.
tensioner clockwise and counterclockwise at least 2 times. On all models, stop engine. Fill coolant reservoir to MAX
Tighten tensioner lock nut. Turn crankshaft clockwise at mark. Let engine cool down. Remove radiator cap and re-
least 2 revolutions, then slowly set No. 1 cylinder at TDC on move wire from negative pressure valve. Fill radiator as
compression stroke. Apply 22 lbs. (10 kg) of force to belt necessary and reinstall radiator cap. Remove hose from
(downward direction) midway between camshaft sprock- heater pipe air relief and quickly install cap on pipe. Fill
ets. Belt deflection should be 0.51-0.59 (13-15 mm). If not, reservoir as necessary and install reservoir cap. Adjust drive
readjust belt tension. belts to proper tension. See page A-60 for belt tension
Install lower and upper belt covers. Install crankshaft pul- ranges.
ley. Tighten bolt to specfication. See TORQUE SPECIFICA-
TIONS. To complete installation, reverse removal proce- TORQUE SPECIFICATIONS
dures. Fill and bleed cooling system. Application Ft. Lbs. (N.m)
If vehicle is equipped with manual A/C, turn ignition on. Camshaft Sprocket Bolt .................................... 58-65 (79-88)
Move temperature control lever to full COOL position. Se- Crankshaft Pulley Bolt .............................. 141-156 (191-211)
lect any fan speed and mode except OFF. If vehicle is also Spark Plugs ......................................................... 14-22 (20-29)
equipped with rear heater, set rear controls to the full HOT Timing Belt Tensioner Lock Nut/Bolt ................ 32-43 (43-58)
position. Water Pump Bolt .............................................. 12-15 (16-20)
If vehicle is equipped with automatic A/C, turn ignition on. Wheel Lug Nut
Move temperature control lever to full HOT position. Select Quest ............................................................... 72-87 (98-118)
any fan speed and mode except OFF. If vehicle is also INCH Lbs. (N.m)
equipped with rear heater, set rear control to the full HOT Cooling Fan & Water Pump Pulley Bolts ............ 52-89 (6-10)
position. Radiator Mounting Bolts ................................. 34-42 (3.8-4.8)
On all models, loosen radiator and engine air relief plugs. Timing Belt Cover ................................................. 27-43 (3-5)
Remove heater pipe air relief cap. See Fig. 9. Connect one
end of 40 clear, heat resistant hose to heater pipe air re-
lief. Fill coolant reservoir to MAX mark and place hose from
heater pipe air relief into reservoir. Ensure hose is below
coolant level at all times.
NISSAN 459
Fig. 7: Locating Air Relief Plug

(Frontier, Pathfinder, QX4 & Xterra)
Fig. 8: Locating Heater Core Inlet Hose

(Frontier, Pathfinder, QX4 & Xterra)
Fig. 9: Locating Air Relief Plugs (Quest)

Fig. 10: Holding Pressure Relief Valve Open
(Quest)
460 PEUGEOT
1.9L 4-Cylinder
TIMING BELT APPLICATION Insert Peugeot Lock Pin Tool (0153-G) or equivalent through
crankshaft lock pin holes. Both camshaft lock pins should
Application Labor Time Belt Part No. be able to be inserted through lock pin holes without effort.
1.9L 4-Cyl. See Fig. 1. If not, timing belt must be removed and rein-
405 stalled.
1989-91 Position belt tension tool on timing belt. Meter reading
DOHC ................. 4.0 Hours ..................... T188 should be between 40-50 SEEM units. If meter reading is
not within limits, timing belt must be retensioned. Remove
SOHC ............... 4.0 Hours ..................... T189 belt tensioning tool, then locking pins. Install lower cover.
Lock flywheel in position with Peugeot Lock Tool (J-36358)
MANUFACTURERS SUGGESTED or equivalent. Install crankshaft pulley.
SCHEDULED MAINTENANCE To complete installation, reverse removal procedure. Ad-
just drive belts to proper tension.
Although the manufacturer does not recommend a specific Removal (SOHC):
scheduled maintenance interval, belt manufacturers suggest Disconnect negative battery cable. Remove right mud
the belt be replaced at 60,000 mile intervals. shield. Remove A/C compressor and alternator drive belts.
Remove upper timing belt cover. Rotate crankshaft using
REMOVAL & INSTALLATION pulley bolt, aligning holes in camshaft sprocket and crank-
TIMING BELT shaft pulley for pin installation. Insert Peugeot Locking Pin
Tool (No. 0-0163) or equivalent, through camshaft sprocket
Removal (DOHC):
and crankshaft pulley locking pin holes. See Figs. 2 and 4.
Disconnect negative battery cable. Raise and support front Remove locking pins. Remove lower flywheel cover. Using
of vehicle. Remove A/C compressor drive belt. Remove A/C Flywheel Stop Tool (No. 91-86) or equivalent, lock flywheel in
compressor from mounting bracket with refrigerant hoses
position. Remove crankshaft pulley retaining bolt and crank-
attached. Suspend compressor from lower frame at bot- shaft pulley. Remove stop tool that was used to lock flywheel
tom of engine compartment. in position.
Remove alternator drive belt, then alternator. Support en- Remove upper portion of timing belt lower cover. Remove
gine. Remove upper engine mount and two upper cover lower portion of timing belt lower cover. Loosen three tim-
bolts. Tilt engine and transmission assembly as far as ing belt tensioner nuts. Do not remove timing belt tensioner
possible. Disconnect wiring harnesses from relay box, then
nuts. Push timing belt tensioner away from timing belt to
pull up on clip and lift upper cover upward. relieve tension. Tighten tensioner retaining bolt next to pul-
Remove lower flywheel housing cover. Hold flywheel in po- ley to hold tensioner in position.
sition with Peugeot Lock Tool (J-36358) or equivalent. Re-
move right mud shield. Remove 4 crankshaft pulley retain-
Remove timing belt from sprockets.
Installation (SOHC):
ing bolts, then crankshaft pulley. Remove lower cover. Re- Position crankshaft pulley and key to crankshaft, then loosely
move flywheel locking tool.
install crankshaft pulley retaining bolt. Insert Peugeot Lock-
Rotate engine, using crankshaft pulley bolt, to align crank- ing Pin Tool (No. 0-0163) or equivalent, through camshaft
shaft lock pin hole with engine lock pin hole. See Fig. 1. sprocket and crankshaft pulley locking pin holes. See Figs.
Insert Peugeot Lock Pin (No.0153-G) or equivalent through
2 and 4.
crankshaft lock pin holes, remove pin. Insert Peugeot Lock Remove crankshaft retaining bolt and pulley. Install timing
Pins (No. 0153-M) or equivalent through camshaft sprocket belt over camshaft sprocket, crankshaft sprocket and water
lock pin holes.
pump sprocket, then position timing belt on tensioner pul-
Loosen timing belt tensioner bolts, then turn tensioner to ley. Ensure timing belt is properly seated on sprockets.
relieve tension on timing belt. Remove timing belt from sprock- Loosen tensioner nut, then turn tensioner square to re-
ets.
lease spring.
Installation (DOHC): Remove locking pins, then tighten tensioner retaining nuts.
Ensure that camshaft and crankshaft locking pins are in Rotate crankshaft 2 turns in direction of engine rotation
position. See Fig. 1. Install belt in order, observing direction
and bring No. 1 cylinder to TDC of compression stroke.
of engine rotation. Start with camshaft sprockets, tensioner, Loosen timing belt tensioner retaining nuts to tension tim-
crankshaft sprocket, water pump sprocket and tensioner. ing belt. After timing belt has tensioned, tighten tensioner
See Fig. 3.
retaining bolts. Position crankshaft pulley and key to crank-
Lift and tilt engine and transmission assembly as far as shaft then loosely install crankshaft pulley retaining bolt.
possible, then position belt tensioning tool on indicated Insert Peugeot Locking Pin Tool (No. 0-0163) or equiva-
section of timing belt and lock in position. Rotate tensioner
lent, through camshaft sprocket and crankshaft pulley lock-
one full turn. Using Peugeot Tensioner Tool (No. 0153-P) ing pin holes. See Figs. 2 and 4. If pins are not aligned with
or equivalent, rotate tensioner counterclockwise until 19 holes, timing belt must be removed and reinstalled. Re-
SEEM units are displayed on belt tensioning tool meter.
move crankshaft retaining bolt and pulley.
See Fig. 3. Without changing tensioner position, torque Install lower and upper portions of timing belt lower cover.
tensioner bolt to 18 ft. lbs., then remove belt tensioning Position crankshaft pulley and key to crankshaft, then loosely
meter.
install crankshaft pulley retaining bolt. Using Peugeot Flywheel
Rotate tensioner counterclockwise until 21 SEEM units are Stop Tool (No. 91-86) or equivalent, lock flywheel in position,
displayed on belt tensioning tool meter. See Fig. 3. Without then tighten crankshaft pulley retaining bolt. To complete in-
changing tensioner position, torque tensioner bolt to 18 ft.
lbs. Remove three locking pins and rotate crankshaft two proper tension. See page A-60 for belt tension ranges.
turns in normal direction of engine rotation.
PEUGEOT 461

TIGHTENING SPECIFICATIONS
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)
Fig. 3: Installing Timing Belt & Tensioning Tool (DOHC)
Fig. 1: Installing Camshaft & Crankshaft Sprocket

Locking Pins (DOHC)
Fig. 4: Installing Crankshaft Sprocket Timing Pin (SOHC)
Fig. 2: Installing Camshaft Sprocket Timing Pin (SOHC)

462 PEUGEOT
2.2L 4-Cylinder
2.2L 4-Cyl.
505
1986-91 ................. 2.7 Hours ..................... T140

TIMING BELT
Removal:
Disconnect battery. Drain cooling system including cylin-
der block. Remove radiator and fan shroud. Remove ther-
mostat housing and auxiliary air device.
Align timing marks for crankshaft, camshaft and intermedi-
ate shaft. See Fig. 1. Remove crankshaft pulley bolt and
pulley. Ensure that crankshaft does not rotate. Remove tim-
ing belt cover. Loosen timing belt tensioner bolts and posi-
tion tensioner out of way. Remove camshaft pulley and tim-
ing belt.
Installation:
Ensure timing marks remain in alignment. See Fig. 1. Re-
move distributor cap and check rotor position. Distributor
rotor must be at a 90 degree angle to the crankshaft. If not,
turn intermediate shaft once or twice.
Install timing belt, centered on pulleys and tensioner. Fig. 1: Locating 2.2L Timing Marks
Loosen belt tensioner mounting bolts and allow spring to
adjust timing belt. Tighten belt tensioner bolts.
To complete installation, reverse removal procedures.
Crankshaft pulley bolt must be reinstalled using Loctite.
tension ranges.
TIGHTENING SPECIFICATIONS
Crankshaft Pulley Bolts ............................................ 98 (133)
Timing Belt Tensioner Nut/Bolt ................................... 18 (26)
PORSCHE 463
*2.0L 4-Cylinder
Belt TIMING BELT
Application Time Kit No. No. Disconnect negative battery cable. Remove accessory drive
2.0L 4-Cyl. belts and any components as necessary to access cam-
924 shaft sprocket cover. Remove camshaft sprocket cover. Align
1977-82 .......... 1.0 Hrs. ...... TCK017 .......... T017 mark on camshaft sprocket with indicator on cylinder head
cover. The TDC mark on flywheel and housing must align
with each other. Loosen timing belt tensioner. Remove
NOTE: A timing belt component kit is available for timing belt.
this application. See page I for information on component Installation:
kits. To install components, reverse removal procedure. Belt
must be tightened until belt can be turned 90 degrees with
thumb and index finger at a point midway between crank-
MANUFACTURERS SUGGESTED shaft and camshaft. Adjust drive belts to proper tension.
SCHEDULED MAINTENANCE See page A-60 for belt tension ranges.
The manufacturer recommends that under normal operating TORQUE SPECIFICATIONS
conditions, check tension at 2,000 miles, then every 15,000 Application Ft. Lbs. (N.m)
miles. Replace belt every 45,000 miles. Camshaft Sprocket Bolt .............................................. 58 (79)
* NOTE: This application is an interference engine. Crankshaft Pulley ................................................... 180 (245)
Tensioner Pulley ......................................................... 29 (39)
See page A-59 for interference engine cautions. INCH Lbs. (N.m)
Camshaft Sprocket Cover ........................................... 84 (10)
464 PORSCHE
*2.5L, *2.7L & *3.0L 4-Cylinder
TIMING BELT APPLICATION Turn crankshaft clockwise to align camshaft sprocket TDC
mark with mark in distributor cap console. See Fig. 2. En-
Belt Part No. sure mark on upper and lower balance shaft sprockets
2.5 L 4-Cyl. align with mark on rear timing belt cover. See Fig. 3.
924 The flywheel mark for No. 1 cylinder must also align with
1987-88 cast boss on clutch housing. On 1986 and earlier models,
Balance Shaft ... 1.5 Hours ..................... T293 release belt tension. On 1987 and later models, mechani-
cal belt tensioner must be removed. See Fig. 5. Remove
Camshaft ............. 1.5 Hours ..................... T107 balance shaft drive belt. Loosen camshaft belt tensioning
944 sprocket lock nut and then sprocket by turning it clockwise.
1983-89 Remove camshaft timing belt.
Balance Shaft ... 4.0 Hours ..................... T293 Installation (Camshaft Belt):
Camshaft ............. 4.0 Hours ..................... T107 Ensure No. 1 cylinder is at TDC and marks on flywheel and
944S cast clutch housing are aligned. Align mark on camshaft
1987-88 sprocket with mark on rear drive belt cover. Install camshaft
timing belt by placing belt on crankshaft sprocket, tensioner
Balance Shaft ... 2.4 Hours ..................... T293 sprocket, water pump pulley and camshaft sprocket. See
Camshaft ............. 2.4 Hours ..................... T152 Fig. 4. Adjust drive belts to proper tension. See page A-60
2.7L 4-Cyl. for belt tension ranges. After drive belt tension is adjusted,
944 install balance belt. To complete installation, reverse re-
1989 moval procedure.
Balance Shaft ... 3.5 Hours ..................... T293 Tension Adjustment:
Camshaft ............. 3.5 Hours ..................... T107 Rotate crankshaft clockwise until TDC mark on camshaft
sprocket aligns with cast mark in distributor cap mount.
3.0L 4-Cyl. Ensure TDC marks on flywheel and cast clutch housing
944 are aligned. Loosen tensioner adjustment bolts. See Fig.
1989-91 5. Using thumb pressure, press downward on camshaft
Balance Shaft ... 3.5 Hours ..................... T293 belt between water pump pulley and camshaft sprocket.
Camshaft ............. 3.5 Hours ..................... T152 Force camshaft belt against belt cover.
968 NOTE: On 944-S models, intake camshaft is chain driven from
1992-95 the exhaust camshaft.
Balance Shaft ... 3.4 Hours ..................... T293
Camshaft ............. 3.4 Hours ..................... T152 Repeat procedure twice to ensure free movement of belt
idler pivot. Allow idler spring tension to apply tension against
1
- With Pwr. Strng. add .3 hours. belt. Tighten adjustment bolts to 15 ft. lbs. (20 N.m).
CAUTION: DO NOT remove balance shaft sprocket mounting

MANUFACTURERS SUGGESTED bolts to replace drive belt. Handle metal insert drive belts carefully.
SCHEDULED MAINTENANCE Mark belt direction of rotation prior to removal if belt is to be
reused.
45,000 miles. Installation (Balance Belt):
Ensure No. 1 cylinder is at TDC and marks on flywheel and
* NOTE: This application is an interference engine. cast clutch housing are aligned. Align mark on camshaft
See page A-59 for interference engine cautions. sprocket with mark on rear drive belt cover. Install balance
belt with color coded tooth facing out. Adjust drive belts to
proper tension. To complete installation, reverse removal
REMOVAL & INSTALLATION procedure.
NOTE: When using belt tension gauge, always zero telltale gauge
needle after lock pin is engaged (turned counterclockwise). Adjust
drive belt tension only on a cold engine. Ensure gauge does not
turn on belt and slides remain flat on belt surface.
TIMING BELT
CAUTION: On models equipped with supplemental restraint system
(air bags), wait 20 minutes after disconnecting battery before
starting repairs. Failure to wait the suggested time may result
in air bag deployment and possible personal injury.
Removal:
Disconnect negative battery cable. Remove splash shield.
Remove air cleaner assembly with air flow sensor. Discon-
nect vent hose and position to one side. Remove timing
belt cover assembly. Remove distributor cap and position
to one side. Raise and support vehicle. Ensure pressure
rod bolts are are slightly loose prior to loosening lock nuts. Fig. 1: Loosening Pressure Rod
See Fig. 1. Remove accessory drive belts.
PORSCHE 465
*2.5L, *2.7L & *3.0L 4-Cylinder (Cont.)

Adjustment:
For upper shaft, align grove 0 with Woodruff key. For lower
shaft, align unmarked grove with Woodruff key. See Fig. 3.
Pull out lock pin on tension gauge and push out gauge pin
opposite lock pin. Zero telltale needle.
Slide tension gauge onto belt. Push in gauge needle until
lock pin is heard engaging. Read value from dial gauge.
On engine with slotted guide roller, tension should be 2.4-
3.0 for both new and used belts.
If adjustment is necessary, turn tensioner clockwise to
tighten and counterclockwise to loosen. Tighten tensioner
nut. After adjusting drive belt tension, adjust idler pulley
position.
Use Adjusting Gauge (9207) or a .020" (.50 mm) feeler
gauge to ensure a .020" (.50 mm) clearance exists be-
tween drive belt (at lower balance shaft sprocket) and idler
pulley is maintained when upper portion of drive belt is
preloaded at .04-.08" (1.0-2.0 mm).
Tighten idler pulley. See Fig. 3. If correct gap cannot be
reached, rotate idler pulley 180 degrees and repeat adjust-
ment. Tighten mounting nut. Install and adjust poly-rib belt. Fig. 2: Aligning Camshaft Sprocket Timing Mark
Balance Shaft Bearing Cover ............................................... 1
Step 1:
2 Bolts @ Bearing (8 mm) ..................................... 11 (15)
Step 2
6 mm ....................................................................... 7 (10)
8 mm ..................................................................... 15 (20)
Step 3:
2 Bolts @ Bearing (8 mm) ..................................... 24 (33)
Balance Shaft Sprocket Mounting Bolt ........................ 33 (45)
Belt Tensioner Mounting Bolt ...................................... 33 (45)
Camshaft Housing Mounting Bolt .............................. 15 (20)
Camshaft Plug (Aluminum) ........................................ 30 (41)
Camshaft Sprocket
Hex Mounting Bolt ..................................................... 33 (45)
Polygon Mounting Bolt .................................... 47-51 (64-69)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt ......................................... 96 (8)
Transport Clamp-to-Camshaft Housing ...................... 96 (8)
1
- Check movement of balance shaft between each tighten- Fig. 3: Aligning Upper Balance Shaft Timing Mark
ing step.
Fig. 4: Drive Belt Positioning

466 PORSCHE
*2.5L, *2.7L & *3.0L 4-Cylinder (Cont.)
Fig. 6: Balance Shaft Drive Belt Positioning
Fig. 5: Mechanical Belt Tensioner

PORSCHE 467
*4.5L, 4.7L, 5.0L & 5.4L V8

TIMING BELT APPLICATION On 4.5L V8, align TDC mark on vibration damper with red
indicator on cover. On 4.7L, 5.0L & 5.4L V8, align mark for
Application Labor Time Belt Part No. 45 degrees BTDC on vibration damper with Red needle.
4.5L V8 Turn crankshaft clockwise. See Fig. 2. On 4.5L V8, rotate
928 crankshaft clockwise until timing marks (notches) on cam-
1978-82 ................. 4.6 Hours ..................... T196 shaft sprockets align with marks cast on camshaft bearing
4.7L V8 caps.
928 On 4.7L, 5.0L & 5.4L V8, lock crankshaft by installing
Porsche Tool (9161/1) or equivalent. Secure tool with slave
1983-84 ................. 4.6 Hours .................... T196 cylinder mounting bolts.
5.0L V8 Remove crankshaft pulley mounting bolt, both pulleys, vi-
928 bration damper and collar. Remove oil dipstick tube. Re-
1985-91 ................. 6.5 Hours ..................... T196 move alternator. Remove left upper and center timing belt
5.4L V8 covers. Loosen timing belt tensioner. Loosen tensioning
928 roller. Remove timing belt.
Installation:
1992-95 ................. 6.5 Hours ..................... T196 On 4.5L V8, align TDC mark on vibration damper with Red
indicator on cover. On 4.7L, 5.0L & 5.4L V8, align mark for
MANUFACTURERS SUGGESTED 45 degrees BTDC on vibration damper with Red needle.
SCHEDULED MAINTENANCE Turn crankshaft clockwise. See Fig. 2. On 4.5L V8, rotate
crankshaft clockwise until timing marks (notches) on cam-
The manufacturer recommends the belt be replaced every shaft sprockets align with marks cast on camshaft bearing
60,000 miles. caps.

TIMING BELT
NOTE: On 1983 4.5L V8 models, the tooth shape of the timing
belt was changed to high torque drive (HTD). See Fig. 1. New HTD
belts can be used on older engines if sprockets with new tooth
shape are installed. NEVER mix sprockets with different tooth
shapes.
NOTE: When replacing drive belt, ensure proper type is used

and new belt teeth match used sprockets. Early design belt uses
square-shouldered teeth with belt thickness of .18" (4.5 mm). Late
design belt uses round teeth (high torque drive type) with a belt
thickness of .22" (5.6 mm). All sprockets must match belt tooth
design.
Removal:
Disconnect negative battery cable. Remove air cleaner in-
take hoses. Remove accessory drive belts. Disconnect
cables for throttle, cruise control and automatic transaxle.
Remove retainers and clamp on console and position cable
aside. Remove clutch slave cylinder.
CAUTION: NEVER operate clutch pedal when slave cylinder is

removed.
Fig. 1: Camshaft Sprocket & Timing Belt Types

468 PORSCHE
*4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)
NOTE: Manufacturer indicates sufficient clearance exists so
TIMING BELT TENSIONER
pistons and valves will not collide when crankshaft is turned
with camshaft timing belt removed. NOTE: The timing belt tensioning mechanism uses hydraulic
dampening and a temperature compensation mechanism to reduce
Preload belt by hand and install belt on sprockets in order belt load and dampen oscillation. See Fig. 4. The tensioner roller
of crankshaft, oil pump, left camshaft, water pump, right and carrier is supported against the pull of toothed belt by a
camshaft and tension roller. See Fig. 2. Ensure belt and push rod and piston on a 7 packet (5 each) bi-metallic diaphragm
camshaft sprocket teeth match. If necessary, rotate cam- spring set. Tensioner is filled with engine oil (which is added
shaft counterclockwise until teeth match. Tighten timing only after installation on block). Replacement tensioners are
belt to specification. Rotate engine 2 revolutions and align not oil filled so oil must be added and unit bled for proper operation.
cylinder No. 1 at TDC of compression stroke. Pockets between tensioner roller housing and engine block are
Check camshaft timing marks for proper alignment and used as oil reservoirs to aid in heat transfer between engine block
retighten camshaft drive belt. Ensure tester is not turned or and tension roller housing and activate bimetallic diaphragm
pushed during tension measurement. Recheck belt ad- springs.
justment at least once. Adjust drive belts to proper tension. When installing tensioner, ensure sealing surface on block
See page A-60 for belt tension ranges. is in good condition. Apply Locktite (No. 574) to sealing
Adjustment: surface before installation. When filling tensioner, damp-
With both upper drive belt guards removed, rotate crank- ing chamber may be bled by pumping tension roller carrier.
shaft (in direction of rotation) and position cylinder No. 1 at Ensure belt is loose and oil filler bolt and bleeder are open.
TDC of compression stroke. Mark on vibration damper To fill, remove the larger oil filler and open Allen head bleeder
should be in alignment with Red indicator on cover. screws on tensioner housing. Using an oil can, slowly pour
Ensure each camshaft sprocket timing mark is in align- oil into filler hole until air-free oil flows from bleeder hole.
ment with mark cast on camshaft bearing cap. Turn engine Install and tighten filler and bleeder screws. Check fluid
over 2 more times until TDC is reached again. level after 1000 miles and at 15,000 mile intervals thereaf-
Check timing belt for damage and wear. Pull out lock pin, ter. To check, remove filler bolt. If oil can be seen, level is
then completely push out gauge pin (opposite lock pin) on okay. If not, add oil as necessary.
Timing Belt Tension Tester (9201) or equivalent. Move tell-
tale to 0 position on gauge. See Fig. 3.
Slide tension tester onto belt section between tension roller Application Ft. Lbs. (N.m)
and lower camshaft sprocket. Ensure measuring pin is Camshaft Housing Mounting Bolt .............................. 14 (20)
resting in belt grove. Push tester down on side closer to Camshaft Pulley Mounting Bolt ................................... 33 (45)
tensioner, until gauge needle, resting on air pump bracket, Front Pulley Mounting Nut ......................... 181-188 (250-260)
engages.
Read measured valve while keeping tester horizontal to
belt and free of tension. Tester must not touch plastic cover.
Move telltale to 0 position on gauge.
Pull out lock pin to disengage gauge needle again. Re-
move tester from timing belt and read measured value.
Correct belt tension if necessary. Adjustment screw is lo-
cated on bottom of engine, at right front side. To adjust,
loosen adjustment screw lock nut and turn adjustment
screw until tension is correct. Tighten lock nut and turn
engine 2 revolutions. Recheck tension adjustment.
TIMING BELT TENSION
Application Scale Value
New or used ..................................................................... 4.5
Fig. 2: View Of Camshaft Drive Belt Installation

PORSCHE 469
*4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)
Fig. 3: Drive Belt Tension Tester

470 RENAULT
*1.7L 4-Cylinder
TIMING BELT APPLICATION Align timing belt marks with timing mark on camshaft
sprocket and crankshaft sprocket. See Fig. 2. Remove TDC
Application Labor Time Belt Part No. tool from crankcase, then rotate crankshaft clockwise, 2
1.7L 4-Cyl. complete revolutions. Reinstall TDC tool through crank-
Alliance & Encore case into crankshaft. Ensure that the camshaft sprocket
1985-87 .................... 2.3 Hours ..................... T119 timing mark is aligned with mark on rear cover plate. See
Fig. 1.
MANUFACTURERS SUGGESTED NOTE: The intermediate shaft sprocket does not have a timing
SCHEDULED MAINTENANCE mark.
Although the manufacturer does not recommend a specific There should be 66 timing belt teeth (cogs) between cam-
scheduled maintenance interval, belt manufacturers suggest shaft sprocket timing mark and crankshaft sprocket timing
the belt be replaced at 60,000 mile intervals. mark. See Fig. 2. Remove TDC tool and install plug into
cylinder block. Check timing belt deflection between interme-
* NOTE: This application is an interference engine. diate shaft sprocket and idler pulley. With belt cold, deflection
See page A-59 for interference engine cautions. should be .295 (7.49 mm). With belt hot, deflection should be
.216 (5.48 mm).
If deflection is excessive, loosen tensioner pulley lock nut,
REMOVAL & INSTALLATION then turn tensioner pulley nut counterclockwise to increase
tension or counterclockwise to decrease tension. While
TIMING BELT holding tensioner pulley lock nut with a suitable wrench,
Removal: tighen tensioner pulley lock nut to specification. To com-
Disconnect negative battery cable. Remove accessory drive plete installation, reverse removal procedures. Adjust drive
belts. Remove timing belt cover. Rotate crankshaft until No. belts to proper tension. See page A-60 for belt tension
1 cylinder is at TDC of compression stroke. Ensure that ranges.
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. Application Ft. Lbs. (N.m)
Loosen timing belt tensioner, then remove timing belt. Tensioner Pulley Lock Nut .......................................... 30 (41)
NOTE: If there is no reference mark on camshaft sprocket rear

cover plate, scribe a matching mark in line with timing mark
on sprocket.
NOTE: DO NOT rotate crankshaft or camshaft with timing belt

removed.
Installation:
Ensure that Renault TDC Tool (Mot. 861) is properly seated
and align camshaft sprocket timing mark with mark on rear
cover plate. See Fig. 1. Position timing belt first over crank-
shaft sprocket, then intermediate shaft sprocket, and then
camshaft sprocket. See Fig. 2.
Position timing belt arrow, indicating direction of rotation
between intermediate shaft sprocket and idler pulley. See
Fig. 2. Loosen tensioner pulley lock nut, then turn tensioner
pulley nut counterclockwise until timing belt is taut. Hold
tensioner pulley nut from turning and tighten lock nut.
Fig. 1: Camshaft Sprocket Alignment Marks
RENAULT 471

472 RENAULT
2.2L 4-Cylinder
2.2L 4-Cyl.
Fuego
1984-85 ................ 2.2 Hours .................... T140
Sportwagon
1984-86 ................ 2.0 Hours .................... T140
scheduled maintenance interval, manufacturers suggest the
belt be replaced at 60,000 mile intervals.

TIMING BELT
Removal:
Remove radiator upper support. Remove upper and lower
hoses from radiator. Disconnect wiring harness connec-
tors from cooling fan and thermo switch. Remove radiator
and A/C condenser as an assembly.
Release tension and remove serpentine drive belt. Re-
move timing belt cover. Remove hose from water pump.
Remove water pump pulley bolt and pulley. Remove water
pump.
Remove timing belt tension spring and plunger from water
pump and install them in replacement water pump. Clean
gasket mating surfaces. Loosen timing belt tensioner idler
bolts. Remove timing belt.
Installation & Adjustment:
Position camshaft sprocket timing index in line with static
timing mark. Position crankshaft so No. 1 piston is at TDC Fig. 1: Installing Timing Belt
of compression stroke. Remove plug in cylinder block and
insert TDC Rod (Mot. 861) or equivalent, into TDC hole in
crankshaft. Install timing belt. See Fig. 1.
Position timing belt cover over sprockets and check cam-
shaft timing mark with index on cover. Remove TDC rod
and install plug in cylinder block. Rotate crankshaft clock-
wise 2 complete revolutions. DO NOT rotate counterclock-
wise. Remove timing belt cover and loosen timing belt
tensioner bolts a maximum of 1/4 turn.
Spring loaded timing belt tensioner will automatically ad-
just to correct position. Ensure clearance between timing
belt tensioner and intermediate shaft cover is .004" (.10
mm). See Fig. 2. Tighten bottom timing belt tensioner bolt.
Tighten top bolt. Test belt tension with Tension Gauge (Ele.
343) or equivalent. Deflection should be .216-.276" (5.5-
7.0 mm). Install timing belt cover. To complete installation,
Fig. 2: Adjusting Intermediate Shaft Cover Clearance

RENAULT 473
Fig. 3: Timing Belt Cover TDC Marks
Fig. 5: Aligning Camshaft & Crankshaft Sprockets

474 SAAB
*2.5L & 3.0L V6
TIMING BELT APPLICATION Turn engine 2 revolutions in normal direction of rotation.
Recheck camshaft and crankshaft timing mark alignment.
Application Labor Time Belt Part No. To complete installation, reverse removal procedure.
900
1994-97 ................. 2.3 Hours .................... T285 Application Ft. Lbs. (N.m)
3.0L V6 Crankshaft Pulley Bolt ................................................ 15 (20)
9000 Valve Cover Nuts ........................................................ 86 (10)
1995-97 ................. 2.3 Hours .................... T285
60,000 miles.


TIMING BELT
Removal:
Move power steering reservoir out of the way, and remove
right side engine-to-frame torque arm. Remove the power
steering line clamp from the torque arm engine mount.
Remove torque arm engine mount.
Relieve tension on serpentine belt and remove serpentine
belt. Remove the water pump pulley. Remove upper part of Courtesy of Saab-Scania of America, Inc.
alternator air intake. Remove the serpentine belt tensioner.
Remove the power steering pump with lines attached, and
move out of way. Remove the timing belt cover. Remove the
6 outer bolts from the crankshaft pulley, NOT the center
bolt.
Turn crankshaft so No. 1 cylinder is at TDC of compression
stroke. Ensure marks on camshaft sprockets and timing
cover align. See Fig. 1. Install Belt Holder (KM-800-1 and
KM-800-2) to hold camshaft sprockets in place. See Fig. 2.
If belt is to be reused, mark belt with direction of rotation.
Remove timing belt from engine.
NOTE: Use the marks on each side of the direction of rotation

arrows to line up the left (drivers side) camshaft sprockets. For
this design (idler pulley located above crankshaft) engine, use
the remaining 3 White marks on the Gates timing belt. Correct
belt marks MUST be used.
Installation:
Ensure crankshaft and camshaft timing marks are still
aligned. Install timing belt. Adjust lower roller counterclock- Courtesy of Saab-Scania of America, Inc.
wise to belt tension of 205-221 ft. lbs. (275-300 N.m). Ad- Fig. 2: Camshaft Belt Holders
just tensioning pulley with a hex head wrench until 2 marks
are aligned. Tighten bolt.
Remove locking tool for camshaft sprockets 1 and 2. Adjust
upper adjusting roller counterclockwise until No. 2 sprocket
moves .03-.07 (1-2 mm) clockwise. Remove camshaft lock-
ing tools.
STERLING 475
*2.5L & *2.7L V6

TIMING BELT APPLICATION Ensure timing belt is seated properly on pulleys. Tighten ad-
juster bolt. Reverse removal procedure to complete installa-
Application Labor Time Belt Part No. tion.
2.5L V6
825 NOTE: After timing belt installation, rotate engine clockwise
several times to ensure valves DO NOT contact pistons.
1987-88 .................. 4.0 Hours ................... T129
827
1989-91 .................. 4.0 Hours ................... T129 A/C Compressor Bolts ............................................... 16 (22)
A/C Compressor Bracket Bolts .................................. 33 (45)
MANUFACTURERS SUGGESTED Alternator Bracket Bolts .............................................. 33 (45)
SCHEDULED MAINTENANCE Alternator Mount Bolts ................................................ 16 (22)
Although the manufacturer does not recommend a specific Crankshaft Pulley Bolt ............................................ 123 (170)
scheduled maintenance interval, belt manufacturers suggest Engine Mount Bolts .................................................... 40 (54)
the belt be replaced at 60,000 mile intervals. Power Steering Pump Mount Bolt ............................... 33 (45)
* NOTE: This application is an interference engine. INCH Lbs. (N.m)
See page A-59 for interference engine cautions. Timing Belt Cover Bolts .............................................. 86 (10)
Valve Cover Bolts ...................................................... 106 (12)
REMOVAL & INSTALLATION Water Pump Bolts .................................................... 106 (12)
TIMING BELT
Removal:
Remove negative battery cable. Turn crankshaft clockwise
to bring No. 1 cylinder to TDC of compression stroke. Re-
move pulley cover from upper timing belt cover. Remove
engine wiring harness clamp from right side of engine com-
partment. Support front of engine. On right side of engine
compartment, remove engine-to-body mount (on front of
engine). Remove lower engine splash shield. Remove A/
C, power steering, and all other drive belts.
Remove alternator. Leaving hoses connected, remove
power steering pump and secure out of way. Remove up-
per timing belt pulley covers. Remove crankshaft pulley.
Remove timing belt lower cover. Loosen timing belt
tensioner to relieve tension on timing belt. If reusing timing
belt, mark direction of belt rotation before removing. Slide
belt off pulleys. Check belt for damage, missing teeth, or
cracks.
Installation:
Remove spark plugs. Turn crankshaft clockwise to bring
No. 1 cylinder to TDC of compression stroke. Advance crank-
shaft an additional 15 degrees from TDC position. Rotate
camshaft pulleys to compression stroke (TDC position) of
No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 de-
grees to TDC position.
Push timing belt tensioner to full release position and snug
adjuster bolt. Install timing belt over crankshaft pulley, front
camshaft pulley, water pump pulley, tensioner and then
over rear camshaft pulley. See Fig. 1. Note position of
timing belt pulley guides on both sides of crankshaft. In-
stall pulley guides so guides form a V groove for belt to
ride in. Loosen timing belt tensioner bolt. To complete in-
proper tension.
NOTE: Always adjust timing belt tension with engine cold.

Timing Belt Tension Adjustment:
Set No. 1 piston to TDC on compression stroke. Rotate
crankshaft clockwise 9 teeth on rear camshaft pulley. Blue
mark on crankshaft pulley should match pointer on lower Fig. 1: Adjusting Timing Belt
cover. Loosen timing belt tensioner bolt. See Fig. 1.
476 STERLING
*2.5L & *2.7L V6 (Cont.)

SUBARU 477
1.2L 3-Cylinder
Belt Part No. Application
1.2L 3-Cyl. Ft. Lbs. (N.m)
Justy INCH Lbs. (N.m)
1987-95 ................. 1.4 Hours ..................... T135 Camshaft Sprocket Bolt ............................ 97-106 (11.0-12.0)
1
- With Air Cond. add .4 hours. Tensioner Bolt ................................................ 50-53 (5.7-6.0)
With Pwr. Strng. add .2 hours. Valve Cover Bolt .............................................. 53-71 (6.0-8.0)
Water Pump Impeller Bolt ............................ 80-89 (9.0-10.0)
60,000 miles.

TIMING BELT
Removal:
Disconnect negative battery cable. Remove alternator drive
belt. Using Pulley Holder (499205500) or equivalent, loosen
crankshaft pulley bolts. Rotate engine until No. 3 cylinder is
at TDC. Remove crankshaft pulley retaining bolts using
access hole in fenderwell housing.
Remove outer timing belt cover. Loosen tensioner retain-
ing bolts. Move tensioner toward outside of engine. Tighten
bolts to hold tensioner. See Fig. 2. Mark timing belt for di-
rection of rotation. Remove crankshaft belt drive sprocket
plate and timing belt.
NOTE: Before removing timing belt, mark it indicating direction

of rotation. Timing belt must be installed in original direction
of rotation.
Inspection: Fig. 1: Exploded View Of Timing Belt Components
Inspect belt for signs of oil contamination. Replace belt if it
is damaged or contaminated. Inspect all drive sprockets
for wear in drive belt area. Inspect tensioner for noise and
grease leakage. Replace tensioner as necessary.
Installation:
Using Pulley Holder (499205500) or equivalent, rotate cam-
shaft to align camshaft sprocket alignment mark with align-
ment mark on timing belt cover. See Fig. 1. Install crank-
shaft belt drive sprocket (if removed) with flanged side fac-
ing inward. Rotate crankshaft so crankshaft belt drive
sprocket aligns with crankcase alignment mark. Remove
valve cover (if it was not previously removed). Loosen valve
adjusting screws to gain rocker arm free play.
Loosen tensioner retaining bolts. Apply tension to timing
belt. Tighten inner and then outer tensioner retaining bolts.
Ensure all timing marks are aligned. Install crankshaft belt
drive sprocket plate. Reverse removal procedure for re-
maining components. Tighten all bolts to specification. See
TORQUE SPECIFICATIONS. Adjust valve clearance. Adjust
ranges.

478 SUBARU
1.8L 4-Cylinder Except Impreza & Legacy
Install belt tensioners and belt idler. Position belt tensioners
Belt to allow belt installation. Install inner (sprocket without dowel
Labor Component Part pin) and outer crankshaft sprockets on crankshaft. Tempo-
Application Time 1 Kit No. No. rarily install crankshaft pulley.
1.8L 4-Cyl. Align center mark on flywheel with mark on flywheel hous-
DL, GL & RX (Coupe, Sedan & Station Wagon) ing. See Fig. 3. Align timing mark on left camshaft sprocket
(sprocket for timing belt closest to engine) with notch in
1985-89 belt cover. See Fig. 4. Install left timing belt first on inner
Left Side ..... 2.7 Hrs ...... TCK299 ........... T299 crankshaft sprocket and then around oil pump sprocket.
Right Side ... 2.7 Hrs. ..... TCK299 ........... T300 Install left timing belt on idler and then camshaft sprocket.
Loyale If reusing belt, install it in original direction of rotation.
1990-94 Loosen left tensioner retaining bolt to apply tension to tim-
Left Side ..... 2.7 Hrs. ..... TCK299 ........... T299 ing belt. Push timing belt by hand to ensure smooth opera-
Right Side ... 2.7 Hrs. ..... TCK299 ........... T300 tion and movement of tensioner. Using Belt Tensioner
Wrench (499437000) or equivalent, apply 17-19 ft. lbs. (23-
XT 26 N.m) of torque to camshaft sprocket in a counterclock-
1985-91 wise direction.
Left Side ..... 2.7 Hrs. ..... TCK299 ........... T299 While applying torque, tighten tensioner bolts. Ensure all
Right Side ... 2.7 Hrs. ..... TCK299 ........... T300 timing marks are aligned. See Figs. 3 and 4.
1
- Both Belts. NOTE: After installing left side timing belt, crankshaft is rotated
With Air Cond. add .4 hours. 1 full turn (360 degrees). This will be the position for installing
With Pwr. Strng. add .2 hours. the right side camshaft belt. The camshaft timing mark for the
left side timing belt will now be pointing straight down (6 oclock
NOTE: A timing belt component kit is available for position). See Fig. 5.
this application. See page I for information on component To install right (outer) timing belt, rotate crankshaft clock-
kits. wise 360 degrees and align center line on flywheel with
timing mark on flywheel housing. Align camshaft sprocket
timing mark with notch in housing. See Fig. 4.
MANUFACTURERS SUGGESTED Install right timing belt over crankshaft and camshaft sprock-
SCHEDULED MAINTENANCE ets, keeping slack out of side opposite tensioner. Ensure
The manufacturer recommends the belt be replaced every reused belt is installed in original direction of rotation.
52,500 miles. Loosen inner tensioner bolt and allow tensioner to apply
belt tension. While turning camshaft sprocket counterclock-
REMOVAL & INSTALLATION wise, apply 17-19 ft. lbs. (23-26 N.m) of torque using Belt
Tension Wrench (499437000) or equivalent.
TIMING BELT
NOTE: When timing belts are properly installed, left side camshaft
Removal:
sprocket timing mark will be pointing DOWN and right side camshaft
Disconnect negative battery cable. Remove alternator drive sprocket timing mark will be pointing UP. Engine timing marks
belt. Remove water pump pulley. Remove dipstick and tube.
for both camshafts are located on TOP side of rear timing belt
Remove crankshaft pulley. If engine is removed from ve- covers. See Figs. 4 and 5.
hicle, crankshaft can be held using Flywheel Stopper
(498277000) or equivalent, for M/T models or Drive Plate
Stopper (498497000) or equivalent, for A/T models.
CAUTION: If reusing timing belt, mark belt to indicate normal

Remove center, left and right timing belt covers. To remove
right side timing belt, loosen tensioner bolts on No. 1 cylin-
der 1/2 turn, rotate tensioner to release belt tension, and
retighten bolts. See Fig. 1. If reusing timing belt, mark belt
to indicate normal direction of rotation. Remove timing belt.
Loosen left side timing belt tensioner bolts on No. 2 cylin-
der 1/2 turn. See Fig. 1. Using tensioner wrench, rotate
tensioner until belt is slack. Tighten tensioner bolts. If re-
using timing belt, mark belt to indicate normal direction of
rotation. Remove outer crankshaft sprocket. Remove tim-
ing belt.
Inspection:
Inspect timing belt for wear and rounded edges of drive
teeth. Inspect belt for signs of oil contamination. Replace
belt if it is damaged or contaminated. Inspect idler pulleys
and tensioners for smooth rotation. Check belt tensioner
roller for squareness. See Fig. 2. Replace tensioner if out- Fig. 1: Identifying Timing Belts & Engine Components
of-square exceeds .02" (.5 mm).
SUBARU 479
1.8L 4-Cylinder Except Impreza & Legacy (Cont.)
Fig. 2: Measuring Tensioner Squareness Fig. 4: Camshaft Positions For Installing Timing Belts
Courtesy of Subaru of America, Inc.

Fig. 3: Aligning Flywheel Timing Marks Fig. 5: Final Installed Position Of Left Timing Belt
Sprocket
While applying torque, tighten inner and then outer tensioner
retaining bolts. Ensure all timing marks are aligned. To
install remaining components, reverse removal procedure.
tension ranges.
Belt Idler Bolt .................................................... 29-35 (39-47)
Belt Tensioner Bolt ........................................... 13-15 (18-20)
Camshaft Case Bolt ......................................... 13-15 (18-20)
Crankshaft Pulley Bolt 1 .................................. 66-79 (90-107)
Oil Pump Pulley Nut ......................................... 13-15 (18-20)
INCH Lbs. (N.m)
Camshaft Sprocket Bolt ...................................... 80-89 (9-10)
Camshaft Support Bolt ......................................... 53-62 (6-7)
Valve Cover Bolt .................................................... 35-44 (4-5)
1
- Coat bolt threads with oil before installation.
480 SUBARU
1.8L & 2.2L 4-Cylinder Impreza & Legacy
TIMING BELT APPLICATION Slight trace of oil at rod oil seal does not indicate a prob-
lem. While holding tensioner using both hands, push rod
Belt section against floor or wall using a force of 33-110 lbs.
Labor Component Part (15-50 kg) to ensure rod section does not move.
Application Time Kit No. No. If rod section moves, replace tension adjuster. Measure
1.8L 4-Cyl. extension of rod beyond body. Rod extension should be
Impreza .606-.646" (15.40-16.40 mm). Replace belt tension adjuster
if extension of rod is not as specified. Inspect belt tensioner
1993 ............... 1 2.2 Hrs. .... TCK172 .......... T172 and belt adjuster rod mating surface. Check spacer and
1994-97 .......... 1 2.2 Hrs. .............................. T254 tensioner bushing.
2.2L 4-Cyl.
Impreza CAUTION: DO NOT allow press pressure to exceed 2205 lbs. (992
1995-98 .......... 1 2.2 Hrs. .............................. T254 kg). DO NOT release pressure until stopper pin is completely installed.
Legacy Installation:
1990-93 .......... 1 2.2 Hrs. .... TCK172 .......... T172 Ensure timing marks are aligned. Using a press, align
1994-98 .......... 1 2.2 Hrs. .............................. T254 holes in belt tension adjuster rod and adjuster body, and
push rod into body. DO NOT allow press pressure to ex-
1
- With Air Cond. add .4 hours. ceed 2205 lbs. (992 kg). Install a stopper pin with a diam-
With Pwr. Strng. add .2 hours. eter of .059" (1.5 mm) through holes in adjuster body and
rod. See Fig. 2.
NOTE: A timing belt component kit is available for Temporarily tighten mount bolts while tension adjuster is
pushed completely right. Install belt tensioner. Ensure belt
this application. See page I for information on component direction of rotation is correct.
kits. Install timing belt, being careful not to move sprockets. In-
stall belt idler No. 2 and belt idler. Loosen tension adjuster
MANUFACTURERS SUGGESTED mount bolts and push tension adjuster completely left.
Tighten adjuster mount bolts.
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.

TIMING BELT
Removal:
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 equiva-
lent for A/T models.
Remove front, left and right timing belt covers. If timing belt
is to be reused, mark belt to indicate original direction of Fig. 1: Removing & Installing Timing Belt
rotation before removal. Use Crankshaft Socket
(499987500) to turn crankshaft pulley.
Align crankshaft and camshaft timing notches with corre-
sponding notches on timing cover and engine block. See
Fig. 1. Use White paint to mark timing belt in relation to
sprocket timing marks. Loosen tensioner adjuster mount-
ing bolts. Remove belt idler. Remove belt idler No. 2. Re-
move timing belt.
Inspection:
is damaged or contaminated. Inspect belt tension adjuster
oil seals for leaks. Inspect rod ends for abnormal wear and
scratches. Timing belt bend diameter must be greater than
2.36" (60.0 mm). Fig. 2: Installing Tension Adjuster Rod Stopper Pin
SUBARU 481
1.8L & 2.2L 4-Cylinder Impreza & Legacy (Cont.)

Ensure the marks on timing belt and sprockets align. See
Fig. 1. Remove stopper from tension adjuster. Remove
rocker covers and ensure valve lash adjuster does not con-
tain air. To complete installation, reverse removal proce-
Camshaft Support Bolt ............................................... 12 (16)
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)
482 SUBARU
2.2L & 2.5L 4-Cylinder SOHC
2.2L 4-Cyl.
Impreza
1999-01 ................ 1 2.2 Hours .................... T304
Legacy
1999 ..................... 1 2.5 Hours .................... T304
Outback
2000-01 ................ 1 2.5 Hours .................... T304
2.5L 4-Cyl.
Forester
1999-01 ................ 1 2.2 Hours .................... T304
Impreza & Outback Sport
1999-01 ................ 1 2.2 Hours .................... T304
Legacy & Outback
2000-01 ................ 1 2.5 Hours .................... T307
1
105,000 miles on all 1999-01 vehicles.

TIMING BELT
Removal:
Disconnect negative battery cable. Raise and support ve- Courtesy of Subaru of America, Inc.
hicle. Remove engine under cover. Fig. 2: Aligning Camshaft & Crankshaft Timing Marks
Lower vehicle. Remove radiator coolant reservoir and set
aside. Remove electric cooling fan and radiator shroud.
On Impreza and Forester, remove accessory drive belt cover.
On all models, remove accessory drive belts.
Hold crankshaft pulley stationary, remove crankshaft pulley
center bolt. Remove crankshaft pulley. Remove timing belt
covers.
Turn crankshaft to align crankshaft and camshaft timing
notches with marks on rear timing cover and engine block.
See Figs. 1 and 2. On manual transmission models, re-
move timing belt guide from top of crankshaft pulley.
On all models, if reusing old belt, use White paint to mark
timing belt in relation to sprocket timing marks. Count num-
ber of teeth between crankshaft sprocket and camshaft
sprockets so that belt will be installed in same position. Z1 = 44 Teeth
See Fig. 3. Z2 = 40.5 Teeth
Fig. 3: Marking Timing Belt For Reinstallation
Remove No. 2 timing belt idler pulley. See Fig. 4. Remove

timing belt. Remove timing belt automatic tensioner with
rod facing up.
Inspection:
is damaged or contaminated.
Inspect belt automatic tensioner oil seals for leaks. Slight
trace of oil at rod oil seal does not indicate a problem.
Inspect rod ends for abnormal wear and scratches.
Fig. 1: Timing Belt Routing & Timing Marks
SUBARU 483
2.2L & 2.5L 4-Cylinder SOHC (Cont.)

Fig. 4: Removing No. 2 Timing Belt Idler Pulley
Measure extension of rod beyond tensioner body. Holding Courtesy of Subaru of America, Inc.
tensioner with rod facing up, rod extension should be .224 Fig. 5: Checking Automatic Tensioner Rod Extension
plus or minus .020 (5.7 mm plus or minus 0.5 mm). See
Fig. 5. Replace automatic tensioner if rod extension is not
as specified.
CAUTION: Always use a vertical type pressing tool to compress

automatic tensioner rod. DO NOT use a bench vise to compress
rod. It may take more than 3 minutes to compress the automatic
tensioner rod.
Place automatic tensioner in a press with tensioner rod
facing up. Apply 66 lbs. (294 N) of pressure on rod. If rod
moves down easily, replace automatic tensioner.
Inspect automatic tensioner and idler pulleys for worn bear-
ings or lubricant leaks. Replace as necessary.
CAUTION: To prevent damage, DO NOT apply more than 2205 lbs. Fig. 6: Compressing Automatic Tensioner Rod
(9807 N) to automatic adjuster rod. Do NOT press automatic tensioner
rod past the top surface of the housing. DO NOT allow press pressure
to exceed 2205 lbs. (1000 kg). Application Ft. Lbs. (N.m)
Installation:
Ensure crankshaft and camshaft timing marks are still 2.2L ........................................................................ 94 (127)
aligned. Place automatic adjuster in a press with rod fac-
2.5L ...................................................................... 130 (177)
ing up. Apply 66 lbs. (294 N) pressure to end of rod. SLOWLY
Idler Pulley Bolt ............................................................. 29 (39)
(taking more than 3 minutes) compress rod into housing
Timing Belt Automatic Tensioner Bolt ............................ 29 (39)
until rod and housing holes are aligned. Insert locking pin
INCH Lbs. (N.m)
through holes. See Fig. 6.
Timing Belt Cover Bolt ..................................................... 44 (5)
Install automatic tensioner on engine with locking pin in Timing Belt Guide Bolt (M/T) ....................................... 89 (10)
place. Install idler pulleys (if removed).
Valve Cover Bolt ................................................................ 44 (5)
Ensure crankshaft and camshaft timing marks are still Water Pump Bolt ...................................... 89-124 (10.0-14.0)
aligned. Install timing belt. If reusing old belt, ensure belt
direction of rotation is correct and mating marks are
aligned.
Install No. 2 idler pulley on engine. Remove automatic
tensioner locking pin. On manual transmission models,
install timing belt guide over crankshaft pulley. Adjust clear-
ance between belt guide and belt to .039 (1.0 mm), plus or
minus .019 (.5 mm).
On all models, install timing belt covers. Clean crankshaft
pulley bolt and bolt hole. Install crankshaft pulley. Coat crank-
shaft pulley bolt threads with engine oil. Install bolt, While
holding crankshaft pulley stationary, tighten bolt to specifi-
cation. See TORQUE SPECIFICATIONS.
CAUTION: If tightening angle of crankshaft pulley bolt is less

than 45 degrees, bolt is damaged. Bolt must be replaced.
Fig. 7: Checking Timing Belt Guide Clearance
Install accessory drive belts. Install radiator fan assembly.
tension ranges.
484 SUBARU
2.5L 4-Cyl. DOHC
Forester
1998 ..................... 1 2.5 Hours .................... T277
Impreza
1996-99 ................ 1 2.5 Hours .................... T277
Legacy & Outback
1996-99 ................ 1 2.5 Hours .................... T277
1
MANUFACTURERS SUGGESTED 96I14512 Courtesy of Subaru of America, Inc.

SCHEDULED MAINTENANCE Fig. 1: Removing Drive Belt Cover
60,000 miles on 1996-97 Federal vehicles. Replace belt at
105,000 miles on all 1998-99 vehicles.
TIMING BELT
Removal:
Remove drive belt cover. See Fig. 1. Remove drive belt.
Remove A/C compressor belt tensioner assembly (if
equipped). Holding crankshaft stationary, remove crank-
shaft pulley bolt. See Fig. 2. Remove crankshaft pulley.
Remove left and right timing belt covers. Remove front belt
cover. See Fig. 6. Rotate crankshaft and align crankshaft
and camshaft timing notches. See Fig. 5.
On manual transmission models, remove timing belt guide
from top of crankshaft pulley. On all vehicles, if reusing
96A14514 Courtesy of Subaru of America, Inc.
timing belt, mark belt with arrow to indicate original direc-
tion of rotation. Also, place mating marks on timing belt and Fig. 2: Removing Crankshaft Pulley Bolt
crankshaft and camshaft sprockets.
Remove lower timing belt idler pulley. Remove timing belt.
Remove timing belt automatic tensioner.
CAUTION: To prevent intake and exhaust valves from contacting

each other, DO NOT rotate crankshaft or camshafts with timing
belt removed.
Inspection:
is damaged or contaminated.
Inspect belt automatic tensioner oil seals for leaks. Slight
trace of oil at rod oil seal does not indicate a problem.
Inspect rod ends for abnormal wear and scratches.
Measure extension of rod beyond tensioner body. Holding
tensioner with rod facing up, rod extension should be .224 Courtesy of Subaru of America, Inc.
plus or minus .020 (5.7 mm plus or minus 0.5 mm). See
Fig. 3. Replace automatic tensioner if rod extension is not Fig. 3: Measuring Automatic Tensioner Rod Extension
as specified. Installation:
Place automatic tensioner in a press with tensioner rod Ensure crankshaft and camshaft timing marks are still
facing up. Apply 66 lbs. (29.9 kg) of pressure on rod. If rod aligned. Place automatic adjuster in a press with rod fac-
moves down easily, replace automatic tensioner. ing up. Apply 66 lbs. (29.9 kg) pressure to end of rod.
Inspect automatic tensioner and idler pulleys for worn bear- SLOWLY (taking more than 3 minutes) compress rod into
ings or lubricant leaks. Replace as necessary. housing until rod and housing holes are aligned. Insert
locking pin through holes.
CAUTION: To prevent damage to automatic tensioner, DO NOT
apply more than 2205 lbs. (1000 kg) to automatic adjuster rod. Compress
Install automatic tensioner on engine with locking pin in
place. Install idler pulleys (if removed). Install timing belt in
tensioner rod with using vertical press. DO NOT use bench vise.
DO NOT press automatic tensioner rod past the top surface of the
correct routing order. Ensure camshaft double marks are
housing.
aligned. If reusing old belt, ensure belt direction of rotation
is correct and mating marks are aligned.
SUBARU 485
96J14513 Courtesy of Subaru of America, Inc.
Fig. 4: Exploded View Of Timing Belt & Related Components
Fig. 5: Aligning Timing Marks & Sprocket Alignment Marks

486 SUBARU
Fig. 6: Removing & Installing Front Belt Cover
Count number of teeth between crankshaft and camshaft

pulleys to ensure belt is correctly installed. See Fig. 5. When
belt is correctly installed, remove automatic tensioner lock-
ing pin.
On manual transmission models, install timing belt guide
over crankshaft pulley. Clearance between belt guide and
belt should be .039 (1.0 mm).
Install timing belt covers. Install crankshaft pulley, Holding
crankshaft stationary, tighten bolt to specification. To com-
plete installation, reverse removal procedure. Adjust drive
ranges.
Application Ft. Lbs.. (N.m)
INCH Lbs. (N.m)
Timing Belt Cover Bolt ................................................. 44 (5.0)
Timing Belt Guide Bolt .................................................. 89 (10)
Water Pump Bolt ...................................... 89-124 (10.0-14.0)
SUBARU 487
2.7L 6-Cylinder
2.7L 6-Cyl.
XT6
1988-91
Left Side ............ 2.9 Hours .................... T151
Right side .......... 2.9 Hours .................... T150
1
- Both Belts.
SCHEDULED MAINTENANCE Fig. 1: Removing Oil Level Gauge & Guide
60,000 miles.
TIMING BELT
Removal:
Loosen water pump pulley and alternator mounting bolts.
Loosen serpentine belt tensioner pulley lock nut and re-
lease belt tension. Ensure adjuster bolt is turned fully coun-
terclockwise and remove serpentine belt.
Remove water pump pulley. Remove crankshaft pulley.
Crankshaft can be held using Flywheel Stopper (498277000)
or equivalent, for M/T models or using Drive Plate Stopper
(498497000) or equivalent, for A/T models.
Unplug oil pressure switch connector. Remove oil level
gauge guide from front of engine. See Fig. 1. Remove cen-
Fig. 2: Loosening Right Hand Timing Belt Tension
ter, left and right timing belt covers.
Loosen right (passenger side) hand timing belt tensioner
bolts 1/2 turn. Rotate tensioner to release belt tension and
retighten bolts. See Fig. 2. If right (passenger side) timing
belt is to be reused, place arrow on belt to indicate direc-
tion of belt rotation. Remove timing belt.
Remove crankshaft outer sprocket. To remove left (driver
side) timing belt, remove idler pulley. See Fig. 3. Remove
rubber plug and retaining bolt located below belt tension
adjuster in rear timing cover. See Fig. 5.
Remove Phillips screw from bottom of belt tension adjuster.
See Fig. 6. Insert slot screwdriver in bottom of belt tension
adjuster and rotate screw clockwise to release belt ten-
sion. Install Belt Adjuster Stopper (13082AA000) or equiva-
lent, on tension adjuster. See Fig. 7.
Remove left hand timing belt tensioner. If timing belt is to Courtesy of Subaru of America, Inc.
be reused, place arrow on belt to indicate direction of belt
rotation. Remove timing belt. Remove belt tension adjuster. Fig. 3: Removing Left Timing Belt Idler Pulley
Inspection:
Inspect timing belt for wear on rounded edges of drive teeth. Using syringe, add engine oil through vent hole on top of
Inspect belt for signs of oil contamination. Replace belt if rubber boot. Add oil until it overflows. Install Phillips screw
damaged or contaminated. Inspect idler pulleys and and new gasket.
tensioners for smooth rotation. Check belt tensioner roller Install belt tension adjuster on engine. Keep belt adjuster
for squareness. See Fig. 8. Replace tensioner in out-of- stopper in place. Tighten bolts to specification. See
square exceeds .020" (.51 mm). TORQUE SPECIFICATIONS.
Installation: Install rubber plug and retaining bolt on engine Install left
If not already done, remove Phillips screw from bottom of timing belt idler pulley. Tighten bolt to specification. See
belt tension adjuster. Insert a standard slot screwdriver TORQUE SPECIFICATIONS.
into hole in bottom of belt tension adjuster. Turn screw Install crankshaft sprocket (if removed). Align center line of
clockwise to compress rubber boot. Install belt adjuster the 3 lines on flywheel or drive plate with mark on housing.
stopper on top of belt tension adjuster. Align left camshaft sprocket timing mark with notch in rear
timing belt cover. See Fig. 9.
488
SUBARU
G00019666

SUBARU 489
Fig. 8: Checking Belt Tensioner Roller Squareness
Fig. 5: Removing Rubber Plug & Retaining Bolt

Fig. 6: Removing Phillips Screw From Belt Tension
Adjuster
CAUTION: Ensure end of tensioner arm contacts top of belt tension

adjuster and all timing marks align.
NOTE: After installing left (drivers side) timing belt, crankshaft

is rotated 1 full turn (360 degrees). This will be the position for
installing the right (passenger side) camshaft belt. The cam-
shaft timing mark for the left side timing belt will now be pointing
straight down (6 oclock position). See Fig. 10.
To install right (passenger side) timing belt, rotate crank-
shaft clockwise 360 degrees. Align flywheel or drive plate
timing marks with mark on housing. Align camshaft sprocket
timing mark with notch in rear timing belt cover. See Fig. 9.
Install right hand timing belt tensioner. Rotate tensioner
assembly down and temporarily tighten retaining bolts.
Install outer crankshaft sprocket. Install right timing belt
starting from crankshaft. If reusing old timing belt, ensure
Courtesy of Subaru of America, Inc. belt is installed in original direction of rotation.
Fig. 7: Installing Belt Adjuster Stopper Loosen right hand tensioner bolts, and allow tensioner to
apply belt tension. Install Belt Tension Wrench (499437100)
Install left (driver side) timing belt starting from the crank- on right camshaft sprocket.
shaft sprocket. If installing used belt, ensure belt is in- Using torque wrench and belt tension wrench, apply 17-18
stalled in original direction of rotation. Install belt tension ft. lbs. (24-25 N.m) or torque in a counterclockwise direc-
adjuster. See Fig. 7. Tighten bolts to specification. See tion to right camshaft sprocket. While applying torque, tem-
TORQUE SPECIFICATIONS. Remove belt adjuster stop- porarily tighten tensioner bolt closest to the tensioner pul-
per from belt tension adjuster. Ensure tensioner moves ley, and then the tensioner pivot bolt.
smoothly after it is installed.
490 SUBARU
Check belt tension. Belt tension should be 33-55 lbs. (15-
25 kg). If belt tension is correct, tighten tensioner bolt clos-
est to the tensioner pulley, and then the tensioner pivot bolt
to specification. See TORQUE SPECIFICATIONS. Ensure
NOTE: When timing belts are properly installed, left camshaft

sprocket timing mark will be pointing DOWN and right camshaft
sprocket timing mark will be pointing UP. Engine timing mark
notches for both camshafts are located on TOP side of rear timing
belt covers. See Figs. 9 and 10.
Install rubber plug and retaining bolt below belt tension
adjuster. Install timing belt covers. Install crankshaft pulley.
Apply engine oil to crankshaft pulley bolt threads. Holding
crankshaft pulley stationary, install and tighten center bolt
to specification.
Courtesy of Subaru of America, Inc. dure. Tighten alternator belt so belt tension is 143-165 lbs.
Fig. 10: Final Installed Position Of Left (Driver Side) (65-75 kg) on new belt or 99-143 lbs. (45-65 kg) on used
Camshaft Sprocket belts. Adjust drive belts to proper tension.
CAUTION: Readjust new alternator belt after 5 minutes of operation.
Belt Tension Adjuster Bolt ................................. 17-20 (23-27)
Crankshaft Pulley Center Bolt 1 ....................... 66-79 (90-107)
Left Hand Tensioner ....................................... 29-35 (39-47)
Right Hand Tensioner .................................... 17-20 (23-27)
INCH Lbs. (N.m)
Oil Level Guide Bolt .............................................. 40-48 (4-5)
1
SUBARU 491
3.3L 6-Cylinder
TIMING BELT APPLICATION CAUTION: Readjust new alternator belt after 5 minutes of operation.
Tighten adjuster bolts. Once all timing marks are aligned,
3.3L 6-Cyl. remove stopper pin from tension adjuster. Install front tim-
SVX ing belt covers. To complete installation, reverse removal
1992-97 ................. 2.6 Hours ..................... T209 procedure. Tighten all nuts and bolts to specification. See
1
- With Air Cond. add .4 hours. tension. See page A-60 for belt tension ranges.
MANUFACTURERS SUGGESTED Application Ft. Lbs. (N.m)
SCHEDULED MAINTENANCE Belt Idler Bolt .................................................... 26-32 (35-43)
Belt Tension Adjuster Bolt ................................. 17-20 (23-27)
For 1992-94 model years, the manufacturer recommends belt Camshaft Sprocket Bolt ............................... 80-94 (108-127)
be replaced every 60,000 miles. For 1995-97 model years, Crankshaft Pulley Bolt 1 ............................ 108-123 (147-167)
the manufacturer recommends belt be replaced at 60,000 Tensioner Bolt .................................................. 26-32 (35-43)
miles on Federal vehicles, and 105,000 miles on California INCH Lbs. (N.m)
vehicles. Timing Belt Cover Bolt .................................... 35-44 (4.0-5.0)
Valve Cover Bolt ................................................ 5-44 (4.0-5.0)
REMOVAL & INSTALLATION Water Pump Pulley Bolt ............................ 84-120 (10.0-14.0)
TIMING BELT 1
Removal:
Disconnect negative battery cable. Remove undercover. Dis-
connect power steering cooler hoses from body. Discon-
nect cooling fan connectors. Remove drive belt cover. Re-
move upper radiator brackets. Remove radiator fan and
sub-fan assemblies. Remove charcoal canister and
bracket. Remove alternator/power steering drive belts and
A/C drive belt. Remove alternator and drive belt cover
bracket.
Remove A/C idler pulley. Remove power steering pump
and bracket. Remove crankshaft pulley and front timing
belt covers. To hold crankshaft, use Crankshaft Pulley
Wrench (49997-7000) or equivalent. If rotation indicating marks
on timing belt have rubbed off, remark timing belt before re-
moving.
Fig. 1: View Of Timing Belt Components
Turn crankshaft to align marks on crankshaft sprocket and cam-
shaft sprockets with marks on cylinder block and timing belt cover.
See Fig. 1. Using White paint, put alignment marks and/or arrows
on timing belt in relation to sprockets. Loosen tensioner adjuster
bolts. Remove timing belt idlers. See Fig. 1. Remove timing belt.
Inspection:
is damaged or contaminated. Inspect tension adjuster for
leaking oil seals and worn rod ends. Slight traces of oil at
rod oil seal do not indicate problem or component failure.
Ensure tension adjuster rod does not move with less than
33-110 lbs. (15-50 kg) of force applied.
Replace tension adjuster if rod moves. Measure tension
adjuster rods extension beyond adjuster body. Distance
should be .606-.646" (15.40-16.40 mm). Replace tension ad-
juster if distance is not correct. Inspect idler pulleys and tensioners
for smooth rotation. Replace components if noise or excessive
play is noted.
Installation:
If tension adjuster was removed or replaced, use a press
to push adjuster rod down far enough to install a stopper
pin. See Fig. 2. Turn sprockets to align timing marks with
marks on rear timing belt covers and oil pump. See Fig. 1.
While aligning marks on timing belt with marks on sprock-
ets, position timing belt properly. Ensure belt rotating direc- Fig. 2: Setting Tension Adjuster
tion is correct. Install idler pulleys. Loosen tension adjuster
attaching bolts and move adjuster fully left.
492 SUZUKI
1.3L 4-Cyl. DOHC Alternator Mount & Adjusting Bolts .................... 13-21 (18-28)
Alternator Pulley Bolts
Swift 1992-94 ........................................................ 70-96 (95-130)
1989-94 .............. 1 2.6 Hours .................... T171 Camshaft Sprocket Bolt .................................... 41-47 (56-64)
1
- With Air Cond. add .2 hours. Crankshaft Sprocket Bolt .............................. 77-85 (105-115)
INCH Lbs. (N.m)
MANUFACTURERS SUGGESTED Alternator Pulley Bolt
SCHEDULED MAINTENANCE 1989-91 ........................................................ 90-108 (10-13)
For 1992-89 model years, although the manufacturer does Timing Belt Outer Cover Bolt ............................ 80-106 (9-12)
not recommend a specific scheduled maintenance interval, Timing Belt Tensioner Stud Nut ........................ 80-106 (9-12)
belt manufacturers suggest the belt be replaced at 60,000 Water Pump Mounting Bolt ............................... 80-106 (9-12)
mile intervals. For 1993-94 model years, the manufacturer Water Pump Pulley Bolt .................................. 89-115 (10-13)
recommends the belt be replaced at 60,000 mile intervals.


TIMING BELT
Removal:
Disconnect negative battery cable. Remove air cleaner and
airflow meter assembly. Raise vehicle and remove right
fender apron extension by pushing center pin into clip. DO
NOT push in too far, as pin may fall into fender. Remove
water pump pulley and belt.
Remove crankshaft pulley 5 mm hexagon bolts. If engine is
in vehicle, remove crankshaft pulley center bolt. Remove
crankshaft pulley. Loosen right engine mount bolt, and push
air cleaner bracket aside. Remove timing belt covers.
Align all sprocket timing marks with timing marks on en-
gine. See Fig. 1. Move timing belt tensioner up and secure.
Mark timing belt for direction of rotation if it is to be reused.
Remove timing belt from sprockets.
Installation:
Align timing marks. Bolts with flanged nuts may be wedged
between cam sprocket teeth to hold camshaft on timing
mark during belt installation (if necessary). See Fig. 2.
CAUTION: While aligning timing marks, DO NOT turn camshaft Fig. 1: Aligning Timing Belt Marks
sprockets more than 20 degrees in either direction from aligned
position. DO NOT turn crankshaft more than 90 degrees in either
direction from aligned position.
Install timing belt so no slack exists on drive side of belt.
Adjust tensioner to remove timing belt slack from other
side of belt, and hand tighten tensioner bolt and nut. Turn
crankshaft 2 revolutions to seat timing belt, and readjust
tensioner.
Tighten tensioner bolt and nut. Ensure drive side of belt is
free of slack. Ensure timing marks are aligned. Install tim-
ing belt outer covers and tighten to specification. See
TORQUE SPECIFICATIONS. To complete installation, re-
verse removal procedure. Tighten bolts to specification.
tension ranges.
SUZUKI 493
Fig. 2: Securing Intake & Exhaust Camshaft Sprockets For

Timing Belt Installation
Fig. 3: Identifying Sprocket Movement Limits

494 SUZUKI
TIMING BELT APPLICATION Turn crankshaft clockwise until punch mark on crankshaft
sprocket is aligned with arrow mark on oil pump housing.
Belt With timing marks aligned, install timing belt. Ensure di-
Labor Component Part rection arrow mark on timing belt is pointed in direction of
Application Time Kit No. No. crankshaft rotation. Ensure drive side of belt is free of slack.
1.3L 4-Cyl. SOHC Move tensioner plate up with finger pressure, and loosely
Samurai secure tensioner bolt. Turn crankshaft 2 revolutions clock-
wise to remove all slack from belt. Tighten tensioner nut
1985-93 .......... 1 3.0 Hrs. .............................. T095 and then tensioner bolt. See TORQUE SPECIFICATIONS.
1994 ............... 1 3.0 Hrs. ............................ 2 T095 Ensure timing marks are aligned. Install timing belt outer
1994 ............... 1 3.0 Hrs. ............................ 3 T243 cover and tighten to specification. See TORQUE SPECIFI-
1995 ............... 1 3.0 Hrs. .............................. T243 CATIONS. Reverse removal procedure to complete instal-
Sidekick lation. Adjust valve clearance. See VALVE CLEARANCE
1989 ............... 1 3.0 Hrs. .............................. T095 SPECIFICATIONS. Adjust drive belts to proper tension. See
Swift page A-60 for belt tension ranges.
Removal (Swift):
1989-93 .......... 1 2.6 Hrs. .............................. T095 Disconnect negative battery cable. Raise and support ve-
1994 ............... 1 2.6 Hrs. .............................. T243 hicle. Remove right side fender apron extension by push-
1995-97 .......... 1 2.6 Hrs ............................... T272 ing center pin into clip. DO NOT push in too far as pin may
1998-01 .......... 1 2.6 Hrs. .... TCK194A ........ T194 fall into fender. Lower vehicle.
1
Remove air cleaner assembly. Support engine with floor
jack. Remove engine mount from timing belt end of engine.
2
For VIN R4100375 and earlier. Loosen water pump pulley bolts. Remove accessory drive
3
For VIN R4100376 and later. belts. Remove water pump pulley.
Remove crankshaft pulley-to-crankshaft bolts. Remove
NOTE: A timing belt component kit is available for crankshaft pulley. It is NOT necessary to remove crank-
shaft center bolt.
this application. See page I for information on component Remove resonator and timing belt cover. Rotate crankshaft
kits. clockwise to align camshaft and crankshaft timing marks.
See Fig. 2. Camshaft sprocket mark should align with V
MANUFACTURERS SUGGESTED mark on rear cover. Punch mark on crankshaft sprocket
should align with mark on oil pump case.
SCHEDULED MAINTENANCE If reusing timing belt, mark belt with an arrow indicating
For 1985-92 model years, although the manufacturer does direction of rotation for installation reference.
not recommend a specific scheduled maintenance interval,
belt manufacturers suggest the belt be replaced at 60,000
mile intervals. For 1993-01 model years, the manufacturer
recommends the belt be replaced at 60,000 mile intervals.
TIMING BELT
Removal (Samurai & Sidekick):
Disconnect negative battery cable. Remove cooling fan and
fan shroud. Discharge A/C system using approved refriger-
ant recovery/recycling equipment and disconnect compres-
sor flexible suction hose from suction pipe (if equipped).
Remove A/C compressor belt (if equipped).
Loosen alternator, and remove water pump pulley and belt.
Remove crankshaft pulley. Remove timing belt cover. Loosen
timing belt tensioner bolt and move away from timing belt.
Secure timing belt tensioner.
Mark belt with an arrow indicating direction of rotation for
installation reference. Remove timing belt from camshaft
and crankshaft sprockets.
CAUTION: With timing belt removed, DO NOT turn camshaft

sprocket more than 20 degrees in either direction from aligned
direction from aligned position. Doing so could damage piston(s)
and/or valve(s) by interference. Also, DO NOT bend timing belt.
Installation (Samurai & Sidekick):
Loosen all valve adjusting screws fully before installing Courtesy of Suzuki of America Corp.
timing belt. Allow camshaft to rotate freely during belt ten- Fig. 1: Exploded View Of Timing Belt Components
sion adjustment. Align timing mark on camshaft sprocket
with V mark on timing belt inner cover. See Fig. 2.
SUZUKI 495
Fig. 3: Releasing Timing Belt Tensioner
Courtesy of Suzuki of America Corp.

Fig. 2: Aligning Timing Belt & Tensioner
Loosen timing belt tensioner eccentric bolt and stud nut.

Move tensioner away from belt and snug bolt and nut. Re-
move timing belt.

sprocket more than 20 degrees in either direction from aligned
direction from aligned position. Doing so could damage piston(s)
and/or valve(s) by interference. Also, DO NOT bend timing belt.
Inspection:
Replace damaged components.
Installation (Swift):
If the tensioner was removed, install tensioner plate on Fig. 4: Adjusting Valve Clearance
tensioner. Ensure tensioner plate lug engages hole on rear
of tensioner. Install tensioner spring. Tighten tensioner bolt Install timing belt. If reusing old belt, ensure belt is installed
finger tight to allow movement of tensioner. in original direction of rotation. Ensure there is no slack in
belt.
NOTE: It is NOT necessary to loosen valve adjusting screws on Move timing belt tensioner plate up with finger pressure,
1995 models. and loosely secure tensioner bolt. See Fig. 3. Turn crank-
shaft 2 revolutions clockwise to remove all slack from belt.
On 1989-94 models with 8-valve engine, remove valve cover. Ensure timing marks are aligned. Tighten tensioner stud
Loosen all valve adjusting screws before installing timing nut and then tensioner bolt. See TORQUE SPECIFICA-
belt. Camshaft must be free to rotate during tension ad- TIONS.
justment. Install timing belt outer cover and resonator. Make sure
On all models, ensure all timing marks align. See Fig. 2. If there are rubber seals installed between water pump and
timing marks are not aligned, rotate camshaft or crank- oil pump case, and another between water pump and cyl-
shaft to align timing marks. DO NOT rotate camshaft or inder head. Install crankshaft pulley.
crankshaft so timing mark moves more than 90 degrees or
engine damage may occur.
496 SUZUKI
On 1989-94 Swift with 8-valve engine, adjust valves. See
VALVE CLEARANCE SPECIFICATIONS. Install valve cover.
tension ranges.
VALVE CLEARANCE SPECIFICATIONS
Cold Hot
Valve In. (mm) In. (mm)
Intake ................. .005-.007 (.13-.18) ........... .009-.011 (.23-.28)
Exhaust ............. .006-.008 (.15-.20) ........ .010-.011 (.25-.28)
Alternator Mount & Adjusting Bolts .................... 13-21 (18-28)
Crankshaft Pulley-To-Crankshaft Bolt ................ 7-10 (10-13)
Except 2000-01 Swift ...................................... 77-85 (105-115)
2000-01 Swift ............................................................. 94 (130)
Engine Mount Bolt (Swift) ............................................... 40 (55)
Timing Belt Tensioner Pulley Bolt ..................... 18-22 (24-30)
INCH Lbs. (N.m)
Timing Belt Tensioner Stud Nut ........................ 80-106 (9-12)
Water Pump Pulley Bolt .................................. 89-115 (10-13)
SUZUKI 497
1.6L 4-Cylinder
TIMING BELT APPLICATION Remove 5 crankshaft pulley-to-crankshaft bolts. Remove
pulley. It is NOT necessary to remove crankshaft center
Application Labor Time Belt Part No. bolt. Remove timing belt cover. See Fig. 1.
1.6L 4-Cyl. SOHC Rotate crankshaft clockwise to align timing marks. See
Esteem Figs. 2 and 3. Stamped E or punch mark on camshaft
1995-00 ................ 1 2.3 Hours .................... T212 sprocket must straight up. Loosen timing belt tensioner
Esteem (Canadian) bolt and stud nut. Move tensioner away from belt, and hand
tighten bolt and nut. See Fig. 4. If reusing old belt, mark belt
2001 ..................... 1 2.3 Hours .................... T212 with an arrow indicating direction of rotation for installation
Sidekick reference. Remove timing belt.
1989-91 ................ 1 3.6 Hours ................... T164
1992-95 CAUTION: With timing belt removed, DO NOT turn camshaft
Convertible ....... 1 3.6 Hours .................... T164 more than 20 degrees in either direction from aligned position.
To prevent piston and valve damage, DO NOT turn crankshaft
Hardtop ............. 1 3.6 Hours .................... T212 more than 90 degrees in either direction from aligned position.
1996-98 ................ 1 3.6 Hours .................... T212
Vitara Inspection (All Models):
1999-01 ................ 1 4.0 Hours .................... T212 Inspect timing belt for damaged teeth, cracking and oil con-
X-90 Replace damaged components.
1996-98 ................ 1 4.0 Hours .................... T212 Installation (All Models):
1
- With Air Cond. add .4 hours, except Esteem. If the tensioner was removed, install tensioner plate on
For Esteem, add .2 hours. tensioner. Ensure tensioner plate lug engages hole on rear
of tensioner. Install tensioner spring. Tighten tensioner bolt
finger tight to allow movement of tensioner.
MANUFACTURERS SUGGESTED On 1989-94 Sidekick with 8-valve engine, remove valve cover.
SCHEDULED MAINTENANCE Loosen all valve adjusting screws. On all models, ensure
timing marks are still aligned. Install timing belt. If reusing
For 1989-92 model years, although the manufacturer does old belt, ensure direction arrow mark on timing belt is
not recommend a specific scheduled maintenance interval, pointed in direction of crankshaft rotation. Ensure drive side
belt manufacturers suggest the belt be replaced at 60,000 of belt is free of slack.
mile intervals. For 1993-01 model years, the manufacturer Loosen tensioner bolt and stud nut to place tension on
recommends the belt be replaced at 60,000 mile intervals. timing belt. Turn crankshaft 2 revolutions clockwise to re-
move all slack from belt. Tighten tensioner stud nut and
REMOVAL & INSTALLATION then tensioner bolt. See TORQUE SPECIFICATIONS.
TIMING BELT Ensure timing marks are aligned. Install timing belt cover
and tighten bolts to specification. Reverse removal proce-
Removal (Esteem): dure to complete installation. If coolant was drained, fill
Disconnect negative battery cable. Remove right side en- and bleed air from system. Adjust drive belts to proper ten-
gine under cover. Remove power steering and A/C com- sion. See page A-60 for belt tension ranges. Adjust valve
pressor drive belts.
Remove A/C compressor and power steering pump with
hoses attached, and secure out of way. Support engine
from above or with floor jack under oil pan. Remove air
cleaner case with air cleaner outlet hose.
From timing belt end of engine, remove engine mount and
mounting bracket. Loosen water pump pulley bolts. Re-
move water pump drive belt and pulley.
Remove 5 crankshaft pulley-to-crankshaft bolts. Remove
pulley. It is NOT necessary to remove crankshaft center
bolt. Remove timing belt cover. See Fig. 1.
Rotate crankshaft clockwise to align timing marks. See
Figs. 2 and 3. Stamped E on camshaft sprocket must
point straight up. Loosen timing belt tensioner bolt and
stud nut. Move tensioner away from belt, and hand tighten
and nut. See Fig. 4.
If reusing old belt, mark belt with an arrow indicating direc-
tion of rotation for installation reference. Remove timing
belt.

or crankshaft sprocket more than 90 degrees in either direction
from aligned position. Doing so could damage pistons and valves.
Removal (Sidekick, Vitara & X-90):
belts.Remove radiator cooling fan, water pump pulley, and Courtesy of Suzuki of America Corp.
fan shroud. It may be necessary to drain cooling system Fig. 1: Exploded View Of Timing Belt Components
and remove upper radiator hose to remove fan shroud.
498 SUZUKI
Courtesy of Suzuki of America Corp.


lash on 1989-94 Sidekick with 8-valve engine. See VALVE
CLEARANCE SPECIFICATIONS.
A/C Compressor Mounting Bolt (Esteem) .................... 17 (23)
Alternator Mount & Adjusting Bolts .................... 13-21 (18-28)
Camshaft Sprocket Bolt .............................................. 43 (60) Fig. 4: Releasing Timing Belt Tensioner
Crankshaft Sprocket Center Bolt ............................... 80 (110)
Engine Mount Bolt/Nut (Esteem) ................................... 40 (55) VALVE CLEARANCE SPECIFICATIONS
Power Steering Pump Bolt (Esteem) ............................. 25 (35)
Timing Belt Tensioner Bolt ......................................... 18 (25) Cold Hot
INCH Lbs. (N.m) Valve In. (mm) In. (mm)
Crankshaft Pulley-To-Crankshaft Bolt ........................ 106 (12) Intake ................. .005-.007 (.13-.18) ........... .009-.011 (.23-.28)
Timing Belt Cover Bolt .................................................. 97 (11) Exhaust ............. .006-.008 (.15-.20) ........ .010-.011 (.25-.28)
Timing Belt Tensioner Stud Nut .................................... 97 (11)
Water Pump Pulley Bolt .................................................. 97 (11)
TOYOTA 499
1.5L 4-Cylinder 1A-C & 3A-C

Labor Component Part For 1980-85 model years, although the manufacturer does
Application Time Kit No. No. not recommend a specific scheduled maintenance interval,
1.5L 4-Cyl. belt manufacturers suggest the belt be replaced at 60,000
Corolla Tercel mile intervals. For 1986-89 model years, the manufacturer
recommends the belt be replaced every 60,000 miles under
1980-82 severe service operating conditions.
A/T ............... 2.8 Hrs. ...... TCK070 .......... T070
M/T .............. 2.8 Hrs. ...... TCK070 .......... T070 REMOVAL & INSTALLATION
Tercel
1983-86 .......... 1 2.7 Hrs. .... TCK070 .......... T070 TIMING BELT
1987-88 NOTE: Do not bend or twist timing belt. Keep belt free of oil,
Wagon water or dust.
3A-C ........... 1 2.7 Hrs. .... TCK070 .......... T070
Removal:
1
With Air Cond., add .3 hours. Drain engine coolant. Remove radiator. Remove air cleaner
assembly. Remove accessory drive belts. Remove water
NOTE: A timing belt component kit is available for pump pulley.
this application. See page I for information on component If equipped with A/C, remove A/C drive belt idler pulley with
bracket. Remove PCV valve from valve cover. Remove valve
kits. cover.
Rotate crankshaft so that No. 1 cylinder is at TDC of com-
pression stroke. Timing notch on crankshaft pulley must
align with 0 timing mark on timing belt cover.
Courtesy of Toyota Motors Sales, U.S.A., Inc.
Fig. 1: Exploded View of Timing Belt & Components

500 TOYOTA
1.5L 4-Cylinder 1A-C & 3A-C (Cont.)
Courtesy of Toyota Motors Sales, U.S.A., Inc.

Fig. 2: Aligning Timing Marks Fig. 5: Installing Used Timing Belt
Inspection:
tamination. Ensure idler pulley rotates freely. Inspect all
sprockets for damage. Replace damaged components.
Measure free length of tension spring. Free length should be
1.512" (38.40 mm) for models up to 1986, and 1.705 (43.3
mm) for 1987-88 models. See Fig. 3. Replace tension spring
if free length is not as specified.
Measure tension of spring at installed length. Tension should
be 8 lbs. at 1.976 (3.83 kg at 50.2 mm) up to 1986 models.
Fig. 3: Measuring Tensioner Spring Free Length
For 1987-88 models, tension should be 15.4 lbs. at 1.976 (7
kg at 50.2 mm). Replace tension spring if necessary.
Installation:
Ensure crankshaft and camshaft timing pulley timing marks
are correctly aligned. See Fig. 2.
Install idler pulley and tension spring (if removed). Secure
idler pulley as far to the left as possible and retighten bolt.
Install timing belt on engine. If reusing old belt, align mat-
ing marks made on disassembly. Ensure belt is installed
in original direction of rotation. See Fig. 5.
Loosen idler pulley retaining bolt, allowing tension spring
to move pulley against timing belt. Use crankshaft retain-
ing bolt to rotate crankshaft clockwise 2 full rotations from
TDC to TDC. Ensure camshaft and crankshaft timing marks
are still aligned. If they are not aligned, remove and rein-
stall timing belt.
Tighten idler pulley mounting bolt. Measure timing belt ten-
sion by applying 4.4 lbs. (2 kg) pressure to belt. See Fig. 4.
Timing belt deflection should be .236-.276 (6-7 mm). If not,
Courtesy of Toyota Motor Sales, U.S.A., Inc. readjust timing belt tension.
Fig. 4: Checking Timing Belt Tension Install timing belt guide on crankshaft. Install timing belt
covers. Install crankshaft pulley. Install and tighten crank-
Ensure cylinder No. 1 rocker arms are loose and cylinder shaft pulley center bolt to specification. See TORQUE
No. 4 rocker arms are tight. If conditions are not as de- SPECIFICATIONS.
scribed, rotate crankshaft one complete revolution. Install water pump pulley. Install A/C idler pulley (if equipped).
Holding crankshaft stationary, remove crankshaft pulley Install accessory drive belts. Adjust drive belts to proper
center bolt. Remove crankshaft pulley. tension. See page A-60 for belt tension ranges.
Remove timing belt covers and gaskets. See Fig. 1. Re- Install valve cover and air cleaner assembly. Install radia-
move timing belt guide. See Fig. 1. If reusing old timing tor. Fill and bleed cooling system.
belt, mark belt with arrow indicating direction of rotation.
Also place mating marks on timing belt and camshaft tim- TORQUE SPECIFICATIONS
ing pulley. Place mating marks on timing belt and crank- Application Ft. Lbs. (N.m)
shaft timing pulley. Camshaft Sprocket Bolt .............................................. 34 (47)
Loosen idler pulley retaining bolt. Move idler pulley away Crankshaft Pulley Bolt .............................................. 87 (118)
from timing belt and tighten retaining bolt. Remove timing Idler Pulley Retaining Bolt ......................................... 27 (37 )
belt.
TOYOTA 501
*1.5L 4-Cylinder 3E
Belt TIMING BELT
Application Time1 Kit No. No. CAUTION: On models equipped with air bag, DO NOT start work
1.5L 4-Cyl. 3E until after 90 seconds from time ignition switch is turned to LOCK
Tercel Sedan position and negative battery cable is disconnected.
1987 ............... 2.3 Hrs. ................................ T136 Removal:
Tercel Disconnect negative battery cable. Raise and support ve-
1988-94 .......... 2.3 Hrs. ...... TCK233 .......... T233 hicle. Remove right side engine under cover (splash) shield.
Lower vehicle. Remove accessory drive belts.
1
- With Air Cond. add .4 hours. Disconnect accelerator cable. On A/T models, disconnect
throttle cable. On all models, disconnect PCV hoses. On
NOTE: A timing belt component kit is available for 1987-91 models, remove air cleaner assembly.
On all models, remove bolt, ground strap and vacuum trans-
this application. See page I for information on component mitting valves with bracket on right engine mount. This is
kits. mount on timing belt end of engine.
Using floor jack, support weight of engine from below. Re-
MANUFACTURERS SUGGESTED move right engine mount from timing belt end of engine.
Remove valve cover. Remove spark plugs.
SCHEDULED MAINTENANCE Set No. 1 cylinder at TDC on compression stroke. Turn
The manufacturer recommends the belt be replaced every crankshaft pulley and align groove on crankshaft with 0
60,000 miles under severe service operating conditions. mark on timing belt cover. Ensure rocker arms on No. 1
cylinder are loose. If not, turn crankshaft pulley one com-
* NOTE: This application is an interference engine. plete revolution.
Courtesy of Toytota Motor Sales, U.S.A., Inc.

Fig. 1: Exploded View Of Timing Belt & Components (1991-94 Shown; 1987-90 Use One-Piece Crankshaft Pulley)
502 TOYOTA
*1.5L 4-Cylinder 3E (Cont.)
Fig. 4: Measuring Tension Spring Free Length
Remove timing belt cover. Noting installed position for re-

assembly reference, remove timing belt guide. See Fig. 1.
If reusing old timing belt, place arrow on belt to indicate
direction of rotation. Place mating marks on belt and crank-
shaft sprocket, and on camshaft sprocket.
Remove timing belt tension spring. See Fig. 1. Loosen No.
1 idler pulley bolt and push pulley to left as far as it will go.
See Fig. 1. Tighten bolt. Remove timing belt.
Inspection:
tamination. Ensure No. 1 and No. 2 idler pulleys rotate
Fig. 2: Routing Timing Belt freely. Inspect all sprockets for damage. Replace damaged
components.
Measure free length of tension spring. See Fig. 4. Tension
spring free length should be 1.528 (38.8 mm) on 1987-89
engines. On 1990-94 engines, free length should be 1.512
(38.4 mm). Replace tension spring if free length is not as
specified.
Measure tension spring at specified installed length. For
1987-89 engines, spring tension should be 18.3 lbs. at
2.157 (8.3 kg at 54.8 mm). For 1990-94 engines, spring
tension should be 11.3 lbs. at 2.028 (5.11 kg at 51.5 mm).
Replace spring if tension is not as specified.
NOTE: Before installing timing belt, remove any oil or water

from camshaft sprocket, crankshaft sprocket and idler pulleys.
Installation:
If camshaft sprocket was removed, align knock pin with No.
1 camshaft bearing cap mark. See Fig. 5. Install camshaft
sprocket with 3E mark facing up. See Fig. 3. Tighten cam-
shaft sprocket bolt to specification. See TORQUE SPECIFI-
CATIONS.
Align crankshaft sprocket timing mark with mark on oil pump
housing. See Fig. 3. If removed, install No. 1 idler pulley.
Move No. 1 idler pulley as far left as it will go, and tempo-
rarily tighten bolt.
Install No. 2 idler pulley (if removed). Install timing belt on
engine. If reusing old belt, ensure all mating marks are
aligned and belt is installed in original direction of rotation.
Loosen No. 1 idler pulley bolt and install pulley tension
spring. Temporarily install crankshaft pulley bolt. Turn crank-
shaft CLOCKWISE 2 revolutions from TDC to TDC. Realign
camshaft and crankshaft sprocket timing marks. If timing
Fig. 3: Aligning Crankshaft & Camshaft Timing Marks marks do not align, remove and reinstall timing belt.
On 1991-94 models with A/C and/or power steering, re- If timing marks do align, tighten No. 1 idler pulley bolt to
move accessory drive pulley from crankshaft pulley. See specification. See TORQUE SPECIFICATIONS. Install tim-
Fig. 1. ing belt guide. Install timing belt covers.
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.
TOYOTA 503
*1.5L 4-Cylinder 3E (Cont.)

Install crankshaft pulley. Holding crankshaft pulley station-
ary, tighten crankshaft pulley bolt to specification. On 1991-
94 models, install accessory drive pulley.
On all models, install spark plugs. Install valve cover. In-
stall right engine mount to engine and body. Install vacuum
switching valves and engine ground strap to engine mount
(if equipped).
Connect negative battery cable. To complete installation,
Accessory Drive Belt Pulley Bolt ................................. 14 (19)
A/C Compressor Bolt ................................................. 18 (24)
A/C Compressor Mounting Bracket Bolt ..................... 20 (27)
Alternator Bracket Bolt .................................................. 13 (18)
Engine Mount
Mount-To-Cylinder Block Bolt/Nut ............................. 47 (64)
Through-Bolt
Fig. 5: Aligning Camshaft Knock Pin With Bearing Cap 1987-90 ...................................................................... 47 (64)
1991-94 ...................................................................... 54 (73)
Idler Pulley Bracket Bolt
12 mm ...................................................................... 20 (27)
14 mm ...................................................................... 27 (37)
No. 1 Idler Pulley Bolt .................................................. 13 (18)
Power Steering Bracket Bolt ....................................... 32 (43)
Spark Plugs .................................................................... 13 (18)
Timing Belt Idler Mount Bolt ........................................ 27 (37)
INCH Lbs. (N.m)
Valve Cover Nut ......................................................... 61 (6.5)
504 TOYOTA
1.5L 4-Cylinder 5E-FE
1.5L 4-Cyl.
Paseo
1992-95 ................. 2.5 Hours ..................... T208
1996-99 ................. 3.5 Hours ..................... T208
Tercel
1995-99 ................. 2.8 Hours ..................... T208
1
With Air Cond. & Pwr. Strng. add .4 hours.
belt be replaced every 60,000 miles under severe service op-
erating 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 recom-
mends the belt be replaced every 90,000 miles or 72 months.
REMOVAL & INSTALLATION If removing crankshaft sprocket, use soft-faced hammer to
lightly tap sprocket from crankshaft. DO NOT pry on outer
TIMING BELT edges of sprocket. Also, note position of outer timing belt
Removal: guide on crankshaft sprocket. Concave surface should face
Disconnect negative battery cable. Raise and support ve- away from engine.
hicle. Remove right engine undercover. Remove accessory Inspection:
drive belts. Remove charcoal canister for access to timing Inspect timing belt for damaged teeth, cracking and oil con-
belt covers. tamination. Ensure idler pulleys rotate freely. Inspect all
Slightly raise engine to remove weight from right (timing sprockets for damage. Replace damaged components.
belt side) engine mount. Remove the through-bolt and right Measure free length of tension spring. Replace tension
engine mount insulator. Remove No. 2 timing belt cover spring if free length is not 1.512" (38.40 mm).
and gasket. See Fig. 1. Measure tension required to extend tension spring to 1.866"
Rotate crankshaft clockwise (viewed from timing belt end (47.40 mm). Replace tension spring if tension is not 7.3
of engine) so cylinder No. 1 is at TDC on compression lbs. (3.3 kg).
stroke. Cylinder No. 1 is front cylinder at timing belt end of Installation:
engine. Ensure timing mark on crankshaft pulley aligns If removed, install crankshaft sprocket with flange toward
with 0 mark on timing belt cover. Remove No. 2 timing belt engine. Install tension spring and No. 1 idler pulley with
cover. bolt loosely installed. DO NOT tighten bolt at this time. Move
With cylinder No. 1 at TDC on compression stroke, ensure No. 1 idler pulley away from timing belt area as far as pos-
hole (5E timing mark) on camshaft sprocket aligns with sible. Temporarily tighten No. 1 idler pulley bolt. Ensure all
timing mark on camshaft bearing cap. See Fig. 3. If timing sprockets and idler pulleys are clean. Temporarily install
mark is not aligned, rotate crankshaft clockwise one revo- crankshaft pulley bolt, and rotate crankshaft so timing mark
lution (360 degrees). on crankshaft sprocket aligns with timing mark on oil pump
Remove bolt and accessory drive belt pulley from front of body. See Fig. 3 or Fig. 4.
crankshaft pulley. Using Pulley Holder (SST 09213-14010)
or equivalent, and Handle (SST 09330-00021) or equiva- CAUTION: If reusing timing belt, ensure reference marks on timing
lent, hold crankshaft pulley, and remove crankshaft pulley belt align with those placed on all sprockets and timing belt
bolt. Using puller, remove crankshaft pulley. is installed in original direction of rotation.
Remove No. 3 and No. 1 timing belt cover and gasket. See
Fig. 1. Note direction of timing belt guide installation for Remove crankshaft pulley bolt. Install timing belt on crank-
installation reference. See Fig. 3. Remove timing belt guide. shaft sprocket, oil pump drive sprocket, No. 1 idler pulley
and then No. 2 idler pulley in sequence. Ensure belt is
CAUTION: If reusing timing belt, mark direction of timing belt tensioned between crankshaft sprocket and camshaft
rotation and place reference mark on timing belt at all sprockets sprocket.
for reassembly reference. Loosen No. 1 idler pulley bolt, allowing tension spring to
move pulley against timing belt. Rotate crankshaft clock-
Remove tension spring from No. 1 idler pulley. See Fig. 1. wise 2 full turns from TDC to TDC. Ensure camshaft timing
Loosen No. 1 idler pulley bolt. Move No. 1 idler away from marks are still aligned. If all timing marks are aligned, tighten
timing belt as far as possible and tighten bolt. Remove No. 1 idler pulley bolt to specification. See TORQUE SPECI-
timing belt, idler pulley bolt and No. 2 idler pulley (if neces- FICATIONS.
sary).
TOYOTA 505
1.5L 4-Cylinder 5E-FE (Cont.)

shaft sprocket and flat side toward timing belt. Install No. 1
and No. 3 timing belt covers and gasket. Align crankshaft
pulley key groove with key in crankshaft. Install crankshaft
pulley. Install and tighten crankshaft pulley bolt to specifi-
cation.
Install accessory drive belt pulley on front of crankshaft and
tighten bolt to specification. See TORQUE SPECIFICA-
TIONS. Install gasket and No. 2 timing belt cover.
dure. If valve cover was removed, apply sealant at ends of
camshafts. See Fig. 2. To ensure proper mount alignment,
install all right (timing belt side) engine mount bolts/nuts
before tightening to specification. See TORQUE SPECIFI-
CATIONS. Adjust drive belts to proper tension. See page A-
60 for belt tension ranges. Fig. 2: Cylinder Head Sealant Application Areas
Accessory Drive Belt Pulley Bolts ............................... 14 (19)
A/C Compressor Mounting Bracket Bolt ..................... 20 (27)
A/C Idler Pulley Bolt
12 mm Bolt ............................................................... 20 (27)
14 mm Bolt ............................................................... 27 (37)
Engine Mount
Right (Timing Belt Side)
Mount-To-Cylinder Block Bolt/Nut ............................. 47 (64)
Through-Bolt ............................................................. 54 (73)
Idler Pulley Bolt
No. 1 Idler Pulley ....................................................... 13 (18)
No. 2 Idler Pulley ....................................................... 20 (27) Courtesy of Toyota Motor Sales, U.S.A., Inc.
Oil Pump Drive Sprocket Nut ...................................... 27 (37)
Power Steering Pump
Adjusting Bracket Bolt .............................................. 15 (20)
Lower Bolt ................................................................ 29 (39)
Upper Bolt ................................................................ 32 (43)
Spark Plugs ................................................................ 13 (18)
INCH Lbs. (N.m)
Valve Cover Nut ......................................................... 61 (6.9)

506 TOYOTA
1.6L 4-Cylinder DOHC, 4A-GE
TIMING BELT APPLICATION Check free length of idler pulley tension spring. See Fig. 2.
Replace spring if free length is not 1.713" (43.5 mm). In-
Application Labor Time Belt Part No. spect spring tension at installed length. Installed tension
1.6L 4-Cyl. DOHC is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if
Corolla FX-16, GTS & Sport (4A-GE) not to specification.
1985-88 ......................... 1 ............................ T112 Installation (1985-87 RWD Corolla):
Corolla GTS (4A-GE, 4A-GELC) If removed, install timing belt idler pulley (tensioner) and
spring. Secure pulley as far to the left as possible and
1989-91 ................... 1.6 Hrs. ....................... T176 temporarily tighten bolt.
MR2 Install timing belt. If reusing old belt, ensure mating marks
1985-88 .................. 2 2.7 Hrs. ...................... T112 made on disassembly match crankshaft and camshaft
1989 ....................... 2 2.7 Hrs. ...................... T176 marks. Ensure arrow points in direction of rotation.
1
- 2.6 hours with FWD. Loosen tensioner pulley bolt allowing tensioner to apply
tension to belt. Temporarily install crankshaft pulley. Turn
1.6 hours with RWD. crankshaft CLOCKWISE 2 revolutions. Align camshaft and
2
- With Air Cond. add .5 hours. crankshaft timing marks. See Fig. 1. If timing marks align,
tighten tensioner pulley bolt to specification. See TORQUE
MANUFACTURERS SUGGESTED SPECIFICATIONS. Remove crankshaft pulley.
SCHEDULED MAINTENANCE Measure timing belt deflection midway between camshaft
sprockets. See Fig. 3. If deflection is not correct, readjust
For 1985 model year, although the manufacturer does not timing belt tension.
recommend a specific scheduled maintenance interval, belt Install timing belt guide on crankshaft. Install timing belt
manufacturers suggest the belt be replaced at 60,000 mile covers. Install crankshaft pulley. Install and tighten center
intervals. For 1986-91 model years, the manufacturer recom- bolt to specification. See TORQUE SPECIFICATIONS.
mends the belt be replaced at 60,000 mile intervals for severe Install water pump pulley and fan assembly. Install gen-
service operating conditions. erator drive belt. Install power steering pump pulley and
drive belt. Adjust drive belt to proper tension. See page A-
REMOVAL & INSTALLATION 60 for belt tension ranges.
Removal (1985-88 FWD Corolla):
TIMING BELT Raise and support vehicle. Remove right front wheel. Re-
Removal (1985-87 RWD Corolla): move engine under cover. Drain engine coolant.
Remove air cleaner intake duct above radiator. If equipped If equipped with cruise control, disconnect accelerator cable
with power steering, remove power steering belt. Remove and cruise control cable from actuator. Disconnect cruise
the power steering pump with hoses attached and set
aside.
Loosen water pump pulley bolts. Remove cooling fan belt.
Remove cooling fan assembly. Remove spark plugs.
pression stroke. Crankshaft pulley notch must align with
0 timing mark on lower timing belt cover. With valve cover
oil filler cap removed, cavity in camshaft should be visible.
If not, turn crankshaft one complete revolution.
Holding crankshaft stationary, remove crankshaft pulley bolt.
Remove crankshaft pulley using gear puller. Remove tim-
ing bel covers and gaskets. Noting installed position for
reassembly reference, remove timing belt guide from crank-
shaft.
If reusing timing belt, place mating marks on timing belt
and camshaft sprockets, and timing belt and crankshaft
sprocket. Also place arrow on belt indicating original direc-
tion of rotation.
Loosen idler pulley (tensioner) bolt. See Fig. 1. Move
tensioner pulley as far left as possible and temporarily
tighten bolt. Remove timing belt. Courtesy of Toyota Motor Sales, U.S.A., Inc.
Inspection (1985-87 RWD Corolla): Fig. 1: Aligning Timing Marks

Check timing belt teeth for cracks or damage. If tooth dam-
age is found, ensure camshaft and crankshaft sprockets
are okay. If wear or cracks on flat side of belt face are found,
check for nicks on idler pulleys. If wear or damage to only
one side of belt is found, check belt guide and alignment of
each pulley and sprocket.
If noticeable wear is found on belt teeth, check timing cover
gasket for damage or improper installation. Ensure sprocket
teeth are free of foreign material.
TOYOTA 507
1.6L 4-Cylinder DOHC, 4A-GE (Cont.)

Install timing belt. If reusing old belt, ensure mating marks
made on disassembly match crankshaft and camshaft
marks. Ensure arrow points in direction of rotation.
Loosen tensioner pulley bolt allowing tensioner to apply
crankshaft CLOCKWISE 2 revolutions. Align camshaft and
crankshaft timing marks. See Fig. 1. If timing marks align,
SPECIFICATIONS. Remove crankshaft pulley.
Measure timing belt deflection midway between camshaft
Install timing belt guide on crankshaft. Install timing belt
covers. Install crankshaft pulley. Install and tighten center
bolt to specification. See TORQUE SPECIFICATIONS.
Install engine mount to timing belt end of engine. Tighten
Install water pump pulley. Install accessory drive belts. Ad-
tension ranges. Install right front wheel and engine under
cover.
Install upper radiator hose. Install windshield washer tank.
Fig. 3: Timing Belt Deflection On FX-16, install ignition coil. On all models, install cruise
control actuator (if equipped). Fill radiator with coolant and
control electrical connector. Remove cruise control actua- bleed air from system.
tor. Remove windshield washer tank and set aside. Removal (MR2):
On FX-16 models, remove ignition coil with wires attached Raise and support vehicle. Remove right front wheel. Re-
and secure out of way. On all models, remove the upper move engine under cover.
radiator hose. Loosen water pump pulley bolts. Remove all accessory
Loosen water pump pulley bolts. Remove all accessory drive belts. Rotate crankshaft so that No. 1 cylinder is at
drive belts. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch on crankshaft pulley
TDC of compression stroke. Notch on crankshaft pulley must align with timing mark on timing belt cover. Remove
must align with 0 timing mark on timing belt cover. Re- oil filler cap from valve cover. Cavity in camshaft should be
move oil filler cap from valve cover. Cavity in camshaft should visible in hole. If not, turn crankshaft one complete revolu-
be visible in hole. If not, turn crankshaft one complete revo- tion.
lution. Support weight of engine with floor jack. Remove engine
Holding crankshaft stationary, remove crankshaft pulley bolt. mount through bolt from timing belt end of engine.
Remove crankshaft pulley using gear puller. Remove tim- Holding crankshaft stationary, remove crankshaft pulley bolt.
ing bel covers and gaskets. Noting installed position for Remove crankshaft pulley using gear puller. Remove tim-
reassembly reference, remove timing belt guide from crank- ing bel covers and gaskets. Noting installed position for
shaft. reassembly reference, remove timing belt guide from crank-
If reusing timing belt, place mating marks on timing belt shaft.
and camshaft sprockets, and timing belt and crankshaft If reusing timing belt, place mating marks on timing belt
sprocket. Also place arrow on belt indicating original direc- and camshaft sprockets, and timing belt and crankshaft
tion of rotation. sprocket. Also place arrow on belt indicating original direc-
Support weight of engine with floor jack. Remove engine tion of rotation.
mount from timing belt end of engine. Loosen idler pulley (tensioner) bolt. See Fig. 1. Move
Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley as far left as possible and temporarily
tensioner pulley as far left as possible and temporarily tighten bolt. Remove timing belt.
tighten bolt. Remove timing belt. Inspection (MR2):
Inspection (1985-88 FWD Corolla): Check timing belt teeth for cracks or damage. If tooth dam-
Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets
age is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on flat side of belt face are found,
are okay. If wear or cracks on flat side of belt face are found, check for nicks on idler pulleys. If wear or damage to only
check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of
one side of belt is found, check belt guide and alignment of each pulley and sprocket.
each pulley and sprocket. Check free length of idler pulley tension spring. See Fig. 2.
Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.713" (43.5 mm). In-
Replace spring if free length is not 1.713" (43.5 mm). In- spect spring tension at installed length. Installed tension
spect spring tension at installed length. Installed tension is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if
is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if not to specification.
not to specification. Installation (MR2):
Installation (1985-88 FWD Corolla): If removed, install timing belt idler pulley (tensioner) and
If removed, install timing belt idler pulley (tensioner) and spring. Secure pulley as far to the left as possible and
spring. Secure pulley as far to the left as possible and temporarily tighten bolt.
temporarily tighten bolt.
508 TOYOTA
1.6L 4-Cylinder DOHC, 4A-GE (Cont.)
Install timing belt. If reusing old belt, ensure mating marks TORQUE SPECIFICATIONS
made on disassembly match crankshaft and camshaft
marks. Ensure arrow points in direction of rotation.
Loosen tensioner pulley bolt allowing tensioner to apply
Corolla (FWD) .......................................................... 101 (137)
crankshaft CLOCKWISE 2 revolutions. Align camshaft and
Corolla (RWD) .......................................................... 105 (142)
crankshaft timing marks. See Fig. 1. If timing marks align,
Engine Mounts (Corolla FWD)
FX-16
SPECIFICATIONS. Remove crankshaft pulley.
Through Bolt .......................................................... 58 (78)
Measure timing belt deflection midway between camshaft
Except FX-16
Mount-To-Engine Bracket Nut ................................ 34 (52)
Through Bolt .......................................................... 64 (87)
Engine Mount (MR2)
covers. Install crankshaft pulley. Install and tighten center
Through Bolt ............................................................. 43 (58)
bolt to specification. See TORQUE SPECIFICATIONS.
Power Steering Pump-To-Bracket Bolts ..................... 29 (39)
Install engine mount to timing belt end of engine. Tighten
Power Steering Pump Pulley Bolt
bolts to specification. See TORQUE SPECIFICATIONS. In-
Corolla (RWD) .............................................................. 33 (44)
stall right front wheel and engine under cover.
Spark Plug .................................................................. 13 (18)
Install water pump pulley. Install accessory drive belts. Ad-
Water Pump Bolts ...................................................... 11 (15)
tension ranges.
Wheel Lug Nut ............................................................. 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolts ....................................................... 69 (7.8)
TOYOTA 509

Belt
1.6L 4-Cyl. SOHC
Corolla, FWD
1984-88 .......... 1 3.1 Hrs. .... TCK070 .......... T070
Corolla RWD
1983 ............... 2 2.5 Hrs. .... TCK070 .......... T070
1984-87 .......... 1.6 Hrs. ...... TCK070 .......... T070
Corolla FX
1987-88 .......... 2.7 Hrs. ...... TCK070 .......... T070
Corolla SR5
1985-87 .......... 1.6 Hrs. ...... TCK070 .......... T070
1988 (FWD) ... 3.1 Hrs. ...... TCK070 .......... T070
1
- With Air Cond. and Pwr. Strng. add .4 hours.
2
- With Air. Cond. add .2 hours; with Pwr. Strng.
add .1 hours.
kits.
For 1983-85 model years, although the manufacturer does
not recommend a specific scheduled maintenance interval, Fig. 1: Aligning Timing Marks For Timing Belt Installation
recommends the belt be replaced at 60,000 mile intervals for
severe service operating conditions.

TIMING BELT
Removal (RWD Models):
Remove power steering and A/C compressor drive belts (if
equipped). On models with power steering, remove power
steering pump with hoses attached and set aside.
Remove air cleaner assembly. Loosen water pump pulley
bolts. Remove cooling fan drive belt. Remove cooling fan.
Disconnect PCV hose and remove valve cover.
Hold crankshaft stationary and remove crankshaft pulley
center bolt. Remove crankshaft pulley using a gear puller.
Remove timing belt covers and gaskets. Noting installed
position for reassembly reference, remove timing belt guide
from crankshaft.
Rotate crankshaft so that No. 1 cylinder is at TDC on com-
pression stroke. Align crankshaft and camshaft timing Fig. 2: Aligning TDC Marks On Crankshaft Sprocket & Oil
marks. See Figs. 1 and 2. Pump Body
If reusing timing belt, place mating marks on belt and
sprockets for reassembly reference. See Fig. 3. Place ar- Measure free length of tension spring. Free length should be
row on belt to indicate original direction of rotation. 1.705 (43.3 mm). See Fig. 4. Replace tension spring if free
Loosen idler pulley bolt. Push idler pulley as far left as length is not as specified.
possible and temporarily tighten center bolt. Remove tim- Measure tension of spring at installed length. Tension should
ing belt. be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension
Inspection (RWD Models): spring if necessary.
Inspect timing belt for damaged teeth, cracking and oil con- Installation (RWD Models):
tamination. Ensure idler pulley rotates freely. Inspect all Align camshaft sprocket timing hole with camshaft bearing
sprockets for damage. Replace damaged components. cap mark. See Figs. 1 and 2. Align timing marks on oil
pump body and crankshaft timing sprocket.
510 TOYOTA


Install idler pulley (tensioner) and spring (if removed). Pry
idler pulley toward left and temporarily tighten. Install tim-
ing belt. If installing used belt, ensure mating marks are
aligned to camshaft sprocket and crankshaft sprocket. See
Fig. 3. Ensure arrow on belt points in original direction of
rotation.
Loosen timing belt idler pulley bolt so that pulley applies
tension to belt. Rotate crankshaft 2 revolutions from TDC to
TDC. Recheck alignment of sprockets and timing belt.
Tighten idler pulley (tensioner) bolt to specification. See
Check timing belt deflection. See Fig. 5. If timing belt de- Courtesy of Toyota Motor Sales, U.S.A., Inc.
flection is not correct, readjust timing belt tension. Fig. 5: Measuring Timing Belt Deflection
covers. Install crankshaft pulley and tighten bolt to specifi- Support weight of engine from below with a floor jack. Work-
cation. Install valve cover. Install air cleaner assembly. ing from below the vehicle, remove the 4 lower engine
To complete installation, reverse removal procedure. mount bolts from the engine crossmember. Remove en-
Tighten bolts and nuts to specification. See TORQUE SPECI- gine mount through-bolt from mount at timing belt end of
FICATIONS. Apply sealant to cylinder head when installing engine. Raise engine slightly and remove timing belt.
valve cover. Adjust drive belts to proper tension. See page Inspection (FWD Models):
... for belt tension ranges. Inspect timing belt for damaged teeth, cracking and oil con-
Removal (FWD Models: tamination. Ensure idler pulley rotates freely. Inspect all
Raise and support vehicle. Remove right front wheel. Re- sprockets for damage. Replace damaged components.
move right undercover from wheelwell. Drain engine cool- Measure free length of tension spring. Free length should be
ant. Disconnect upper radiator hose. 1.705 (43.3 mm). See Fig. 4. Replace tension spring if free
Loosen water pump pulley bolts. Remove all accessory length is not as specified.
drive belts. Remove generator with wires attached and set Measure tension of spring at installed length. Tension should
aside. Remove A/C compressor from mount with hoses be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension
attached, and set aside. Remove water pump pulley. spring if necessary.
Remove upper and center timing belt covers. Turn crank- Installation (FWD Models):
shaft until No. 1 cylinder is at TDC of compression stroke. Insert timing belt between engine mount and body. Lower
Crankshaft pulley notch must align with 0 timing mark on engine and install engine mount through-bolt through body
lower timing belt cover. Remove valve cover. Camshaft and mount insulator. Tighten bolt to specification. See
sprocket timing mark must align with mark on bearing cap. TORQUE SPECIFICATIONS.
See Fig. 1. Align camshaft sprocket timing hole with camshaft bearing
Hold crankshaft stationary and remove crankshaft pulley cap mark. See Figs. 1 and 2. Align timing marks on oil
center bolt. Remove crankshaft pulley using a gear puller. pump body and crankshaft timing sprocket.
Remove lower timing belt cover. Install idler pulley (tensioner) and spring (if removed). Pry
Noting installed position for reassembly reference, remove idler pulley toward left and temporarily tighten. Install tim-
timing belt guide from crankshaft. ing belt. If installing used belt, ensure mating marks are
If reusing timing belt, place mating marks on belt and aligned to camshaft sprocket and crankshaft sprocket. See
sprockets for reassembly reference. See Fig. 3. Place ar- Fig. 3. Ensure arrow on belt points in original direction of
row on belt to indicate original direction of rotation. rotation.
Loosen idler pulley bolt. Push idler pulley as far left as
possible and temporarily tighten center bolt.
TOYOTA 511

Loosen timing belt idler pulley bolt so that pulley applies Install right under cover. Install right front wheel. Adjust drive
tension to belt. Rotate crankshaft 2 revolutions from TDC to belts to proper tension. See page A-60 for belt tension
TDC. Recheck alignment of sprockets and timing belt. ranges.
Tighten idler pulley (tensioner) bolt to specification. See TORQUE SPECIFICATIONS
Check timing belt deflection. See Fig. 5. If timing belt de- Application Ft. Lbs. (N.m)
flection is not correct, readjust timing belt tension. A/C Compressor-To-Block Bolts (4) ........................... 18 (25)
Install timing belt guide on crankshaft. Install timing belt Camshaft Sprocket Bolt .................................................. 34 (47)
covers. Install crankshaft pulley and tighten bolt to specifi- Crankshaft Pulley Bolt .............................................. 87 (118)
cation. Engine Mount Through-Bolt (FWD Models) 58 (78)
Install water pump pulley. Install valve cover. Install air Engine Mount-To-Crossmember Bolt ............................ 29 (39)
cleaner assembly. Install A/C compressor to engine mount. Timing Belt Idler Pulley Bolt ........................................ 27 (37)
Install generator. Install valve cover. Apply sealant to cylin- Wheel Lug Nut ............................................................. 76 (103)
der head when installing valve cover. INCH Lbs. (N.m)
Install upper radiator hose. Refill cooling system. Valve Cover Bolts ....................................................... 69 (7.8)
512 TOYOTA
1.6L & 1.8L 4-Cylinder DOHC
TIMING BELT APPLICATION Loosen idler pulley (tensioner) bolt. Push idler pulley as far
to the left as possible, and snug tighten bolt. Remove tim-
Belt ing belt.
Labor Component Part Inspection (Celica):
Application Time Kit No. No. No. Check timing belt teeth for cracks or damage. If tooth dam-
1.6L 4-Cyl. DOHC age is found, ensure camshaft and crankshaft sprockets
Celica are okay. If wear or cracks on flat side of belt face are found,
check for nicks on idler pulleys. If wear or damage to only
1990-92 .......... 3.1 Hrs. ...... TCK036 .......... T036 one side of belt is found, check belt guide and alignment of
1993 ............... 3.1 Hrs. ................................ T239 each pulley and sprocket.
Corolla (4A-FE) Check free length of idler pulley tension spring. See Fig. 2.
1988-92 .......... 2.6 Hrs. ...... TCK036 .......... T036 Replace spring if free length is not 1.51" (38.4 mm) for 1.6L
1993-97 .......... 2.6 Hrs. ...... TCK236 .......... T236 (4AF engine), or 1.252 (31.8 mm) for 1.8L (4AF engine).
1.8L 4-Cyl. DOHC Check tension at installed length. Tension should be 8.8
Celica lbs. at 1.976 (4 kg at 50.2 mm) for 1.6L (4AF engine), or
11.7 lbs. at 1.480 (5.3 kg at 37.6 mm) for 1.8L (7AF en-
1994-97 .......... 2.8 Hrs. ................................ T235 gine). If tension is not as specified, replace spring.
Corolla Installation (Celica):
1993-97 .......... 2.6 Hrs. ................................ T235 Ensure No. 1 cylinder is at TDC on compression stroke.
1
- 2.6 hours with FWD. Crankshaft Woodruff key will be at 12 oclock position. On
1.6L engine, timing mark notch on crankshaft sprocket will
1.6 hours with RWD. align with timing mark on oil pump housing. See Fig. 3.
2
- With Air Cond. add .5 hours. Crankshaft sprocket on 1.8L engine does not have notch.
On 1.6L and 1.8L, hole in camshaft sprocket must align
NOTE: A timing belt component kit is available for with mark on bearing cap.
this application. See page I for information on component NOTE: Engine should be cold when installing timing belt.
kits.
Ensure idler pulley (tensioner) is pushed as far to the left
as possible and pulley bolt is snug tight. If reusing old
MANUFACTURERS SUGGESTED timing belt, install belt and align match marks made during
SCHEDULED MAINTENANCE removal. Install new timing belt.
Loosen idler pulley (tensioner) bolt and allow pulley to move
against belt. Install timing belt guide on crankshaft (dished
belt be replaced at 60,000 mile intervals for severe service
side facing away from belt).
operating conditions.

TIMING BELT
Removal (Celica):
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).
Support weight of engine with a floor jack. Remove engine
Loosen water pump pulley bolts, then remove all acces-
sory drive belts.
On 1.8L (7AF engine), remove A/C compressor front en-
gine mount with hoses attached. Remove A/C compressor
mount from engine. Fig. 1: Placing Mating Marks On Timing Belt & Sprockets
On 1.6L and 1.8L engine, remove upper and center timing
belt covers.
pression stroke. Notch in crankshaft pulley must align with
0 timing mark on timing belt cover. Hole in camshaft tim-
ing pulley must align with mark on bearing cap. See Fig. 3.
Remove water pump pulley. Remove crankshaft pulley bolt.
Using gear puller, remove crankshaft pulley. Remove lower
timing belt cover. See Fig. 6. Remove timing belt guide
(large washer) from crankshaft sprocket.
If reusing timing belt, mark direction of rotation on timing Courtesy of Toyota Motor Sales, U.S.A., Inc.
belt. Match mark timing belt with marks on both sprockets
for installation reference. See Fig. 1. Place arrow on belt to
indicate original direction of rotation.
TOYOTA 513
1.6L & 1.8L 4-Cylinder DOHC (Cont.)

(1993-97 1.6L & 1.8L)
Install lower timing belt cover. Install crankshaft pulley. In-

stall crankshaft pulley center bolt. Rotate crankshaft
CLOCKWISE 2 revolutions from TDC to TDC.
Ensure crankshaft pulley notch aligns with 0 timing mark
on lower timing belt cover. Ensure camshaft sprocket tim-
ing marks align. If timing marks are not aligned, remove
Fig. 3: Aligning Timing Marks (1.6L; 1.8L Uses Same and reinstall timing belt. If timing marks are aligned, final
Camshaft Sprocket Timing Mark) tighten crankshaft pulley center bolt. See TORQUE SPECI-
FICATIONS.
With idler pulley bolt still loose, measure timing belt deflec-
tion at midway point of belt longest run. See Fig. 4. Deflec-
tion should be .20-.24" with pressure of 4.4 lbs. (5-6 mm at
2.0 kg) applied. See Fig. 4. If deflection is not as specified,
readjust tension on belt by moving idler pulley (tensioner).
Tighten idler pulley bolt to specification. See TORQUE
SPECIFICATIONS.
Install upper and center timing belt covers. When installing
Measure Deflection valve cover, ensure sealant is apply in correct position. See
Here Fig. 5.
Install water pump pulley. On 1.8L engine, install A/C com-
pressor mount to engine. Install A/C compressor.
On 1.6L and 1.8L engines, install all accessory drive belts.
Adjust belts to proper tension. See page A-60 for belt ten-
sion ranges. Final tighten water pump pulley bolts.
Install engine mount to timing belt end of engine. Install
front wheel and engine under cover. Install cruise control
actuator (if equipped).
Courtesy of Toyota Motor Sales, U.S.A., Inc. Removal (1988-92 Corolla):
Fig. 4: Timing Belt Deflection 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.
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.
Support weight of engine with a floor jack. Remove engine
Remove water pump pulley. Remove crankshaft pulley bolt.
Using gear puller, remove crankshaft pulley. Remove tim-
ing belt covers. Remove timing belt guide (large washer)
from crankshaft sprocket.
Fig. 5: Identifying Cylinder Head Sealant Application Areas
514 TOYOTA
If reusing timing belt, mark direction of rotation on timing Remove upper timing belt cover. With No. 1 cylinder at TDC,
belt. Match mark timing belt with marks on both sprockets hole in camshaft sprocket must align with mark on bearing
for installation reference. See Fig. 1. Place arrow on belt to cap. See Fig. 3.
indicate original direction of rotation. Support weight of engine with a floor jack. Remove engine
Loosen idler pulley (tensioner) bolt. Push idler pulley as far mount at timing belt end of engine.
to the left as possible, and snug tighten bolt. Remove tim- Remove crankshaft pulley bolt. Using gear puller, remove
ing belt. crankshaft pulley. Remove center and lower timing belt cov-
Inspection (1988-92 Corolla): ers. Remove timing belt guide (large washer) from crank-
Check timing belt teeth for cracks or damage. If tooth dam- shaft sprocket.
age is found, ensure camshaft and crankshaft sprockets If reusing timing belt, mark direction of rotation on timing
are okay. If wear or cracks on flat side of belt face are found, belt. Match mark timing belt with marks on both sprockets
check for nicks on idler pulleys. If wear or damage to only for installation reference. See Fig. 1. Place arrow on belt to
one side of belt is found, check belt guide and alignment of indicate original direction of rotation.
each pulley and sprocket. Loosen idler pulley (tensioner) bolt. Push idler pulley as far
Check free length of idler pulley tension spring. See Fig. 2. to the left as possible, and snug tighten bolt. Remove tim-
Replace spring if free length is not 1.51" (38.4 mm). Check ing belt.
tension at installed length. Tension should be 8.8 lbs. at Inspection (1993-97 Corolla):
1.976 (4 kg at 50.2 mm). Check timing belt teeth for cracks or damage. If tooth dam-
Installation (1988-92 Corolla): age is found, ensure camshaft and crankshaft sprockets
Ensure No. 1 cylinder is at TDC on compression stroke. are okay. If wear or cracks on flat side of belt face are found,
Crankshaft key will be at 12 oclock position, and timing check for nicks on idler pulleys. If wear or damage to only
mark notch on crankshaft sprocket will align with timing one side of belt is found, check belt guide and alignment of
mark on oil pump housing. See Fig. 3. Hole in camshaft each pulley and sprocket.
sprocket must align with mark on bearing cap. Check free length of idler pulley tension spring. See Fig. 2.
See TENSION SPRING FREE LENGTH (1993-97 CO-
NOTE: Engine should be cold when installing timing belt. ROLLA). Replace spring if free length is not to specifica-
Ensure idler pulley (tensioner) is pushed as far to the left tion.
as possible and pulley bolt is snug tight. If reusing old Check tension at installed length. See TENSION SPRING
timing belt, install belt and align match marks made during INSTALLED TENSION (1993-97 COROLLA). Replace
removal. Install new timing belt. spring if tension is not to specification.
Loosen idler pulley (tensioner) bolt and allow pulley to move TENSION SPRING FREE LENGTH (1993-97 COROLLA)
against belt. Rotate crankshaft CLOCKWISE 2 revolutions Free Length
from TDC to TDC. Application In (mm)
Recheck timing mark alignment. If timing marks are not 1993-94 1.6L (4AF) ................................................ 1.453 (36.9)
aligned, remove and reinstall timing belt. 1995-97 1.6L (4AF) ................................................ 1.717 (43.6)
With idler pulley bolt still loose, measure timing belt deflec- 1993-97 1.8L (7AF) ................................................ 1.252 (31.8)
tion should be .20-.24" with pressure of 4.4 lbs. (5-6 mm at TENSION SPRING INSTALLED TENSION (1993-97
2.0 kg) applied. See Fig. 4. If deflection is not as specified, COROLLA)
Tighten idler pulley bolt to specification. See TORQUE Tension At Installed Length
SPECIFICATIONS. Install timing belt guide to crankshaft Application Lbs. At In. (Kg At mm)
sprocket. 1993-94 1.6L (4AF) .............................. 13 at 1.988 (5.9 at 50.5)
Install timing belt covers. Install crankshaft pulley. Tighten 1993-94 1.8L (7AF) ......................... 26.5 at 1.988 (12.4 at 50.5)
center bolt to specification. See TORQUE SPECIFICA- 1995-97 1.6L (4AF) ............................. 8.6 at 1.717 (3.9 at 43.6)
TIONS. When installing valve cover, ensure sealant is ap- 1995-97 1.8L (7AF) ........................... 11.7 at 1.480 (5.3 at 37.6)
ply in correct position. See Fig. 5. Installation (1993-97 Corolla):
Install water pump pulley. Install accessory drive belts. Ad- Ensure No. 1 cylinder is at TDC on compression stroke.
just drive belts to proper tension. See page A-60 for belt Crankshaft woodruff key will be at 12 oclock position. On
tension ranges. Final tighten water pump pulley bolts. 1.6L engine, timing mark notch on crankshaft sprocket will
Install front wheel and engine under cover. align with timing mark on oil pump housing. See Fig. 3.
Removal (1993-97 Corolla): Crankshaft sprocket on 1.8L engine does not have notch.
Raise and support vehicle. Remove right front wheel and On 1.6L and 1.8L, hole in camshaft sprocket must align
engine undercover. Lower vehicle. with mark on bearing cap.
Remove windshield washer tank. Remove cruise control
actuator from right side of engine compartment. Loosen NOTE: Engine should be cold when installing timing belt.
water pump pulley bolts, then remove all accessory drive
belts. Remove water pump pulley. Remove valve cover. Ensure idler pulley (tensioner) is pushed as far to the left
On models with A/C, remove A/C compressor from mount as possible and pulley bolt is snug tight. If reusing old
bracket with hoses attached, and set aside. Remove A/C timing belt, install belt and align match marks made during
compressor mount bracket from engine. removal. Install new timing belt.
Disconnect engine wiring harness from upper timing belt Loosen idler pulley (tensioner) bolt and allow pulley to move
cover. Rotate crankshaft so that No. 1 cylinder is at TDC of against belt. Install timing belt guide on crankshaft (dished
compression stroke. Notch in crankshaft pulley must align side facing away from belt).
with 0 timing mark on timing belt cover.
TOYOTA 515

Install lower timing belt cover. Install crankshaft pulley. In- TORQUE SPECIFICATIONS
stall crankshaft pulley center bolt. Rotate crankshaft
CLOCKWISE 2 revolutions from TDC to TDC.
A/C Compressor Mount Bracket-To-Engine
Ensure crankshaft pulley notch aligns with 0 timing mark
Celica (1.8L) ................................................................. 35 (47)
on lower timing belt cover. Ensure camshaft sprocket tim-
A/C Compressor-To-Mount Bolts
ing marks align. If timing marks are not aligned, remove
Celica (1.8L) ............................................................. 18 (25)
and reinstall timing belt. If timing marks are aligned, final
tighten crankshaft pulley center bolt. See TORQUE SPECI-
Crankshaft Pulley Bolt .................................................. 87 (118)
FICATIONS.
Engine Mounts
With idler pulley bolt still loose, measure timing belt deflec-
Celica (1993)
Mount Bolt .............................................................. 47 (64)
tion should be .20-.24" with pressure of 4.4 lbs. (5-6 mm at
Mount Nut .............................................................. 38 (52)
2.0 kg) applied. See Fig. 4. If deflection is not as specified,
Celica (1994-97) & Corolla (1988-92)
Mount-To-Engine Bracket Bolt ............................... 47 (64)
Tighten idler pulley bolt to specification. See TORQUE
SPECIFICATIONS.
Through-Bolt .......................................................... 64 (87)
Install upper and center timing belt covers. When installing
Corolla (1993-97)
valve cover, ensure sealant is apply in correct position. See
Mount-To-Body Bolt ................................................ 19 (25)
Fig. 5.
Mount-To-Engine Bracket Bolt ............................... 47 (64)
Install water pump pulley. Install A/C compressor mount to
engine. Install A/C compressor.
Power Steering Pump-To-Bracket Bolts ..................... 29 (39)
Install all accessory drive belts. Adjust belts to proper ten-
Spark Plug .................................................................. 13 (18)
sion. See page A-60 for belt tension ranges. Final tighten
water pump pulley bolts.
Wheel Lug Nut ............................................................. 76 (103)
Install engine mount to timing belt end of engine. On 1995-
INCH Lbs. (N.m)
97 models, ensure engine ground strap is connected to
Timing Belt Cover Bolt ............................................... 65 (7.4)
ground wire on passenger side shock tower. Install front
Valve Cover Cap Nuts
wheel and engine under cover. Install cruise control actua-
1988-92 1.6L ............................................................... 69 (7.8)
tor (if equipped).
1993-97 1.6L & 1.8L ................................................... 52 (5.9)
Water Pump Pulley Bolt ................................................. 82 (9.3)
516 TOYOTA
1.8L 4-Cylinder Diesel
TIMING BELT APPLICATION Inspection (All Models):
Check timing belt for wear, cracks or missing teeth. If de-
Application Labor Time Belt Part No. fective, check if injection pump camshaft is locked or there
1.8L 4-Cyl. Diesel are nicks on belt side of idler pulley lock. Replace belt and
Camry components as needed.
1984-85 ................ 5.0 Hours .................... T098 Inspect belt for excessive wear on one side only. If dam-
Corolla aged, check the belt guide and the alignment of each
sprocket. Before installing new belt, remove idler pulleys
1984-85 ................ 2.7 Hours .................... T098 and spring. Check idler pulley bearings for noise or rough-
ness.
MANUFACTURERS SUGGESTED Inspect spring for proper free length and tension. Standard
SCHEDULED MAINTENANCE free length is 2.045" (51.93 mm). Replace idler pulley and/
or spring as necessary.
The manufacturer recommends the belt be replaced every Check camshaft, injection pump and crankshaft timing
60,000 miles. sprockets for wear or damage. If belt teeth are worn, check
timing belt cover gasket for damage and proper installa-
REMOVAL & INSTALLATION tion. Replace components as necessary.
TIMING BELT Installation (All Models):
Removal (1984):
Install timing belt tensioner, with larger bolt behind water
pump, and loosely fasten mounting bolts. Swing tensioner
Disconnect negative battery cable. Remove air cleaner. toward the left. Check alignment of timing marks on each
Drain engine coolant and remove radiator hoses, cooling pulley. See Fig. 2
fan shroud and radiator from vehicle. Remove drive belts,
cooling fan and pulley. NOTE: When tightening idler pulley and timing sprocket mount
If equipped with A/C, remove compressor pulley from crank- bolts, do not move idler pulley bracket or apply tension to timing
shaft pulley. Using Pulley Holder and Socket (09213-14010 belt.
& 09330-00020) or equivalent, remove crankshaft pulley
set bolt and washer. Install timing belt onto camshaft timing pulley. Ensure tim-
Using a puller, remove crankshaft pulley. If equipped with A/ ing belt is securely meshed and not loose. Align marks of
C, remove idler pulley. Remove timing belt cover mount injector pump drive pulley and install timing belt onto pul-
bolts. Remove timing belt cover and belt guide. ley. Install timing belt over lower idler pulley and under crank-
Disconnect glow plugs by removing 4 screw grommets shaft timing belt pulley. Ensure timing belt is not twisted or
and glow plug connecting nuts. Disconnect current sensor too tight.
by removing nut, plate washer, insulator and current con- Install tensioner spring and loosen bolts until tensioner
nector. Remove glow plug connector and glow plugs. moves by spring tension. Using crankshaft pulley set bolt,
Using crankshaft set bolt, rotate engine and align TDC mark turn crankshaft 2 complete revolutions clockwise from TDC
on camshaft timing pulley with top surface of cylinder head to TDC. Always turn crankshaft clockwise. Check that each
on intake manifold side. Using pliers, remove tensioner pulley aligns with marks. If marks DO NOT align, remove
spring. Loosen tensioner set bolts and remove timing belt. timing belt and repeat procedure in previous step.
Removal (1985): Ensure that each pulley aligns with timing mark. See Fig. 2.
Disconnect negative battery cable. Remove air cleaner. After ensuring proper alignment of pulley marks, tighten
Drain engine coolant and remove radiator hoses, washer, tensioner pulley set bolts. Reverse remaining removal pro-
and radiator reservoir tanks. Remove drive belts, cooling cedures to complete installation. Adjust drive belts to proper
fan and pulley. tension. See page A-60 for belt tension ranges.
Remove cruise control actuator (if equipped). Disconnect TORQUE SPECIFICATIONS
the accelerator and cruise control cables. Disconnect the
actuator vacuum hose. Remove the actuator cover, and the
actuator. Disconnect the wiring connector. Camshaft Sprocket Bolt .................................. 69-75 (94-102)
Remove power steering pump with bracket (if equipped). Crankshaft Pulley Washer/Bolt
1984 ..................................................................... 102 (137)
Remove drive belt and pulley. Remove 3 mounting bolts
and PS pump with bracket. Place pump aside and sus- 1985 ......................................................................... 72 (98)
pend it. Remove alternator with bracket. Injection Pump Drive Pulley Bolts
1984 ............................................................... 43-47 (58-64)
Remove No. 2 timing belt cover. Set No. 1 cylinder to TDC 1985 ............................................................... 10-15 (20-28)
on compression stroke. Align mark of camshaft pulley with
top end of cylinder head. Using Special Service Socket Nozzle Holder Mount Bolt
1984 ............................................................... 20-22 (27-29)
(09213-14010 and 09330-00020) or equivalent, remove
crankshaft pulley. 1985 ............................................................... 51-65 (69-88)
Remove No. 1 timing belt cover and belt guide. Jack up Tensioner Pulley Bolts
1984 ......................................................................... 14 (19)
engine slightly. Remove RH engine mounting insulator and
bracket. Using a screwdriver, remove tension spring. 1985 ......................................................................... 27 (37)
Loosen the No. 1 idler pulley mount bolt. Remove timing INCH Lbs. (N.m)
Glow Plugs ............................................................... 108 (13)
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.
TOYOTA 517
1.8L 4-Cylinder Diesel (Cont.)
Fig. 1: Exploded View Of Timing Belt Cover & Gears
Fig. 2: Aligning Camshaft, Crankshaft & Injection Pump

Sprocket Timing Marks
518 TOYOTA
2.0L 4-Cylinder Except RAV4
TIMING BELT APPLICATION Using Toyota tool (09278-54011) or equivalent, hold timing
sprocket in place, then remove sprocket retaining bolt and
Belt sprocket. Remove No. 1 idler pulley and tension spring.
Labor Component Part Using Toyota tools (09213-54010 and 09330-00020) or
Application Time 1 Kit No. No. equivalents, remove crankshaft pulley retaining bolt, then
2.0L 4-Cyl. pulley.
Camry Remove No. 1 timing belt cover and gasket assembly. Re-
move timing belt and belt guide. Remove No. 2 idler pulley
1983-86 .......... 3.6 Hrs. ...... TCK087 .......... T087 and crankshaft timing sprocket.
1987-91 .......... 3.0 Hrs. ...... TCK199 .......... T199 Installation (1983-86 Camry):
Celica Install crankshaft timing sprocket over crankshaft key. See
1986 Fig. 2. Install No. 2 idler pulley. Tighten idler pulley retain-
GTS ............. 3.0 Hrs. ................................ T125 ing bolt. Temporarily install timing belt onto sprockets. In-
Exc. GTS ..... 2.8 Hrs. ...... TCK087 .......... T087 stall timing belt guide. Install No. 1 timing belt cover and
1987-88 gasket assembly.
GTS ............. 3.0 Hrs. ................................ T125
Install crankshaft pulley. Pull timing belt upward and align
preset mark on No. 1 timing belt cover with crankshaft pul-
Exc. GTS ..... 2.8 Hrs. ...... TCK199 .......... T199 ley groove. See Fig. 4. Align camshaft oil seal retainer pre-
1989 ............... 3.0 Hrs. ...... TCK199 .......... T199 set mark with center of small hole on camshaft timing pul-
1990-93 .......... 4.3 Hrs. ................................ T125 ley. Install timing belt. Loosen No. 1 idler pulley retaining
MR2 bolt 1/2 turn and release spring tension on timing belt. To
1991-95 .......... 4.0 Hrs. ................................ T125 complete installation, reverse removal procedure. Adjust
1
- With Air Cond. add .5 hours. ranges.
Removal (Celica w/3S-GE Engine):
NOTE: A timing belt component kit is available for Disconnect negative battery cable. Raise and support ve-
hicle. Remove right front wheel and engine undercover.
this application. See page I for information on component Remove radiator reservoir tank. Remove cruise control ac-
kits. tuator and bracket.
Remove the power steering oil reservoir bolts and position
MANUFACTURERS SUGGESTED reservoir aside. Remove accessory drive belts. Remove
alternator and bracket. Raise the engine slightly with suit-
SCHEDULED MAINTENANCE able jack with wooden block between jack and engine.
For 1983-85 model years, although the manufacturer does Remove the right engine mount through bolt, then mount.
not recommend a specific scheduled maintenance interval, Remove the valve cover. Remove spark plugs. Remove No. 2
belt manufacturers suggest the belt be replaced at 60,000 timing belt cover with gasket. Set the cylinder No. 1 to TDC by
mile intervals. For 1986-95 model years, the manufacturer rotating crankshaft pulley until groove is aligned with 0 tim-
recommends the belt be replaced at 60,000 mile intervals for ing mark. See Fig. 8. Ensure alignment marks of camshaft
severe service operating conditions. pulleys and No. 3 timing belt cover are aligned. See Fig. 9.
Loosen the spring loaded idler pulley attaching bolt. Pry
REMOVAL & INSTALLATION pulley as far left as possible and temporarily tighten bolt.
Remove the timing belt from the camshaft timing pulleys.
TIMING BELT Hold the camshaft flats with a suitable wrench and remove
Removal (1983-86 Camry): the camshaft sprocket attaching bolts, sprockets and pins.
Disconnect negative battery cable. Raise and support ve- Mark the intake and exhaust camshaft sprockets for instal-
hicle. Remove right front wheel. Remove fender apron seal. lation reference before removing.
Remove alternator drive belt. Remove cruise control actua- Remove the crankshaft pulley attaching bolt, then using
tor and bracket. Remove power steering oil reservoir tank suitable puller, remove the crankshaft pulley. Remove No.
and drive belt. 1 timing cover, then the timing belt guide from crankshaft
Raise engine slightly and remove right side engine mount sprocket. Remove the timing belt, spring loaded idler pul-
insulator and bracket. Remove No. 2 timing belt cover and ley, tension spring and fixed idler pulley from engine.
gasket assembly. Remove spark plugs. Align oil seal re- Installation (Celica w/ 3S-GE Engine):
tainer mark with center of small hole on camshaft timing Install fixed idler pulley. Pry the idler pulley as far to the left
sprocket by turning crankshaft pulley clockwise. See Fig. 1. as possible, then temporarily tighten attaching bolt. Tem-
This will position No. 1 cylinder at 90 BTDC of compres- porarily install the timing belt on crankshaft sprocket, oil
sion stroke. pump sprocket, fixed idler pulley and water pump pulleys.
Loosen No.1 idler pulley retaining bolt and move pulley Install the timing belt guide on crankshaft sprocket and
toward left as far as possible, then temporarily tighten re- timing cover No. 1. Install the crankshaft pulley. Ensure
taining bolt. Remove timing belt from camshaft timing crankshaft pulley groove is still aligned with 0 timing mark.
sprocket
TOYOTA 519
2.0L 4-Cylinder Except RAV4 (Cont.)

This indicates No.1 cylinder is at TDC of compression move under spring tension. Allow pulley to take up belt
stroke. See Fig. 8. tension.
On models equipped with 2-hole camshaft flanges, use Rotate crankshaft clockwise two complete revolutions, from
suitable wrench to align camshaft knock pins and cam TDC compression stroke to TDC compression stroke, then
lobes as shown. See Fig. 10. On models equipped with 5- tighten spring loaded idler pulley. Ensure that timing belt
hole camshaft flanges, use suitable wrench to align cam- has tension between water pump sprocket and camshaft
shaft alignment marks as shown. See Fig. 11. sprocket. Install upper timing belt cover. To complete in-
Hang the timing belt on camshaft sprocket pulleys with stallation, reverse removal procedure. Adjust drive belts to
sprocket S markings facing outward. Align the camshaft proper tension. See page A-60 for belt tension ranges.
sprocket alignment marks with No. 3 timing cover match Removal (1990-93 Celica & 1991-95 MR2 With 3S-GTE En-
mark and install sprockets. See Fig. 9. On models equipped gine):
with 2-hole camshaft flange, ensure camshaft knock pin is Raise and support vehicle, then remove right front wheel
aligned with sprocket hole. (Celica) or right rear wheel (MR2). Remove right engine
On models equipped with 5-hole camshaft flange, insert undercover. Remove radiator reservoir tank. Remove charge
knock pin into any holes in alignment. On 5-hole flange air cooler. Remove strut tower-to-firewall braces.
type cams, if knock pin alignment is not exact, camshafts
can be rotated slightly to compensate. While holding the NOTE: Air bag system must be disarmed before working on vehicle.
camshafts with suitable wrench, install and tighten cam- Turn ignition to LOCK. Disconnect negative battery cable. Wait
shaft sprocket attaching bolts. at least 20 seconds before working on vehicle.
Loosen the spring loaded idler pulley attaching bolt just Loosen power steering oil reservoir tank. Remove acces-
enough to allow pulley to move by itself under spring ten- sory drive belts. Remove alternator and alternator brack-
sion. Allow the pulley to take up belt tension. Rotate the ets. Use a suitable jack to raise engine slightly and remove
crankshaft clockwise 2 complete revolutions. Tighten pul- weight from engine mounting on right side. Remove right
ley bolt. Ensure that the timing belt has tension between engine mount insulator and bracket.
crankshaft sprocket and intake camshaft sprocket. See Fig. Remove control cables, electrical connectors, vacuum
12. To complete installation, reverse removal procedure. hoses and coolant hoses from throttle body. Remove throttle
Adjust drive belts to proper tension. See page A-60 for belt body assembly. Remove No. 2 timing belt cover. Remove
tension ranges. spark plugs. Place No.1 cylinder at TDC of compression
Removal (1987-91 Camry & 1988-89 Celica w/3S-FE En- stroke by turning crankshaft pulley to align groove with No.1
gine): timing belt cover 0 mark.
Disconnect negative battery cable. Raise and support Ensure alignment marks on camshaft sprockets and No. 3
vehicle. Remove right front wheel. Remove undercover. timing belt cover are aligned as shown in Fig. 15. If not, turn
Remove cruise control actuator and bracket (if equipped). crankshaft one complete revolution (360) to align marks.
Remove accessory drive belts. Remove alternator and Remove timing belt from camshaft timing sprockets.
bracket. Loosen No.1 idler pulley attaching bolt and shift to left as
Use a jack to raise engine slightly. Remove right side en- far as possible. Temporarily tighten pulley attaching bolt,
gine mount through-bolt, and mount. then relieve tension from timing belt. Remove timing belt
from camshaft sprocket.
NOTE: Position a wooden block between jack and engine to
prevent damage.
Support timing belt so meshing of crankshaft sprocket and
timing belt does not shift. Remove sprockets, No. 1 timing
belt covers, timing belt guide and timing belt. Install crank-
Remove spark plugs. Remove upper timing belt cover and shaft sprocket and No. 2 idler pulley.
gasket. Rotate crankshaft pulley until pulley groove is Installation (1990-93 Celica & 1991-95 MR2 With 3S-GTE
aligned with 0 indication on timing marks, then ensure Engine):
camshaft sprocket hole is aligned bearing cap No. 1 align- Temporarily install No. 1 idler pulley and tension spring.
ment mark. See Fig. 14. Install pulley attaching bolt. Do not tighten bolt. Install ten-
Loosen spring loaded idler pulley attaching bolt, then pry sion spring, then pry toward left as far as it will go and
pulley as far to left as possible. Temporarily tighten attach- tighten. Temporarily install timing belt onto crankshaft
ing bolt. Remove timing belt from camshaft sprocket. sprocket, oil pump, No. 2 idler pulley and water pump pul-
Remove crankshaft pulley attaching bolt, then using suit- ley.
able puller, remove crankshaft pulley. Remove lower timing
belt cover and gasket. Remove belt and belt guide.
Installation (1987-91 Camry & 1988-89 Celica w/ 3S-FE
Engine):
Temporarily install timing belt on crankshaft sprocket, oil
pump sprocket, fixed idler pulley and water pump
sprocket. Install camshaft sprocket, washer and attach-
ing bolts. Rotate camshaft by turning sprocket attaching
bolt to align bearing cap mark and camshaft sprocket.
See Fig. 14.
Install timing belt on camshaft sprocket. Ensure that belt
has tension between crankshaft sprocket, water pump
sprocket and camshaft sprocket. Loosen spring loaded
idler pulley attaching bolt just enough to allow pulley to
Fig. 1: Aligning Oil Seal Retainer Mark With Camshaft
Sprocket Hole
520 TOYOTA
Fig. 5: Installing Tension Spring & Idler Pulley
Fig. 2: Installing Crankshaft Sprocket
Fig. 6: Crankshaft Pulley Angle
Fig. 3: Installing No. 2 Idler Pulley
Fig. 7: Positioning Sprocket To BTDC Or ATDC
Fig. 4: Aligning Mark On No. 1 Timing Belt Cover With

Groove In Crankshaft Pulley
521
TOYOTA
Fig. 11: Aligning Marks On 5-Hole Camshaft Flange With

Marks On Camshaft Bearing Caps
Fig. 8: Positioning Crankshaft pulley At TDC (3S-GE) Install timing belt guide. Install No. 1 timing belt cover and
gasket. Make sure camshaft groove is aligned with drilled
out mark of No.1 camshaft bearing cap.
Place No.1 cylinder at TDC of compression stroke by turn-
ing crankshaft pulley and aligning its groove with 0 mark
on No. 1 timing belt cover. Turn camshaft and align marks
on camshaft sprockets and cylinder head cover.
Install timing belt. Ensure that tension between crankshaft
and intake camshaft timing sprockets exists. To complete
Camshaft Timing Sprocket Bolt ........................ 40-43 (54-59)
Engine Mount
Fig. 9: Aligning Camshaft Sprocket Marks With Marks On Bolt ........................................................................... 65 (88)
No. 3 Timing Belt Cover (3S-GE) 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)
Fig. 10: Aligning Camshaft Sprocket With 2-Hole Camshaft

Flange (3S-GE)
522
TOYOTA
Fig. 14: Camshaft Sprocket Alignment (3S-FE)
Fig. 12: Timing Belt Installation (3S-GE)
Fig. 15: Aligning Camshaft Sprocket Timing Marks (3S-GTE)
Fig. 13: Installing Cylinder Head Packing (3S-GE)

TOYOTA 523
2.0L 4-Cylinder RAV4

TIMING BELT APPLICATION Check that each pulley aligns with timing marks as shown.
See Fig. 3. Slowly turn crankshaft pulley 1-7/8 revolutions
Application Labor Time Belt Part No. and align groove with mark at 45 degrees BTDC (for No. 1
2.0L 4-Cyl. cylinder) of No. 1 timing belt cover. See Fig. 5. Tighten No. 1
RAV4 idler pulley mounting bolt to specification.
1996-00 Place right engine mounting bracket in position but do not
With ABS ........... 1 5.3 Hours .................... T199 install bolts. Install No. 2 timing belt cover. Disconnect en-
gine wire protector between cylinder head cover and No. 3
Without ABS ...... 1 3.3 Hours .................... T199 timing belt cover. Install No. 2 timing belt cover. Install en-
1
- With Air Cond. add .2 hours. gine wire to No. 2 timing belt cover. Install engine wire pro-
tector to mounting bolts of No. 2 timing belt cover.
MANUFACTURERS SUGGESTED Remove crankshaft pulley. Install engine mounting bracket-
to-engine bolts and tighten to specification. Install crank-
SCHEDULED MAINTENANCE shaft pulley, and tighten pulley bolt to specification. To com-
For 1996-97 model years, the manufacturer recommends the plete installation, reverse removal procedure. Adjust drive
belt be replaced every 60,000 miles for severe service operat- belts to proper tension. See page A-60 for belt tension
ing conditions. For 1998 model year, the manufacturer recom- ranges.
mends the belt be replaced every 90,000 miles for severe TORQUE SPECIFICATIONS
service operating conditions. For 1999-00 models years, the
manufacturer recommends the belt be replaced every 90,000 Application Ft. Lbs. (N.m)
miles or 72 months. Camshaft Timing Pulley Bolt ........................................ 40 (54)
Crankshaft Pulley Bolt .................................................. 80 (108)
REMOVAL & INSTALLATION Generator Bracket Bolts ............................................. 31 (42)
TIMING BELT Engine Mount Insulator-To-Body Bolts ........................ 38 (52)
Removal: Engine Mount Insulator-To-Bracket Nut ...................... 27 (37)
Disconnect negative battery cable. Disconnect power steer- No. 1 Idler Pulley Mounting Bolt ...................................... 31 (42)
ing reservoir and remove reservoir bracket. Disconnect wire Wheel Lug Nut .......................................................... 76 (103)
harness bracket for Data Link Connector No. 1. Remove INCH Lbs. (N.m)
generator and generator bracket. Water Pump Bolts ......................................................... 78 (8.8)
Remove ABS actuator. Raise and support vehicle. Remove
right front wheel. Remove right engine undercover. Remove
power steering drive belt. Slightly jack up engine and re-
move right engine mounting insulator.
NOTE: Always turn crankshaft clockwise.

Remove spark plugs, remove crankshaft pulley. Remove
right engine mounting bracket. Remove No. 2 timing belt
cover. See Fig. 2. Temporarily install crankshaft pulley with
pulley bolt. Set No. 1 cylinder to TDC on compression stroke.
See Fig. 3.
Loosen mounting bolt of No. 1 idler pulley and shift pulley
toward left as far as it will go to relieve belt tension. See Fig.
4. Temporarily tighten idler pulley. Remove crankshaft pul-
ley and No. 1 timing belt cover.
If reusing timing belt, mark direction of rotation on belt. Also
place match marks on belt and camshaft pulley. See Fig. 6.
Remove timing belt from engine.
Inspection:
Inspect idler pulleys for smoothness. Ensure free length of
tension spring is 1.653" (42.0 mm). See Fig. 6. Spring ten-
sion should be 8.5 lbs. (3.85 kg) at length of 1.988. If not
as specified, replace spring. Inspect timing belt cover gas-
kets. Replace if gaskets are cracked or peeling.
Installation:
Ensure that No. 1 cylinder is set to TDC on compression
stroke by temporarily installing No. 1 timing belt cover and
crankshaft pulley. Align groove with timing mark 0 on No.
1 timing belt cover. Ensure that camshaft and timing belt
match marks are aligned. Remove crankshaft pulley and
timing belt cover. Install timing belt. If reusing old belt, en-
sure rotation direction and mating marks are in correct po-
sition.
Install timing belt guide on crankshaft with cup side facing 96B14507 Courtesy of Toyota Motor Sales, U.S.A., Inc.
out. Install No. 1 timing belt cover, crankshaft pulley, and Fig. 1: Exploded View Of Timing Belt & Related Components
crankshaft pulley bolt. Loosen No. 1 idler pulley 1/2 turn to
tension timing belt. Slowly turn crankshaft pulley 2 revolu-
tions from TDC to TDC.
524 TOYOTA
2.0L 4-Cylinder RAV4 (Cont.)

Fig. 5: Locating 45 Degrees BTDC Mark
96B14507 Courtesy of Toyota Motor Sales, U.S.A., Inc.

Fig. 2: Removing No. 2 Timing Belt Cover
96H14511 Courtesy of Toyota Motor Sales, U.S.A., Inc.
Fig. 6: Aligning Match Marks Of Timing Belt & Camshaft

Pulley
Fig. 3: Setting No. 1 Cylinder To TDC
Fig. 4: Loosening No. 1 Idler Pulley Mounting Bolt

TOYOTA 525
2.2L 4-Cylinder
TIMING BELT APPLICATION CAUTION: If reusing timing belt, mark direction of timing belt
Belt rotation on belt. Place mating marks on timing belt at camshaft
sprocket and at crankshaft sprocket for reassembly reference.
Labor Component Part Also place reference mark on timing belt at upper edge of No.
Application Time Kit No. No. 1 timing belt cover. See Fig. 2.
2.2L 4-Cyl.
Camry Loosen No. 1 idler pulley bolt. See Fig. 1. Move No. 1 idler
pulley outward, away from timing belt as far as possible.
1992-01 .......... 1 3.0 hrs. .... TCK199 .......... T199 Temporarily retighten No. 1 idler pulley bolt. Remove tim-
Camry Solara ing belt from camshaft sprocket.
1999-01 .......... 1 3.0 hrs. .... TCK199 .......... T199 Using Pulley Holder (SST 09213-54015) or equivalent, hold
Celica crankshaft pulley. Remove crankshaft pulley bolt.
1990-91 .......... 1 3.1 hrs. ..... TCK199 .......... T199 Using gear puller, remove crankshaft pulley. Remove No. 1
1992-99 .......... 1 2.4 hrs. ..... TCK199 .......... T199 timing belt cover and gasket. Note direction of timing belt
guide installation. See Fig. 1. Remove timing belt guide.
Celica GT & GTS
Loosen No. 1 idler pulley bolt. See Fig. 1. Remove timing
1990-91 .......... 1 2 3.1 hrs. ... TCK199 .......... T199 belt from crankshaft sprocket. Remove idler pulleys (if nec-
1992-93 .......... 1 2 3.1 hrs. ... TCK199 .......... T199 essary).
MR2
1991-95 .......... 1 3.5 hrs. ..... TCK199 .......... T199
1
- With Air Cond. add .2 hours. On MR2 with turbo
and Air Cond., time is 4.5 hours.
2
On all-wheel drive Celica, add 1.2 hours.
kits.
belt be replaced every 60,000 miles under severe service driv-
ing conditions. For 1998-01 model years, the manufacturer
recommends the belt be replaced every 90,000 miles.

TIMING BELT
Removal:
hicle. Remove lower engine cover. On Celica and Camry,
remove right front wheel. On all models, lower vehicle.
On MR2, remove right hood side panel and cruise control
actuator. Remove right rear wheel. On Celica and Camry,
remove alternator from engine and secure out of way. On
Camry, remove coolant reservoir tank if it interferes with
timing belt removal. Remove engine control (torque) rod
from front of engine.
On all models, remove accessory drive belts. Using floor
jack, slightly raise engine to remove weight from right (tim-
ing belt side) engine mount at timing belt cover.
Remove right (timing belt side) engine mount and bracket
from front of engine. Remove spark plugs. Remove No. 2
timing belt cover and gaskets. See Fig. 1.
compression stroke. Cylinder No. 1 is front cylinder at tim-
ing belt end of engine. Courtesy of Toyota Motor Sales, U.S.A., Inc.
Ensure timing mark on crankshaft pulley aligns with 0" Fig. 2: Aligning Camshaft Timing Marks
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.
526 TOYOTA
Inspection: Using crankshaft pulley bolt, rotate crankshaft so timing
Inspect timing belt for damaged teeth, cracking or oil con- mark on crankshaft sprocket aligns with timing mark on oil
tamination. Ensure idler pulleys rotate freely. Replace com- pump housing. See Fig. 4. This will position keyway in crank-
ponents if damaged or worn. shaft sprocket at 12 oclock position.
Ensure free length of tension spring is within specification.
See TENSION SPRING SPECIFICATIONS table. Measure CAUTION: If reusing timing belt, ensure reference marks on timing
free length between from inside edges of hooked portion of belt align with reference marks placed on crankshaft and camshaft
spring. Do not measure spring coils. See Fig. 3. sprockets. Ensure timing belt is installed in original direction
Measure tension needed to extend tension spring to speci- of rotation.
fied installed length. Replace spring if tension is not within Ensure all sprockets and idler pulleys are clean. Install
specification. timing belt on crankshaft sprocket, oil pump sprocket, No.
TENSION SPRING SPECIFICATIONS 1 idler pulley and then No. 2 idler pulley in sequence.
Application Specification
shaft sprocket and flat side toward timing belt. Install No. 1
Free Length
timing belt cover and new gasket.
Except 2000-99 Camry ........................... 1.811" (46.00 mm)
2000-99 Camry ...................................... 1.654" (42.00 mm)
Align crankshaft pulley key groove with key in crankshaft.
Tension At Spring Installed Length 1
ley bolt to specification.
Camry (1992-95)
Green Spring ............................. 7.2-8.3 lbs (3.25-3.75 kg)
compression stroke. Ensure timing mark on crankshaft
Silver Spring .......................... 10.5-11.6 lbs. (4.75-5.25 kg)
pulley aligns with 0 mark on No. 1 timing belt cover. If
Camry (1996-01) .......................... 7.2-8.3 lbs (3.25-3.75 kg)
reusing timing belt, ensure reference mark on timing belt
Camry Solara ............................... 7.2-8.3 lbs (3.25-3.75 kg)
aligns with upper edge of No. 1 timing belt cover.
Celica & MR2 ............................... 7.2-8.3 lbs. (3.25-3.75 kg)
Rotate camshaft and align hole in camshaft sprocket with
1
- At 1.988" (50.50 mm) alignment mark on camshaft bearing cap. See Fig. 2. In-
stall timing belt on camshaft sprocket. If reusing timing
Revised Timing Belt Tension Spring: belt, ensure reference mark on timing belt aligns with ref-
For 1992-96 Camry models, the timing belt tension spring erence mark on camshaft sprocket. Ensure tension exists
was revised. When replacing the timing belt on 1992-96 on timing belt between crankshaft and camshaft sprock-
Camry with 2.2L, tension spring MUST be replaced. The ets.
revised tension spring 0(part no. 905-7-17003) is a 13-coil
design which replaces the original 10-coil design. CAUTION: DO NOT rotate crankshaft counterclockwise, as viewed
This information is from Toyota technical service bulletin from timing belt end of engine.
EG001-99; January 29, 1999.
Installation: Loosen No. 1 idler pulley bolt turn. Rotate crankshaft
Install No. 2 idler pulley (if removed). Install and tighten bolt pulley 2 full revolutions clockwise from TDC to TDC.
to specification. See TORQUE SPECIFICATIONS. Ensure Ensure timing mark on crankshaft pulley aligns with 0"
idler pulley is clean and rotates smoothly. mark on No. 1 timing belt cover and hole in camshaft
Install No. 1 idler pulley and tension spring (if removed). sprocket aligns with alignment mark on camshaft bearing
Pry No. 1 idler pulley away from timing belt area as far as cap. See Fig. 2. If timing marks are not aligned, remove
possible. Temporarily tighten No. 1 idler pulley bolt. En- timing belt and reinstall.
sure idler pulley is clean and rotates smoothly. Rotate crankshaft clockwise 1 and 7/8 revolutions and align
crankshaft pulley 0 mark with 45-degree Before Top Dead
Center (BTDC) mark on No. 1 timing belt cover. See Fig. 5.
Tighten No. 1 idler pulley bolt to specification. See TORQUE
SPECIFICATIONS. Install No. 2 timing belt cover and gas-
kets. Install and tighten spark plugs to specification.
dure. Install all bolts/nuts on right (timing belt side) engine
mount before tightening to specification.
On Camry, when installing control rod and bracket on strut
tower and right (timing belt side engine mount, tighten bolts
to specification in sequence. See Fig. 6. On MR2, tighten
engine mount bolts in correct locations. See Fig. 7. Adjust
ranges.

TOYOTA 527

TORQUE SPECIFICATIONS (CAMRY)
Coolant Outlet Bolt ...................................................... 11 (15)
Engine Mounts & Brackets
Bracket-To-Cylinder Block Bolt ............................... 38 (52)
Oil Pump Sprocket Nut ............................................... 21 (29)
Power Steering Pump-To-Bracket Bolt ....................... 32 (43)
Spark Plug .................................................................. 13 (18)
Valve Cover Nut .......................................................... 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Coolant By-Pass
Pipe-To-Water Pump Nut ........................................ 78 (8.8)
No 3 Timing Belt Cover Bolt ...................................... 69 (7.8)
Oil Pan Bolt/Nut ......................................................... 48 (5.4)
Oil Pump Body Cover Bolt .......................................... 78(8.8)
Oil Pump Pick-Up Tube Bolt/Nut ................................ 48 (5.4)
Oil Pump-To-Cylinder Block Bolt ................................ 82 (9.3)
Fig. 5: Aligning Crankshaft Pulley With 45-Degree BTDC Water Pump-To-Water Pump Cover Bolt ................... 82 (9.3)
Mark
TORQUE SPECIFICATIONS (CELICA)
Bracket-To-Cylinder Block Bolt .................................. 38 (52)
To-Bracket
Bolt ........................................................................ 27 (37)
Nut ......................................................................... 38 (52)
Fig. 6: Control Rod & Bracket Bolt Installation Sequence
(Camry)
Power Steering Pump-To-Bracket Bolt
Adjusting Bolt ........................................................... 29 (39)
All Others .................................................................. 32 (43)
Spark Plug .................................................................. 13 (18)
Valve Cover Nut .......................................................... 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Water Pump-To-Water Pump Cover Bolt ................... 78 (8.8)
528 TOYOTA
Fig. 8: Water Pump Bolt Removal & Installation Sequence

Fig. 7: Installing Left (Flywheel Side) Engine Mount Bolts (Celica & MR2)
(MR2)
TORQUE SPECIFICATIONS (MR2)

Left (Flywheel Side) Engine Mount
Through-Bolt ............................................................. 58 (79)
Bracket Bolt .......................................................................... 1
Support Bracket Bolt/Nut .......................................... 54 (73)
Bracket-To-Cylinder Block Bolt .................................. 45 (61)
Mounting Bracket Nut ............................................... 38 (52)
Through-Bolt ............................................................. 58 (79)
Idler Pulley Bracket-To-Cylinder Block Bolt
12-mm Head ............................................................ 20 (27)
14-mm Head ............................................................ 27 (37)
Fuel Pulsation Damper .............................................. 25 (34)
Spark Plug .................................................................. 13 (18)
Valve Cover Nut .......................................................... 17 (23)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Water Pump-To-Cylinder Block Bolt ....................................... 2
Water Pump-To-Water Pump Cover Bolt ................... 78 (8.8)
1
- Tighten bolts to specification. See Fig. 7
2
- Tighten Bolts to 78 (8.8) INCH lbs. in sequence. See
Fig. 7. On models without A/C, tighten large bracket
bolt to 20 ft. Lbs. (27 N.m).
TOYOTA 529

TIMING BELT APPLICATION Check the free length of idler pulley spring. Length of spring
should be 1.563" (39.70 mm). Under 8.8 lbs. (4 kg) ten-
Belt Part No. sion, spring should measure 2.05" (52.0 mm) in length.
2.2L 4-Cyl. Diesel Check camshaft timing pulley, injection pump pulley and
Pickup crankshaft pulley for wear or damage.
1981 ........................ 2.2 Hours ................... T079 Installation:
1982 Before installing timing belt, engine should be cold. Always
turn crankshaft clockwise. Install idler pulley loose enough
Up To 5/31 ............ 2.2 Hours ................... T079 so it may be moved side to side by hand. Check alignment
From 6/1 ............... 2.2 Hours ................... T084 of timing marks on each pulley. See Fig. 2. Injection pump
1983 ........................ 2.2 Hours ................... T084 timing is normally retarded.
1
- With Air Cond. add .7 hours. Install timing belt and idler spring. Turn the crankshaft 2
revolutions clockwise from TDC to TDC. While turning crank-
shaft make sure idler pulley bracket is moving. Ensure that
MANUFACTURERS SUGGESTED each pulley aligns with marks. See Fig. 3. Tighten timing
SCHEDULED MAINTENANCE belt idler pulley bolt. Reverse removal procedure to com-
plete installation. Adjust drive belts to proper tension. See
The manufacturer recommends the belt be replaced every page A-60 for belt tension ranges.
100,000 miles.
* NOTE: This application is an interference engine. Application Ft. Lbs. (N.m)
See page A-59 for interference engine cautions. Camshaft Sprocket Bolt .................................. 69-75 (94-102)
Camshaft-To-Timing Pulley ............................ 69-75 (94-102)
REMOVAL & INSTALLATION Crankshaft Pulley Bolt .................................... 69-75 (94-102)
TIMING BELT
NOTE: Late model 1982 engines with extra idler pulley use a different
design timing belt. ALL timing pulleys and camshaft pulleys are
also different from early 1982 engines. Timing pulleys and camshaft
pulleys are not interchangeable between engines.
Removal:
Using starter, turn engine over until No. 1 piston is at TDC
on compression stroke. Disconnect negative battery cable.
Remove fan belts, fan and pulley. Remove damper attach-
ing bolt and using puller, remove damper.
Remove air cleaner assembly. Drain cooling system. Re-
move radiator hoses, shroud and radiator as necessary.
Identify and remove any wiring, hoses and lines interfering
with timing belt cover removal. Remove crankshaft damper
bolt. Do not apply tension to timing belt during damper bolt
removal.
Remove crankshaft damper pulley using pulley removal
tool (SST09213-60016) or equivalent. Detach timing belt
cover mount bolts and remove belt cover and belt guide.
Discard gasket. See Fig. 1. Loosen idler pulley bolt, and
remove timing belt.
CAUTION: Before removing bolts securing crankshaft pulley,

camshaft pulley, and injection pump pulley, release tension on
timing belt. Do not bend or twist belt, and keep belt free from
oil, water or steam.
On late model 1982 engines, an extra idler pulley is used
between the crankshaft and oil pump timing pulleys. Re- Fig. 1: Exploded View Of Cylinder Head & Timing Belt
move center retaining bolt to remove pulley. Components
Inspection:
Check timing belt for wear, cracks, or missing teeth. Re-
place belt if defective. Before installing a new belt, remove
idler pulley and spring. Check idler pulley bearing for
smooth operation.
530 TOYOTA
Fig. 2: Aligning Timing Marks Fig. 3: Realigning Timing Marks

TOYOTA 531

TIMING BELT APPLICATION If equipped with A/C, remove compressor pulley from crank-
shaft pulley. Using Special Service Tools (09213-54012 and
Application Labor Time Belt Part No. 09330-00020) or equivalent, remove crankshaft pulley set
2.4L 4-Cyl. Diesel bolt and washer.
Pickup Using Puller (09213-60017) or equivalent, remove crank-
1984-87 ................ 2.2 Hours .................... T084 shaft pulley. If equipped with A/C , remove idler pulley. On
2L, remove timing belt cover mount bolts, timing belt cover,
and belt guide. On 2L-T, remove No. 1 turbocharger water
MANUFACTURERS SUGGESTED pipe, air cleaner pipe, No. 1 air cleaner hose, and timing
SCHEDULED MAINTENANCE cover. Disconnect glow plugs by removing 4 screw grom-
The manufacturer recommends the belt be replaced every mets and glow plug connecting nuts. Disconnect current
100,000 miles. sensor by removing nut, plate washer, insulator and cur-
rent connector. Remove glow plug connector and glow
* NOTE: This application is an interference engine. plugs.
See page A-59 for interference engine cautions. 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
REMOVAL & INSTALLATION tensioner set bolts and remove timing belt. Using Pulley
Holder (09278-54011), and a wrench, remove camshaft
TIMING BELT pulley set bolt. Using Puller (09950-20015), remove cam-
Removal: shaft pulley. Using Pulley Holder (09278-54011), and a
Disconnect negative battery cable. Drain engine coolant wrench on injection pump drive pulley, remove set bolt on
and radiator hoses, fan shroud, and radiator from vehicle. pulley.
Remove water pump pulley, drive belts, cooling fan and
pulley. See Fig. 1.

Fig 1: Exploded View Of Timing Belt Components
532 TOYOTA
Fig 2: Aligning Timing Marks

Fig. 3: Realigning Timing Marks
Using Puller (09213-60017), remove injection pump drive
pulley. Remove lower timing belt idler pulley. Using Puller
(09213-60017), remove crankshaft timing belt pulley.
Inspection:
Check timing belt for wear, cracks or missing teeth. If de-
fective, check if injection pump camshaft is locked or if there
are nicks on belt side of idler pulley lock. Replace belt and
components as needed. Inspect belt for excessive wear on
one side only. If damaged, check belt guide and alignment
of each pulley. Before installing new belt, remove idler pul-
leys and spring. Check idler pulley bearings for noise or
roughness.
Inspect spring for proper free length and tension. Standard
free length is 1.563" (39.70 mm). See Fig. 4. Installed ten-
sion is 8.8 lbs. at 2.05" (4.0 kg at 52 mm). Replace idler Ensure that each pulley aligns with timing mark. See Fig. 3.
pulley and/or spring as necessary. Tighten tensioner pulley set bolts to 14 ft. lbs. (19 N.m).
Check camshaft, injection pump and crankshaft timing Install glow plugs and tighten to 9 ft. lbs. (13 N.m). Install
sprockets for wear or damage. If there is noticeable wear current sensor, insulator, plate washer and nut. Install 4
on belt teeth, check timing belt cover gasket for damage glow plug connecting nuts and 4 screw grommets.
and proper installation. Replace components as neces- Align set key on crankshaft with key groove of timing belt
sary. guide, and install guide with curved side facing out. Using
Installation: a new gasket, install belt cover. On 2L-T, install air cleaner
Install lower idler pulley. Install timing belt tensioner, with pipe and No. 1 air cleaner hose. Connect accelerator cable
large bolt behind water pump, and loosely fasten mounting and PCV hose. Install timing belt cover and No. 1 water
bolts. Swing tensioner toward the left. Set No. 1 cylinder to pipe. Connect turbocharger water hoses.
TDC of compression stroke and check alignment of timing If equipped with A/C, install idler pulley. Install crankshaft
marks on each pulley. See Fig. 2. If using a new timing belt, pulley using Driver (09214-60010). Install washer and bolt
note that injection pump timing is normally in the retarded and tighten bolt to 101 ft. lbs. (137 N.m). Install drive pulley
position. onto crankshaft drive pulley. Install water pump pulley and
cooling fan. Install radiator, hoses and fan shroud. Fill en-
NOTE: When tightening idler pulley and timing sprocket mount gine cooling system and connect negative battery cable.
bolts, DO NOT move idler pulley bracket or apply tension to timing Install drive belts. Adjust drive belts to proper tension. See
belt. page A-60 for belt tension ranges. Start engine and check
for leaks.
Install timing belt onto camshaft timing pulley. Ensure tim-
ing belt is securely meshed and not loose. Align marks of TORQUE SPECIFICATIONS
injector pump drive pulley and install timing belt onto pul- Application Ft. Lbs. (N.m)
ley. Install timing belt over lower idler pulley and under crank- Camshaft Pulley Bolt .................................................. 73 (98)
shaft timing belt pulley. Ensure timing belt is not twisted or Crankshaft Pulley Bolt ............................................ 101 (137)
too tight. Glow Plugs ................................................................... 9 (13)
Install tensioner spring and loosen bolts until tensioner Injector Pump Drive Pulley Bolt ................................... 47 (64)
moves by spring tension. Using crankshaft pulley set bolt, Timing Belt Idler Pulley Bolt ........................................ 29 (39)
turn crankshaft 2 complete revolutions clockwise from TDC Timing Belt Tensioner Pulley Bolts ............................. 14 (19)
to TDC. Check that each pulley aligns with marks. If marks
DO NOT align, remove timing belt and follow repeat the
procedure in this step.
TOYOTA 533
2.8L 6-Cylinder
TIMING BELT APPLICATION CAUTION: Ensure camshaft timing pulleys are installed in original
Application Labor Time Belt Part No. location. Guide on exhaust side must be toward No. 2 timing cover
and intake side guide facing away from No. 2 timing cover. See
2.8L 6-Cyl. Fig. 1.
Celica Supra
1982-83 TORQUE SPECIFICATIONS
A/T ..................... 3.5 Hours .................... T074 Application Ft. Lbs. (N.m)
M/T .................... 3.3 Hours .................... T074 Camshaft Housing Bolt ............................................ 1 16 (22)
1984-86 Camshaft Timing Pulley Bolt ...................................... 51 (69)
A/T ..................... 3.5 Hours .................... T101 Crankshaft Pulley Bolt ............................................ 195 (265)
M/T .................... 3.3 Hours .................... T101 Idler Pulley Bolt ........................................................... 36 (49)
Cressida Oil Pump Drive Pulley Bolt .......................................... 16 (22)
Rear Timing Cover Bolt .............................................. 36 (49)
1983 ................... 3.1 Hours .................... T074 Timing Belt Case Bolt
1984-88 .............. 3.1 Hours .................... T101 8 mm ........................................................................ 13 (18)
10 mm ...................................................................... 27 (37)
MANUFACTURERS SUGGESTED INCH Lbs. (N.m)
SCHEDULED MAINTENANCE No. 2 Timing Belt Cover ............................................ 108 (12)
1
- Tighten in 3 steps in proper sequence. See Fig. 5.
recommends the belt be replaced at 60,000 mile intervals for
severe service operating conditions.

TIMING BELT
Removal:
Remove air cleaner, upper radiator hose, fan shroud and
air intake connector. Remove all drive belts. Position No. 1
cylinder at TDC of compression stroke. See Fig. 3. Remove
camshaft covers and No. 3 timing cover.
To relieve timing belt tension, loosen idler pulley set bolt.
Rotate idler pulley toward alternator side of engine. Using
gear puller, remove crankshaft pulley. Remove No. 1 timing
cover. If timing belt is to be reused, place arrow on belt to
indicate belt rotation. Remove timing belt.
Inspection:
Inspect drive belt for wear, cracks or damage to teeth. Check
pulleys for wear or damage. If defective, service or repair
as necessary. Check idler pulley bearing for smooth op-
eration. Idler pulley tension spring free length must be 2.72"
(69.0 mm) or less. See Fig. 6. Replace spring if not within
specification.
Installation:
Install oil pump drive pulley (if removed). Tighten bolt to
specification. Install idler pulley and tension spring. Posi-
tion idler pulley to alternator side of engine as far as pos-
sible. Using Pulley Installer (SST 09214-60010), install
crankshaft timing pulley. Install timing belt on crankshaft
pulley. If used belt is installed, ensure belt is installed in
proper direction of rotation. Install No. 1 timing cover and
gasket. See Fig. 1.
Install crankshaft pulley and tighten bolt to specification.
Ensure No. 1 cylinder is on TDC of compression stroke.
Install timing belt on crankshaft pulley.
Rotate engine 2 complete revolutions in direction of rota-
tion and position No. 1 cylinder at TDC of compression
stroke. Recheck alignment of match marks.
Install timing belt cover and crankshaft pulley. To complete
Fig. 2: Aligning Camshaft Match Hole
534 TOYOTA
Fig. 5: Camshaft Housing Bolt Tightening Sequence
Fig. 3: Camshaft Pulley Match Marks
Fig. 6: Measuring Belt Tensioner Spring Free Length
Fig. 4: Aligning Camshaft & Pulley

TOYOTA 535
3.0L 6-Cylinder 7M-GE

TIMING BELT APPLICATION Inspect tension spring for damage, and measure spring
free length. Replace tension spring if damaged or free
Application Labor Time Belt Part No. length is not 2.216" (56.274 mm).
3.0L 6-Cyl. Installation:
Cressida Install No. 1 idler pulley as far to the left as possible (away
1989-91 ................. 3.1 Hours ..................... T126 from timing belt), and temporarily tighten retaining bolt. Align
1992 ...................... 3.1 Hours ..................... T237 timing marks on camshaft sprockets with timing mark on No.
4 timing belt cover. See Fig. 2. Install timing belt.
Supra Loosen No. 1 idler pulley retaining bolt. Pry No. 1 idler pul-
1986-90 ................. 3.3 Hours ..................... T126 ley as far to the right as possible (toward timing belt), and
1991-92 ................. 3.3 Hours ..................... T237 temporarily tighten retaining bolt. Install tension spring.
Loosen No. 1 idler pulley retaining bolt until idler pulley
MANUFACTURERS SUGGESTED moves with spring force of tension spring.
SCHEDULED MAINTENANCE Temporarily install crankshaft pulley retaining bolt. Using
crankshaft pulley retaining bolt, rotate crankshaft clockwise
The manufacturer recommends the belt be replaced every (viewed from front of engine) 2 full revolutions.
60,000 miles for severe service operating conditions.
REMOVAL & INSTALLATION crankshaft counterclockwise.
TIMING BELT Ensure all timing marks are properly aligned. See Fig. 2.
Tighten No. 1 idler pulley retaining bolt to 27 ft. lbs. (37
Removal:
N.m). Check timing belt deflection.
Disconnect negative battery cable. Drain cooling system. To remove slack in timing belt, rotate intake and exhaust
Remove radiator. Remove all accessory drive belts. Re-
camshaft timing pulleys inward by applying a turning torque
move power steering pump with hoses attached and se-
of 14 ft. lbs. (19 N.m). See Fig. 4.
cure aside (if equipped). Remove spark plugs. Disconnect
hoses from air pipe.
Remove crankshaft pulley retaining bolt. Install timing belt
guide with cupped side toward front of engine.
Remove coolant outlet and fan. Remove spark plug wire
clamps across front of No. 2 timing belt cover. Remove CAUTION: Ensure timing belt guide is installed with cupped side
retaining bolts, No. 3 timing belt cover and gaskets. See toward front of engine and flat side against crankshaft sprocket.
Fig. 1.
Rotate crankshaft so cylinder No. 1 is at TDC of compres- To install remaining components, reverse removal proce-
sion stroke. Ensure timing mark on crankshaft pulley aligns dure. Apply sealant to coolant outlet before installing. Tighten
with 0 mark on timing belt cover. bolts/nuts to specification. See TORQUE SPECIFICATIONS.
Ensure timing marks on camshaft sprockets align with tim- Adjust drive belts to proper tension. See page A-60 for belt
ing marks on No. 4 timing belt cover. See Fig. 2. If timing tension ranges.
marks are not aligned, rotate crankshaft 360 degrees and TORQUE SPECIFICATIONS
recheck alignment.
Remove power steering belt pulley. Using Pulley Holder Application Ft. Lbs. (N.m)
(SST 09213-58011) or equivalent, and Handle (SST 09330- Camshaft Sprocket Bolt ............................................ 80 (109)
00021) or equivalent, hold crankshaft pulley and remove Coolant By-Pass Outlet Bolt ....................................... 13 (18)
retaining bolt. Coolant Inlet Nut ......................................................... 14 (19)
Using puller, remove crankshaft pulley. Remove fan bracket, Crankshaft Pulley Bolt ............................................ 181 (245)
No. 1 timing belt cover and gasket. See Fig. 1. Fan Bracket Bolt ......................................................... 30 (41)
Note direction of timing belt guide installation. Mark direc- Idler Pulley Bolt
tion of timing belt rotation. Remove timing belt guide and No. 1 Pulley .............................................................. 27 (37)
tension spring. See Fig. 1. Loosen No. 1 idler pulley retain- No. 2 Pulley .............................................................. 13 (18)
ing bolt. Power Steering Pump Pulley Nut ................................ 32 (43)
Position No. 1 Idler pulley as far to the left as possible Spark Plug .................................................................. 13 (18)
(away from timing belt), and temporarily tighten retaining Tension Spring Bracket Bolt ....................................... 13 (18)
bolt. Remove timing belt. INCH Lbs. (N.m)
Inspection: Fan Retaining Nut ........................................................ 48 (5)
Inspect timing belt for damaged teeth, cracking or oil con- Timing Belt Cover Bolt
tamination. Replace timing belt if damaged or contami- No. 1 & 2 Covers ........................................................ 48 (5)
nated. Inspect idler pulleys and fan for smooth rotation. No. 3 & 4 Covers ........................................................ 74 (8)
Replace component if defective.
536 TOYOTA
3.0L 6-Cylinder 7M-GE (Cont.)
Fig. 3: Aligning Camshaft Pin Holes & Timing Marks
Fig. 1: Exploded View Of Timing Belt & Components Fig. 4: Checking Timing Belt Tension

TOYOTA 537
3.0L 6-Cylinder 2JZ, 1993-97

Belt Part No. 242 on threads of idler pulley bolt. Install and tighten bolt to
3.0L 6-Cyl. 2JZ specification. See TORQUE SPECIFICATIONS. Ensure idler
Supra pulley is clean and rotates smoothly, and idler pulley bracket
1993-97 ................. 2.7 Hours ..................... T215 moves freely.
sing crankshaft pulley bolt, rotate crankshaft and align tim-
1
- With Turbo add .9 hours. ing mark on crankshaft sprocket with timing mark on oil
pump body. See Fig. 2. Install timing belt on crankshaft
MANUFACTURERS SUGGESTED sprocket.
SCHEDULED MAINTENANCE shaft sprocket and flat side against timing belt. Install gas-
The manufacturer recommends the belt be replaced every kets and No. 1 timing belt cover. Align crankshaft pulley key
60,000 miles or 96 months for severe operating conditions. groove with crankshaft key. Install crankshaft pulley and
tighten pulley bolt to specification. See TORQUE SPECIFI-
REMOVAL & INSTALLATION CATIONS.
TIMING BELT der) 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 so tim-
ing marks on camshaft sprockets align with timing marks
Removal: on No. 4 timing belt cover. See Fig. 2. Install timing belt on
Disconnect negative battery cable. Remove battery, and camshaft sprockets. Ensure tension exists on timing belt
drain cooling system. Place reference mark on fan clutch between camshaft sprockets.
and water pump for reassembly reference. Remove drive Using press, apply pressure on rod of timing belt tensioner
belt, cooling fan, fan clutch and water pump pulley. until rod is retracted and holes in rod and housing are
Remove radiator and lower engine cover. Remove oil filler aligned. See Fig. 4.
cap, No. 2 and No. 3 timing belt covers, gasket and drive Install hexagon wrench through holes in housing and rod
belt tensioner. See Fig. 1. to hold rod in retracted position. See Fig. 4. Release press.
Rotate crankshaft clockwise so cylinder No. 1 (front cylin- Install dust boot on timing belt tensioner. Install timing belt
der) is at TDC on compression stroke. Ensure timing mark tensioner. Alternately tighten timing belt tensioner bolts to
on crankshaft pulley aligns with 0 mark on timing belt specification. See TORQUE SPECIFICATIONS.
cover.
Timing marks on camshaft sprockets must align with tim- CAUTION: Always rotate crankshaft clockwise. DO NOT rotate
ing marks on No. 4 timing belt cover. See Fig. 2. If condi- crankshaft counterclockwise.
tions are not as described, rotate crankshaft clockwise one Remove hexagon wrench from timing belt tensioner. Ro-
complete revolution tate crankshaft clockwise 2 full revolutions from TDC to
Alternately loosen timing belt tensioner bolts. Remove bolts, TDC. DO NOT rotate crankshaft counterclockwise.
timing belt tensioner and dust boot. See Fig. 1. Remove Ensure timing marks on camshaft sprockets align with tim-
timing belt from camshaft sprockets. ing marks on No. 4 timing belt cover, and timing mark on
Using Handle (SST 09330-00021) and Pulley Holder (SST crankshaft pulley aligns with 0 mark on timing belt cover.
0921370010) or equivalent, hold crankshaft pulley and re- See Fig. 2. If timing marks are not aligned, remove timing
move crankshaft pulley bolt. Using puller, remove crank- belt and reinstall.
shaft pulley. To install remaining components, reverse removal proce-
Remove No. 1 timing belt cover and gaskets. Note direc- dure. Use care when installing drive belt tensioner bolts to
tion of timing belt guide installation for reassembly refer- avoid dropping bolts into timing belt cover.
ence. See Fig. 1. Remove timing belt guide. Tighten fasteners to specification. See TORQUE SPECIFI-
Inspection: CATIONS. Adjust fluid levels and check ignition timing. Ad-
Inspect timing belt for damaged teeth, cracking or oil con- just drive belts to proper tension. See page A-60 for belt
tamination. Replace timing belt if damaged or contami- tension ranges.
nated. Check idler pulley and drive belt tensioner for smooth
rotation. Replace idler pulley or drive belt tensioner if de- TORQUE SPECIFICATIONS
fective. Inspect timing belt tensioner for signs of oil leak- Application Ft. Lbs. (N.m)
age. Replace timing belt tensioner if oil leakage exists. A/C Compressor Bolt/Nut ........................................... 38 (52)
NOTE: Timing belt tensioner may have a small amount of oil Camshaft Sprocket Bolt .............................................. 59 (80)
on rod seal under normal conditions. If excessive amount of oil Crankshaft Pulley Bolt ............................................ 239 (324)
exists, replace timing belt tensioner. Drive Belt Tensioner Bolt ............................................ 15 (20)
Hold timing belt tensioner body, and press rod against solid Fan Clutch-To-Water Pump Nut ................................. 12 (16)
surface. Replace timing belt tensioner if rod moves. Mea- Idler Pulley Bolt ........................................................... 25 (34)
sure timing belt tensioner rod protrusion from end of rod to Timing Belt Tensioner Bolt ......................................... 20 (27)
edge of housing. See Fig. 3. Replace timing belt tensioner Water Pump Bolt ........................................................ 15 (20)
if distance is not .315-.343" (8.00-8.80 mm). INCH Lbs. (N.m)
Valve Cover Bolt/Nut .................................................. 73 (8.3)
538 TOYOTA
3.0L 6-Cylinder 2JZ, 1993-97 (Cont.)

TOYOTA 539
3.0L 6-Cylinder 2JZ, 1998

TIMING BELT APPLICATION Removal (Turbo):
Disconnect the negative battery cable. Remove battery and
Application Labor Time Belt Part No. battery tray. Raise and support vehicle. Remove lower en-
3.0L 6-Cyl. 2JZ-GE & 2JZ-GTE gine cover. Drain cooling system.
Supra Remove No. 2 air tube located below radiator. Remove air
1998 ..................... 1 2.7 Hours .................... T215 intake hose to air intake chamber for access to timing belt
covers. Remove air cleaner duct located above radiator.
1
- With Turbo add .9 hours. Remove lower fan shroud and radiator assembly.
On manual transmission models, remove drive belt
MANUFACTURERS SUGGESTED tensioner damper, located between drive belt tensioner and
stud on front of engine. See Fig. 1. Rotate drive belt tensioner
SCHEDULED MAINTENANCE clockwise. Remove drive belt.
The manufacturer recommends the belt be replaced every Place reference mating marks on fan clutch, water pump
90,000 miles or 72 months for severe operating conditions. pulley, and water pump stud for reassembly reference. Re-
move cooling fan, fan clutch, and water pump pulley.
REMOVAL & INSTALLATION Remove front bracket for power steering pump for access
to timing belt covers. It may be necessary to remove pump
TIMING BELT pulley. Remove oil filler cap and No. 3 timing belt cover. See
Fig. 1. Remove No. 2 timing belt cover and gasket. Remove
drive belt tensioner.
battery cable at least 90 seconds before working on vehicle. CAUTION: DO NOT rotate crankshaft counterclockwise. Rotate
crankshaft clockwise (as viewed from front of engine).
der) is at TDC on compression stroke. Ensure timing mark
cover.
Timing marks on camshaft sprockets must align with tim-
ing marks on No. 4 timing belt cover. See Fig. 2. If not, rotate
crankshaft clockwise one complete revolution (360 de-
grees).
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.
Alternately loosen timing belt tensioner bolts. Remove bolts,
timing belt tensioner, and dust boot. See Fig. 1. Remove
timing belt from camshaft sprockets. On automatic trans-
mission models, remove clamps securing oil cooler lines
near crankshaft pulley.
On all models, use Handle (SST 09330-00021) and Pulley
Holder (SST 09213-70010) or equivalent to hold crankshaft
pulley. Remove crankshaft pulley bolt. Using gear puller,
remove crankshaft pulley.
Remove No. 1 timing belt cover and gaskets. Note direc-
ence (flat side toward timing belt). See Fig. 1. Remove
timing belt guide. If reusing timing belt, place mating refer-
ence marks on timing belt and crankshaft sprocket. Re-
move timing belt.

Fig. 1: Exploded View Of Typical Timing Belt & Components
Fig. 2: Aligning Camshaft Timing Marks (Turbo)

540 TOYOTA
3.0L 6-Cylinder 2JZ, 1998 (Cont.)
Inspection (Turbo):
nated. Check idler pulley and drive belt tensioner for smooth
rotation. Replace idler pulley or drive belt tensioner if de-
fective. Inspect timing belt tensioner for signs of oil leak-
age. Replace timing belt tensioner if oil leakage exists.
NOTE: Timing belt tensioner may have a small amount of oil

exists, replace timing belt tensioner.
Hold timing belt tensioner body, and press rod against solid
surface. Replace timing belt tensioner if rod moves. Mea-
sure timing belt tensioner rod protrusion from end of rod to
edge of housing. See Fig. 3. Replace timing belt tensioner
if distance is not .315-.346" (8.00-8.80 mm).
Compress and extend drive belt tensioner damper. Make
sure there is no abnormal resistance or unusual operation
sounds. Replace if defective.
CAUTION: Before discarding drive belt tensioner damper, gas

must be released from damper. Fully extend damper. Drill small
hole in damper, just above lower mounting stud hole. Use care
as gas will force metal chips to fly out while drilling hole. Courtesy of Toyota Motor Sales, U.S.A., Inc.
Installation (Turbo): Fig. 4: Aligning Camshaft & Crankshaft Tlming Marks

242 or equivalent on threads of idler pulley bolt. Install and
timing mark on crankshaft sprocket with timing mark on oil
pump body. See Fig. 4. Install timing belt on crankshaft
sprocket.

belt and crankshaft sprocket align, and timing belt is installed
shaft sprocket and flat side against timing belt. Install gas-
kets and No. 1 timing belt cover. Align crankshaft pulley key
groove with crankshaft key. Install crankshaft pulley and Fig. 5: Retracting Timing Belt Tensioner Rod
tighten pulley bolt to specification while holding crankshaft.
See TORQUE SPECIFICATIONS. Using spanner wrench, rotate camshaft sprockets so tim-
On automatic transmission models, reinstall clamps for ing marks on camshaft sprockets align with timing marks
oil cooler lines near crankshaft pulley. on No. 4 timing belt cover. See Fig. 2. Clean oil or water off
Rotate crankshaft clockwise so cylinder No. 1 (front cylin- of crankshaft sprocket and install timing belt on camshaft
der) is at TDC on compression stroke. Ensure timing mark sprockets. Ensure tension exists on timing belt between
on crankshaft pulley aligns with 0 mark on timing belt camshaft sprockets.
cover.
Using press, apply pressure on rod of timing belt tensioner
until rod is retracted and holes in rod and housing are
Install 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
TOYOTA 541

TDC. DO NOT rotate crankshaft counterclockwise.
ing marks on No. 4 timing belt cover, and timing mark on
crankshaft pulley aligns with 0 mark on timing belt cover.
See Fig. 2. If timing marks are not aligned, remove timing
belt and reinstall.
dure. Use care when installing drive belt tensioner bolts to
avoid dropping bolts into timing belt cover.
Ensure water pump and fan clutch reference marks are
aligned. Tighten fasteners to specification. See TORQUE

Removal (Non-Turbo):
Remove battery and battery tray. Raise and support vehicle.
Drain cooling system.
Remove air cleaner duct located above radiator. Remove
lower fan shroud and radiator assembly. Rotate drive belt
tensioner clockwise. Remove drive belt.
Place reference mating marks on fan clutch, water pump
pulley, and water pump stud for reassembly reference. Re-
move cooling fan, fan clutch, and water pump pulley.
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.
der) is at TDC on compression stroke. Ensure timing mark
cover.
Timing marks on camshaft sprockets must align with tim-
ing marks on No. 4 timing belt cover. See Fig. 6. If not, rotate
crankshaft clockwise one complete revolution (360 de-
grees).
CAUTION: Crankshaft must be correctly positioned by aligning

sub-timing mark with 0 mark on timing belt cover to prevent
valves from contacting pistons.
Fig. 7: Aligning Sub-Timing Marks (Non-Turbo)

Fig. 6: Aligning Camshaft Timing Marks (Non-Turbo)
542 TOYOTA
Rotate crankshaft pulley 60 degrees counterclockwise. Align
sub-timing mark with 0 mark on timing belt cover. Per-
form STEP 1. See Fig. 7. Ensure dot marks of camshaft
sprockets are aligned with timing marks of No. 4 timing
belt cover. See Fig. 7, STEP 2. If necessary, use spanner wrench to rotate camshaft sprock-
ets so timing marks on camshaft sprockets align with tim-
CAUTION: It reusing timing belt, place arrow on timing belt to ing marks on No. 4 timing belt cover. See Fig. 6. Install
indicate direction of rotation. Place reference mark on timing timing belt on camshaft sprockets. Ensure tension exists
belt and each camshaft sprocket for reassembly reference. on timing belt between camshaft sprockets.
Using Handle (SST 09330-00021) and Pulley Holder (SST Using press, apply pressure on rod of timing belt tensioner
09213-70010) or equivalent to hold crankshaft pulley, re- until rod is retracted and holes in rod and housing are
move crankshaft pulley bolt. DO NOT allow the crankshaft aligned. See Fig. 5.
pulley to rotate. Install hexagon wrench through holes in housing and rod
Alternately loosen timing belt tensioner bolts. Remove bolts, to hold rod in retracted position. See Fig. 5. Release press.
timing belt tensioner, and dust boot. See Fig. 1. Remove Install dust boot on timing belt tensioner. Install timing belt
timing belt from camshaft sprockets. tensioner. Alternately tighten timing belt tensioner bolts to
Remove crankshaft pulley using gear puller. Remove No. 1 specification. See TORQUE SPECIFICATIONS.
timing belt cover and gaskets. Note direction of timing belt
guide installation for reassembly reference (flat side to-
ward timing belt). See Fig. 1. Remove timing belt guide. If
reusing timing belt, place mating reference marks on tim- Remove hexagon wrench from timing belt tensioner. Ro-
ing belt and crankshaft sprocket. Remove timing belt. tate crankshaft clockwise 2 full revolutions from TDC to
Inspection (Non-Turbo): TDC.
Inspect timing belt for damaged teeth, cracking or oil con- Ensure timing marks on camshaft sprockets align with tim-
tamination. Replace timing belt if damaged or contami- ing marks on No. 4 timing belt cover, and timing mark on
nated. Check idler pulley and drive belt tensioner for smooth crankshaft pulley aligns with 0 mark on timing belt cover.
rotation. Replace idler pulley or drive belt tensioner if de- If timing marks are not aligned, remove timing belt and
fective. Inspect timing belt tensioner for signs of oil leak- reinstall.
age. Replace timing belt tensioner if oil leakage exists. Tighten crankshaft pulley bolt to specification. Install No. 2
and No. 3 timing belt covers. To install remaining compo-
NOTE: Timing belt tensioner may have a small amount of oil nents, reverse removal procedure. Use care when install-
on rod seal under normal conditions. If excessive amount of oil ing drive belt tensioner bolts to avoid dropping bolts into
exists, replace timing belt tensioner. timing belt cover.
Hold timing belt tensioner body, and press rod against solid Ensure water pump and fan clutch reference marks are
surface. Replace timing belt tensioner if rod moves. Mea- aligned. Tighten fasteners to specification. See TORQUE
sure timing belt tensioner rod protrusion from end of rod to SPECIFICATIONS. Adjust drive belts to proper tension. See
edge of housing. See Fig. 3. Replace timing belt tensioner page A-60 for belt tension ranges.
if distance is not .315-.346" (8.00-8.80 mm). TORQUE SPECIFICATIONS
Installation (Non-Turbo):
Install idler pulley and plate washer (if removed). Apply Loctite Camshaft Sprocket Bolt .............................................. 60 (81)
242 or equivalent on threads of idler pulley bolt. Install and
Drive Belt Tensioner Bolt ............................................ 15 (21)
Drive Belt Tensioner Damper Bolt .................................. 15 (21)
Fan Clutch-To-Water Pump Nut ................................. 12 (16)
Using crankshaft pulley bolt, rotate crankshaft and align Idler Pulley Bolt ........................................................... 1 26 (35)
timing mark on crankshaft sprocket with timing mark on oil
Power Steering Pump Pulley Bolt
pump body. See Fig. 7, STEP 3. Clean oil or water off of
Turbo ............................................................................ 32 (43)
crankshaft sprocket and install timing belt on crankshaft
Power Steering Pump-To-Front Bracket (Non-Turbo)
sprocket and around idler pulley.
Right Side Bolt ........................................................... 2 29 (39)
CAUTION: If reusing timing belt, ensure reference marks on timing Left Side Bolt .............................................................. 2 42 (58)
belt and crankshaft sprocket align, and timing belt is installed Timing Belt Tensioner Bolt ......................................... 20 (27)
in original direction of rotation. Water Pump Bolt ........................................................ 15 (21)
INCH Lbs. (N.m)
Install timing belt guide with cupped side away from crank- Fan-To-Fan Clutch Nuts ................................................ 65 (7.5)
shaft sprocket and flat side against timing belt. Install gas- No. 1 & No. 2 Timing Belt Cover Bolt ................................ 71 (8)
kets and No. 1 timing belt cover. Align crankshaft pulley key No. 4 Timing Belt Cover Bolt ...................................... 78 (8.8)
groove with crankshaft key. Install crankshaft pulley. 1
Ensure sub-timing mark (60 degrees BTDC) of crankshaft 2
- Right and left side as viewed from rear of engine.
pulley is aligned with 0 timing mark of No. 1 timing belt
cover. See Fig. 7, STEP 4. Temporarily install crankshaft
pulley bolt.
TOYOTA 543
2.5L & 3.0L V6 1988-97

2.5L V6 WARNING: To prevent air bag deployment, disconnect negative
Camry
1988-91 ................. 3.8 Hours ..................... T157 TIMING BELT
3.0L V6 Removal (2.5L & 1992-93 3.0L V6):
Avalon Disconnect negative battery cable. Remove cruise control
1995-97 ................. 3.0 Hours ..................... T257 actuator and vacuum pump. Remove power steering res-
Camry ervoir with hoses attached, and secure them aside. Raise
1992-93 ................. 3.9 Hours ..................... T200 and support vehicle. Remove right front wheel. Remove
1994-97 ................. 3.0 Hours ..................... T257 right lower engine cover. Remove all drive belts.
Remove top braces on right engine mount at timing belt
cover. Slightly raise engine to remove weight from right
MANUFACTURERS SUGGESTED engine mount. Remove retaining bolts/nuts and right en-
SCHEDULED MAINTENANCE gine mount assembly. Remove spark plugs. Remove re-
taining bolts, No. 2 timing belt cover, gasket and right en-
Although the manufacturer does not recommend a specific gine mount bracket. See Fig. 1. Note bolt length and loca-
scheduled maintenance interval for normal operating condition of No. 2 timing belt cover bolts for reassembly refer-
tions, belt manufacturers suggest the belt be replaced at 60,000 ence.
mile intervals. The manufacturer recommends the belt be re-
placed at 60,000 miles or 96 months for severe operating CAUTION: If timing belt is to be reused, mark direction of timing
conditions. 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.

544 TOYOTA
2.5L & 3.0L V6 1988-97 (Cont.)
Rotate crankshaft clockwise so No. 1 cylinder is at TDC of Measure timing belt tensioner rod protrusion from end of
compression stroke. Ensure timing mark on crankshaft rod to edge of timing belt tensioner housing. See Fig. 5. On
pulley aligns with 0 mark on No. 1 timing belt cover. En- 2.5L engines, replace timing belt tensioner if distance is
sure timing marks on camshaft sprockets are aligned with not .413-.453 (10.5-11.5 mm). On 3.0L engines, replace
timing marks on No. 3 timing belt cover. See Fig. 2. Re- timing belt tensioner if distance is not .394-.413" (10.01-
move retaining bolts and timing belt tensioner. 10.49 mm).
Install Camshaft Sprocket Holder (SST 09278-54012) or Installation (2.5L & 1992-93 3.0L V6):
equivalent, in holes on front of right camshaft sprocket. Install No. 1 idler pulley (if removed). Apply Loctite 242 on
Slightly rotate right camshaft sprocket clockwise to release threads of No. 1 idler pulley retaining bolt. Install and tighten
tension on timing belt between camshaft sprockets. Re- retaining bolt to specification. See TORQUE SPECIFICA-
move timing belt from camshaft sprockets. TIONS. Ensure idler pulley is clean, and pulley rotates
Using Pulley Holder (SST 09213-54014) or equivalent, and smoothly.
Handle (SST 0933000021), hold crankshaft pulley, and re- Install timing belt on crankshaft sprocket with installation
move retaining bolt. If timing belt is to be reused, ensure mark on timing belt aligned with timing mark on crankshaft
reference mark placed on timing belt aligns with upper sprocket. See Fig. 2. Install timing belt guide with cupped
edge of No. 1 timing belt cover when timing mark on crank- side away from crankshaft sprocket. Install No. 1 timing
shaft pulley is aligned with 0 mark on No.1 timing belt belt cover and gasket. Align crankshaft key with key groove
cover. of crankshaft pulley and install crankshaft pulley. Tighten
Using puller, remove crankshaft pulley. DO NOT allow crank- retaining bolt to specification.
shaft to rotate. Remove No. 1 timing belt cover and gasket.
If timing belt is to be reused, mark direction of belt rotation, CAUTION: If reusing timing belt, ensure timing mark on crankshaft
and place reference marks on timing belt and crankshaft sprocket is aligned with reference mark placed on timing belt,
sprocket for reassembly reference. Note direction of timing and timing belt is installed in original direction of rotation.
belt guide installation for reassembly reference. See Fig. Install No. 2 idler pulley. Tighten retaining bolt to specifica-
1. Remove timing belt guide and timing belt. Remove idler tion. Ensure idler pulley rotates smoothly. Rotate crank-
pulleys (if necessary). shaft pulley so timing mark on crankshaft pulley aligns with
Removal (1994-97 3.0L V6): 0 mark on No. 1 timing belt cover. Rotate left camshaft so
Disconnect negative battery cable. Remove coolant reser- timing mark on camshaft sprocket aligns with timing mark
voir. Raise and support vehicle. Remove right side front on No. 3 timing belt cover. See Fig. 2.
wheel. Remove right lower engine cover. Remove acces- Rotate right camshaft so knock pin hole in camshaft aligns
sory drive belts. with timing mark on No. 3 timing belt cover. See Fig. 2. If
Remove engine stabilizer rod, engine mounting bracket reusing timing belt, ensure reference mark placed on tim-
and right engine mount brace, located near timing belt ing belt aligns with upper edge of No. 1 timing belt cover
cover. Remove the alternator bracket for access to timing
belt covers. Remove No. 2 timing belt cover. See Fig. 1.
Use Pulley Holder (SST 09213-54015) or equivalent, and
Handle (SST 0933000021) or equivalent, to hold crank-
shaft pulley. Remove crankshaft pulley bolt. Using puller,
remove crankshaft pulley. Remove No. 1 timing belt cover.
See Fig. 1.
Remove engine mounting bracket. Note direction of timing
belt guide installation for reassembly reference. Remove
timing belt guide.
on oil pump body. See Fig. 3. Ensure timing marks on cam-
shaft sprockets are aligned with timing mark on No. 3 tim-
ing belt cover. See Fig. 3. If timing marks are not aligned,
rotate crankshaft clockwise one full revolution (360 de-
grees).
Remove retaining bolts, timing belt tensioner and dust boot.
Remove crankshaft pulley bolt from crankshaft. Install cam-
shaft sprocket holder (SST 09278-54012) or equivalent, in
holes on front of right camshaft sprocket. Slightly rotate
right camshaft sprocket clockwise to release tension on
timing belt between camshaft sprockets. Remove timing
belt from camshaft sprockets.
Inspection (2.5L & 3.0L V6):
tamination. Ensure idler pulleys rotate freely. Replace dam-
aged components. Inspect timing belt tensioner for signs
of oil leakage. Replace timing belt tensioner if oil leakage
exists. Hold timing belt tensioner body. Press rod against
solid surface. Replace timing belt tensioner if rod moves. Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)
TOYOTA 545
2.5L & 3.0L V6 1988-97 (Cont.)

when timing mark on crankshaft pulley is aligned with 0 Using camshaft sprocket holder, slightly rotate right cam-
mark on No. 1 timing belt cover. shaft sprocket so knock pin hole in camshaft sprocket aligns
Using camshaft sprocket holder, slightly rotate left cam- with knock pin hole in camshaft. Install knock pin in right
shaft sprocket clockwise, and install timing belt on cam- camshaft. Install right camshaft sprocket retaining bolt, and
shaft sprocket. Ensure reference mark on timing belt aligns tighten it to specification. See TORQUE SPECIFICATIONS.
with timing mark on camshaft sprocket. Place washer on bottom side of timing belt tensioner. Us-
Using camshaft sprocket holder, slightly rotate left cam- ing press, apply pressure on rod of timing belt tension until
shaft sprocket, and align timing mark on camshaft sprocket rod is retracted, and holes in rod and housing are aligned.
with timing mark on No. 3 timing belt cover. Ensure tension Install hexagon wrench through holes in housing and rod
exists on timing belt between crankshaft sprocket and left to hold rod in retracted position. See Fig. 6. Release press,
camshaft reference mark on timing belt with timing mark and install dust boot on timing belt tensioner. Install timing
on right camshaft sprocket. Install right camshaft sprocket belt tensioner. Tighten retaining bolts to specification. See
on camshaft with flange side toward cylinder head. Ensure TORQUE SPECIFICATIONS.
timing mark on right camshaft sprocket aligns with timing Remove hexagon wrench from timing belt tensioner. Ro-
mark on No. 3 timing belt cover. See Fig. 2. tate crankshaft clockwise 2 full revolutions from TDC to
TDC. Ensure timing marks on camshaft sprockets align
with those on No. 3 timing belt cover. See Fig. 2.
CAUTION: Crankshaft must always be rotated clockwise. DO

NOT rotate crankshaft counterclockwise.
Installation (1994-97 3.0L V6):
Install timing belt plate. Install and tighten bolt to specifica-
tion. Install No. 1 and No. 2 idler pulleys (if removed). Install
and tighten bolts to specification. See TORQUE SPECIFI-
CATIONS. Ensure idler pulleys are clean and rotate
smoothly.
Using camshaft sprocket holder, rotate each camshaft
sprocket so timing mark on camshaft sprocket aligns with
timing mark on No. 3 timing belt cover. See Fig. 3. Align
reference marks on timing belt with dot on crankshaft
Fig. 3: Aligning Timing Marks (1994-97 3.0L) sprocket and timing marks on camshaft sprocket. Ensure
front mark is pointing toward timing belt end of engine.
CAUTION: Ensure reference marks on timing belt align with timing

mark on camshaft sprockets and dot on crankshaft sprocket
when installing timing belt. Front mark must face toward timing
belt end of engine.
ley, left camshaft sprocket, No. 2 idler pulley, right camshaft
sprocket, and then on No. 1 idler pulley. Using press, apply
pressure on rod of timing belt tension until rod is retracted
and holes in rod and housing are aligned. Install hexagon
wrench through holes in housing and rod to hold rod in
retracted position. See Fig. 6. Release press and install
dust boot on timing belt tensioner. Install timing belt
tensioner. Install and alternately tighten bolts to specifica-
tate crankshaft clockwise until timing mark on crankshaft
sprocket aligns with timing mark on oil pump body. See
Fig. 3. Ensure timing mark on each camshaft sprocket is
aligned with timing mark on No. 3 timing belt cover. See
Fig. 3. If all timing marks are not aligned, remove timing
Fig. 4: Identifying Timing Belt Reference Marks (1994-97 3.0L) belt and reinstall. Remove crankshaft pulley bolt.
546 TOYOTA
2.5L & 3.0L V6 1988-97 (Cont.)
Install timing belt guide with cupped side away from crank- TORQUE SPECIFICATIONS (2.5L V6)
tighten bolts to specification.
Using new gaskets, install No. 1 and No. 2 timing belt Engine Crossmember-To-Body Bolt .......................... 29 (39)
covers. Install and tighten bolts to specification. See
Engine Mount Through-Bolt ........................................ 64 (87)
Align crankshaft key with key groove of crankshaft pulley.
Crossmember Bolt .................................................. 54 (73)
Idler Pulley Bolt
ley bolt to specification. To install remaining components,
No. 1 Idler Pulley ....................................................... 25 (34)
reverse removal procedure. Tighten fasteners to specifica-
No. 2 Idler Pulley ....................................................... 29 (39)
tion. See TORQUE SPECIFICATIONS. Adjust drive belts to
Idler Pulley Support Bolt ............................................. 13 (18)
Bolt ........................................................................... 47 (64)
Nut
Bracket Side .......................................................... 38 (52)
Body Side .............................................................. 65 (88)
Water Pump Bolt ........................................................ 14 (19)
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
No. 3 Timing Belt Cover Bolt ......................................... 65 (7)
Valve Cover Nut ............................................................ 52 (6)
Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion TORQUE SPECIFICATIONS (3.0L V6)
Front Engine Mount-To-Crossmember Bolt
Toyota Motor Corporation Bolt .................................. 59 (80)
Toyota Motor Manufacturing Bolt ............................... 49 (66)
Front Engine Mount-To-Cylinder
Block Bolt .................................................................. 47 (64)
Power Steering Pump Bracket
Right Engine Mount Brace Bolt ................................... 23 (31)
Stabilizer Bar Link-To
Lower Control Arm Nut ............................................. 29 (39)
Fig. 6: Retracting Timing Belt Tensioner Rod Timing Belt Idler Pulleys
Wheel Lug Nut .......................................................... 76 (103)
INCH Lbs. (N.m)
Valve Cover Bolt ......................................................... 71 (8.0)
Water Pump Bolt/Nut ................................................. 71 (8.0)
TOYOTA 547
3.0L V6 1998-01
TIMING BELT APPLICATION Disconnect engine coolant reservoir hose from water out-
let. Disconnect ground strap connectors. On Camry Solara,
Application Labor Time Belt Part No. remove shock tower suspension brace.
3.0L V6 1MZFE On all models, remove engine stabilizer rod, engine mount-
Avalon ing bracket. Remove right engine mount brace, located near
1998-01 ................. 3.0 Hours ..................... T257 timing belt cover. Remove generator-to-engine bracket for
Camry & Camry Solara access to timing belt covers.
1998-01 ................. 3.0 Hours ..................... T257 Using Pulley Holder (SST 09213-54015) or equivalent, and
Highlander pulley. Remove crankshaft pulley bolt. Using gear puller,
2001 ...................... 3.8 Hours ..................... T257 remove crankshaft pulley. Remove No. 1 and 2 timing belt
Sienna covers and gaskets. See Fig. 1. Remove engine mounting
1998-01 ................. 3.8 Hours ..................... T257 bracket from front (timing belt end) of engine. Note direc-
ence. Remove timing belt guide.
SCHEDULED MAINTENANCE NOTE: Always turn crankshaft clockwise, as viewed from timing
90,000 miles or 72 months. Temporarily install crankshaft pulley bolt in crankshaft. Us-
REMOVAL & INSTALLATION timing mark on crankshaft sprocket aligns with timing mark
on oil pump body. See Figs. 2 and 3.
WARNING: To prevent air bag deployment, disconnect negative Ensure timing marks on camshaft sprockets are aligned
battery cable at least 90 seconds before working on vehicle. with timing the mark on No. 3 timing belt cover. See Figs. 2
and 3. If timing marks are not aligned, rotate crankshaft
TIMING BELT clockwise one full revolution (360 degrees).
Removal (Avalon, Camry & Camry Solara): If reusing old belt, ensure there are 3 installation marks
Raise and support vehicle. Remove right side front wheel. and front arrow marked on belt. See Fig. 4. If not, place
Remove right fender apron seal. Remove accessory drive
belts. Lower vehicle.

548 TOYOTA
3.0L V6 1998-01 (Cont.)
Fig. 4: Identifying Timing Belt Reference Marks & Front Mark

Fig. 2: Aligning Timing Marks (1998)

belt tensioner body with pushrod facing upward. Press rod
against solid surface. Replace timing belt tensioner if push
rod moves.
Measure timing belt tensioner push rod protrusion from
end of rod to edge of timing belt tensioner housing. See
.425" (10.01-10.8 mm).
NOTE: Engine should be cold when installing timing belt.

Installation (Avalon, Camry & Camry Solara):
Courtesy of Toyota Motor Sales, U.S.A., Inc. Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler
Fig. 3: Aligning Timing Marks (1999-01) pulley bolt, coat threads with Loctite 242 or equivalent. In-
stall and tighten bolts to specification. See TORQUE SPECI-
mating mark on belt where it contacts the crankshaft and FICATIONS. Ensure idler pulleys are clean and rotate
camshaft sprockets. Also, mark belt with arrow showing smoothly.
direction of rotation. Temporarily install crankshaft pulley bolt in crankshaft. If
Alternately loosen 2 bolts, and remove timing belt tensioner necessary, use crankshaft pulley bolt to rotate crankshaft
and dust boot. Do NOT hold tensioner with push rod facing clockwise until timing mark on crankshaft sprocket aligns
downward. Remove timing belt. with timing mark on oil pump body. See Figs. 2 and 3.
Inspection (Avalon, Camry & Camry Solara): Using spanner wrench, rotate each camshaft sprocket so
Inspect timing belt for damaged teeth, cracking or oil con- timing mark on camshaft sprocket aligns with timing mark
tamination. Ensure idler pulleys rotate freely and are not on No. 3 timing belt cover. See Figs. 2 and 3.
leaking oil. Replace damaged components. Check water
pump for leaks or worn out bearing. CAUTION: Clean timing belt sprockets before installing timing
belt. Wipe off any oil or water with rag, DO NOT use any cleaning
CAUTION: Never hold timing belt tensioner with pushrod facing solvents.
downward.
TOYOTA 549
3.0L V6 1998-01 (Cont.)

Using gear puller, remove crankshaft pulley. Remove No. 1
and 2 timing belt covers and gaskets. See Fig. 1. Remove
engine mounting bracket from front of engine. Note direc-
ence. Remove timing belt guide.

Courtesy of Toyota Motor Sales, U.S.A., Inc. with timing mark on No. 3 timing belt cover. See Fig. 3. If
Fig. 6: Retracting Tlming Belt Tensloner Rod timing marks are not aligned, rotate crankshaft clockwise
Install timing belt on crankshaft sprocket, water pump pul- Alternately loosen 2 bolts, and remove timing belt tensioner
ley, left (front of vehicle side) camshaft sprocket, No. 2 idler and dust boot. Do NOT hold tensioner with push rod facing
pulley, right (firewall side) camshaft sprocket, and then on downward. Remove timing belt.
No. 1 idler pulley. If reusing old belt, ensure belt installation Inspection (Highlander):
marks align with camshaft and crankshaft sprocket marks. Inspect timing belt for damaged teeth, cracking or oil con-
Ensure front (or rotation direction mark) points in correct tamination. Ensure idler pulleys rotate freely and are not
direction. leaking oil. Replace damaged components. Inspect water
Using press, SLOWLY apply about 200-2200 lbs. (100- pump for leaks or worn out bearing.
1000 Kg) of pressure on push rod of timing belt tensioner
until rod is retracted and holes in rod and housing are CAUTION: Never hold timing belt tensioner with pushrod facing
aligned. See Fig. 6. Align holes in housing and push rod. downward.
Install hex wrench through housing and push rod hole to Inspect timing belt tensioner for signs of oil leakage. Re-
secure push rod. Release press and install dust boot on place timing belt tensioner if oil leakage exists. Hold timing
timing belt tensioner. belt tensioner body with pushrod facing upward. Press rod
Install timing belt tensioner. Install and alternately tighten against solid surface. Replace timing belt tensioner if push
bolts to specification. See TORQUE SPECIFICATIONS. rod moves.
Remove hex wrench from timing belt tensioner. Slowly ro-
tate crankshaft clockwise 2 revolutions until timing mark NOTE: Engine should be cold when installing timing belt.
body. Installation (Highlander):
Ensure timing mark on each camshaft sprocket is aligned Install No. 1 and 2 idler pulleys (if removed). Install and
with timing mark on No. 3 timing belt cover. See Fig. 2. If all tighten bolts to specification. See TORQUE SPECIFICA-
timing marks are not aligned, remove timing belt and rein- TIONS table. Ensure idler pulleys are clean and rotate
stall. Remove crankshaft pulley bolt. smoothly.
Install timing belt guide with cupped side away from crank- Temporarily install crankshaft pulley bolt in crankshaft. If
shaft sprocket and flat side toward timing belt. Install en- necessary, use crankshaft pulley bolt to rotate crankshaft
gine mounting bracket on front of cylinder block. Install and clockwise until timing mark on crankshaft sprocket aligns
tighten bolts to specification. See TORQUE SPECIFICA- with timing mark on oil pump body. See Fig. 3.
TIONS. Using spanner wrench, rotate each camshaft sprocket so
Using new gaskets, install No. 1 and 2 timing belt covers. timing mark on camshaft sprocket aligns with timing mark
Ensure there are no gaps in gasket. Cut off any excess on No. 3 timing belt cover. See Fig. 3.
gasket. Install and tighten bolts to specification.
CAUTION: Clean timing belt sprockets before installing timing
Align crankshaft key with key groove of crankshaft pulley. belt. Wipe off any oil or water with rag, DO NOT use any cleaning
solvents.
ley bolt to specification. See TORQUE SPECIFICATIONS.
To install remaining components, reverse removal proce- Install timing belt on crankshaft sprocket, water pump pul-
dure. Tighten fasteners to specification. Connect engine ley, left (front of vehicle side) camshaft sprocket, No. 2 idler
ground strap. Adjust drive belts to proper tension. See page pulley, right (firewall side) camshaft sprocket, and then on
A-60 for belt tension ranges. No. 1 idler pulley. If reusing old belt, ensure belt installation
Removal (Highlander): marks align with camshaft and crankshaft sprocket marks.
Raise and support vehicle. Remove right side front wheel. Ensure front (or rotation direction mark) points in correct
Remove right fender apron seal. Remove accessory drive direction.
belts. Lower vehicle. Using press, SLOWLY apply about 200-2200 lbs. (100-
Remove control (torque) rod from timing belt end of en- 1000 Kg) of pressure on push rod of timing belt tension
gine. Remove engine mount from timing belt end of en- until rod is retracted and holes in rod and housing are
gine. Remove generator mounting bracket from engine for aligned. See Fig. 6. Align holes in housing and push rod.
access to timing belt covers. Install hexagon wrench through housing and push rod hole
Using Pulley Holder (SST 09213-54015) or equivalent, and to secure push rod. Release press and install dust boot on
Handle (SST 09330-00021) or equivalent, hold crankshaft timing belt tensioner.
pulley. Remove crankshaft pulley bolt.
550 TOYOTA
3.0L V6 1998-01 (Cont.)
Install timing belt tensioner. Install and alternately tighten
Remove hex wrench from timing belt tensioner. Slowly ro-
tate crankshaft CLOCKWISE 2 revolutions until timing mark
body.
Ensure timing mark on each camshaft sprocket is aligned
stall. Remove crankshaft pulley bolt.
tighten bolts to specification. See TORQUE SPECIFICA-
TIONS.
Using new gaskets, install No. 1 and 2 timing belt covers.
Ensure there are no gaps in gasket. Cut off excess gasket.
Install and tighten bolts to specification.
Install generator bracket. Install crankshaft pulley. Install
and tighten crankshaft pulley bolt. See TORQUE SPECIFI-
CATIONS.
Install engine mount and control (torque) rod to engine and Courtesy of Toyota Motor Sales, U.S.A., Inc.
body. Connect engine ground strap.
Fig. 7: Exploded View Of Outer Cowl Top Panel
Install accessory drive belts. Adjust drive belts to proper (1998-00 Sienna)
tension. See page A-60 for belt tension ranges. Install right
fender apron shield. Install right front wheel.
Removal (Sienna):
Remove the outer cowl top panel along with the ventilation
louvers and windshield wiper arm assembly. See Figs. 7
and 8. Raise and support vehicle.
Remove right side front wheel. Remove right fender apron
seal. Remove accessory drive belts. Lower vehicle. Dis-
connect Data Link Connector 1 (DLC1) from right side en-
gine mounting bracket.
Disconnect engine coolant reservoir hose from water out-
let. Disconnect ground strap connectors.
Remove engine stabilizer rod and engine mounting bracket,
located near timing belt cover. Remove generator-to-en-
gine bracket for access to timing belt covers.
Using Pulley Holder (SST 09213-54015) or equivalent, and
crankshaft pulley. Remove No. 1 and 2 timing belt covers
and gaskets. See Fig. 1. Remove engine mounting bracket
from front of engine. Note direction of timing belt guide
installation for reassembly reference. Remove timing belt
guide.

on oil pump body. See Figs. 2 and 3.
with timing mark on No. 3 timing belt cover. See Figs. 2 and
3. If timing marks are not aligned, rotate crankshaft clock-
wise one full revolution (360 degrees).
Alternately loosen 2 bolts, and remove timing belt tensioner Courtesy of Toyota Motor Sales, U.S.A., Inc.
and dust boot. Do NOT hold tensioner with push rod facing Fig. 8: Exploded View Of Outer Cowl Top Panel
downward. Remove timing belt. (2001 Sienna)
TOYOTA 551
3.0L V6 1998-01 (Cont.)

Inspection (Sienna): Ensure timing mark on each camshaft sprocket is aligned
Inspect timing belt for damaged teeth, cracking or oil con- with timing mark on No. 3 timing belt cover. See Figs. 2 and
tamination. Ensure idler pulleys rotate freely and are not 3. If all timing marks are not aligned, remove timing belt
leaking oil. Replace damaged components. Inspect water and reinstall. Remove crankshaft pulley bolt.
pump for leaks or worn out bearing. Install timing belt guide with cupped side away from crank-
CAUTION: Never hold timing belt tensioner with pushrod facing gine mounting bracket on front of cylinder block. Install and
downward. tighten bolts to specification. See TORQUE SPECIFICA-
Inspect timing belt tensioner for signs of oil leakage. Re- TIONS.
place timing belt tensioner if oil leakage exists. Hold timing Using new gaskets, install No. 1 and 2 timing belt covers.
belt tensioner body with pushrod facing upward. Press rod Ensure there are no gaps in gasket. Cut off excess gasket.
against solid surface. Replace timing belt tensioner if push Install and tighten bolts to specification.
rod moves. Align crankshaft key with key groove of crankshaft pulley.
Measure timing belt tensioner push rod protrusion from Install crankshaft pulley. Install and tighten crankshaft pul-
end of rod to edge of timing belt tensioner housing. See ley bolt to specification. See TORQUE SPECIFICATIONS.
Fig. 5. Replace timing belt tensioner if distance is not .394- Install generator bracket. Install engine stabilizer rod and
.425" (10.01-10.8 mm). engine mounting bracket, located near timing belt cover.
Connect engine ground strap.
NOTE: Engine should be cold when installing timing belt. To install remaining components, reverse removal proce-
dure. Tighten fasteners to specification. Adjust drive belts
Installation (Sienna): to proper tension. See page A-60 for belt tension ranges.
Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler TORQUE SPECIFICATIONS
pulley bolt, coat threads with Loctite 242 or equivalent. In-
stall and tighten bolts to specification. See TORQUE SPECI- Application Ft. Lbs. (N.m)
FICATIONS table. Ensure idler pulleys are clean and rotate Camshaft Sprocket Bolt (Except Highlander)
smoothly. Left Hand (Front End of Vehicle Side) ......................... 92 (125)
Temporarily install crankshaft pulley bolt in crankshaft. If Right Hand (Firewall Side of Vehicle) ........................... 65 (88)
necessary, use crankshaft pulley bolt to rotate crankshaft Camshaft Sprocket Bolt (Highlander) ....................... 92 (125)
clockwise until timing mark on crankshaft sprocket aligns Crankshaft Pulley Bolt ............................................ 159 (215)
with timing mark on oil pump body. See Figs. 2 and 3. Engine Mount Bracket-to-Engine Bolt ............................. 21 (28)
Using spanner wrench, rotate each camshaft sprocket so Engine Control (Torque) Rod Bolt .................................. 47 (64)
timing mark on camshaft sprocket aligns with timing mark Generator Adjusting Lock Bolt ........................................ 13 (18)
on No. 3 timing belt cover. See Figs. 2 and 3. Generator Pivot Bolt
Except Avalon ............................................................... 38 (52)
CAUTION: Clean timing belt sprockets before installing timing Avalon ........................................................................... 41 (56)
belt. Wipe off any oil or water with rag, DO NOT use any cleaning Power Steering Pump Bolt .......................................... 32 (43)
solvents. Power Steering Pump Bracket
Install timing belt on crankshaft sprocket, water pump pul- To-Cylinder Head Bolt .............................................. 32 (43)
ley, left (front of vehicle side) camshaft sprocket, No. 2 idler Right Engine Mount Brace Bolt ................................... 23 (31)
pulley, right (firewall side) camshaft sprocket, and then on Shock Tower Brace-to-Shock Tower Nuts
No. 1 idler pulley. If reusing old belt, ensure belt installation Camry Solara .............................................................. 59 (80)
marks align with camshaft and crankshaft sprocket marks. Timing Belt Idler Pulleys
Ensure front (or rotation direction mark) points in correct No. 1 Idler Pulley Bolt .............................................. 1 25 (34)
direction. No. 2 Idler Pulley Bolt ............................................... 32 (43)
Using press, SLOWLY apply about 200-2200 lbs. (100- Timing Belt Tensioner Bolt ......................................... 20 (27)
1000 kg) of pressure on push rod of timing belt tension Wheel Lug Nut .......................................................... 76 (103)
until rod is retracted and holes in rod and housing are Wiper Arm Nuts
aligned. See Fig. 6. Align holes in housing and push rod. Sienna ......................................................................... 15 (20)
Install hexagon wrench through housing and push rod hole INCH Lbs. (N.m)
to secure push rod. Release press and install dust boot on No. 1 & 2 Timing Belt Cover Bolt ................................ 75 (8.5)
timing belt tensioner. No. 3 Timing Belt Cover Bolt ...................................... 75 (8.5)
Install timing belt tensioner. Install and alternately tighten Timing Belt Plate Bolt ................................................ 71 (8.0)
bolts to specification. See TORQUE SPECIFICATIONS. Water Pump Bolt/Nut
Remove hex wrench from timing belt tensioner. Slowly ro- Except Sienna ............................................................. 71 (8.0)
tate crankshaft clockwise 2 revolutions until timing mark Sienna ........................................................................ 69 (7.8)
1
body.
552 TOYOTA
3.0L V6 3V-ZE
3.0L V6 TIMING BELT
Pickup Removal:
1988-92 ................. 4.1 Hours ..................... T154 Disconnect negative battery cable. Drain cooling system.
1993-95 ................. 4.1 Hours ..................... T240 Remove lower engine covers. Remove radiator. Remove
all accessory drive belts.
T100 Remove power steering pump with hoses attached and
1993-94 ................. 4.1 Hours ..................... T240 secure aside (if equipped). Remove spark plugs. Discon-
4Runner nect hoses from air pipe.
1988-92 ................. 4.1 Hours ..................... T154
1993-95 ............... 4.1 Hours ..................... T240 NOTE If separating fluid coupling from fan bracket, place reference
mark on fluid coupling and fan bracket for reassembly reference.
MANUFACTURERS SUGGESTED Remove coolant outlet. See Fig. 1. Remove fan. Remove
SCHEDULED MAINTENANCE spark plug wire clamps across front of No. 2 timing belt
cover. Remove studs for coolant outlet from No. 2 idler pul-
The manufacturer recommends the belt be replaced every ley. Remove bolts, No. 2 timing belt cover and gaskets. See
60,000 miles for severe operating conditions. Fig. 1.

TOYOTA 553
3.0L V6 3V-ZE (Cont.)

CAUTION: If reusing timing belt, mark direction of timing belt rotation
Install timing belt on crankshaft sprocket with reference
mark on timing belt aligned with reference mark (dot) on
and ensure reference marks are on timing belt. See Fig. 2. If reference
crankshaft sprocket. See Fig. 2. Install timing belt on water
marks are not apparent, place reference mark on timing belt and
all sprockets for reassembly reference. Also place reference mark
pump.
on timing belt at upper edge of No. 1 timing belt cover with cylinder
No. 1 at TDC on compression stroke. See Fig. 2.
in original direction of rotation and reference mark on timing
Rotate crankshaft clockwise so cylinder No. 1 is at TDC on belt aligns with reference mark (dot) on crankshaft sprocket.
compression stroke. Cylinder No. 1 is front cylinder on right Install timing belt guide with cupped side away from crank-
side when viewed from rear of engine. Ensure timing mark shaft sprocket and flat side against timing belt. Install No. 1
on crankshaft pulley aligns with 0 mark on timing belt timing belt cover and gasket. Align groove of crankshaft
cover. pulley with crankshaft key. Install crankshaft pulley. Install
Ensure timing marks on camshaft sprockets align with tim- and tighten crankshaft pulley bolt to specification. See
ing marks on No. 3 timing belt cover. See Fig. 3. If timing TORQUE SPECIFICATIONS. Install power steering belt
marks are not aligned, rotate crankshaft clockwise one pulley on crankshaft pulley.
complete revolution and recheck alignment. Rotate crankshaft so cylinder No. 1 is at TDC on compres-
Remove bolts and timing belt tensioner with dust boot. sion stroke. Ensure timing mark on crankshaft pulley aligns
Remove bolts/nuts, fan bracket and gasket. See Fig. 1. with 0 mark on timing belt cover.
Install Camshaft Sprocket Holder (SST 09278-54012) or Rotate left camshaft so timing mark on camshaft sprocket
equivalent, in holes on front of right camshaft sprocket. aligns with timing mark on No. 3 timing belt cover. See Fig.
Slightly rotate right camshaft sprocket clockwise to release 3. Rotate right camshaft so pin hole in camshaft aligns with
tension on timing belt between camshaft sprockets. timing mark on No. 3 timing belt cover.
Remove timing belt from camshaft sprockets. Remove Pull timing belt outward (toward outside of cylinder block)
power steering belt pulley. Using Pulley Holder (SST 09213- at area near sprocket on water pump. Ensure reference
58012) and Handle (SST 09330-00021) or equivalent, hold mark on timing belt aligns with upper edge of No. 1 timing
crankshaft pulley. Remove crankshaft pulley bolt. belt cover when crankshaft pulley timing mark is aligned
NOTE: If reusing timing belt, ensure reference mark placed on
with 0 mark on No. 1 timing belt cover. See Fig. 2.
timing belt aligns with upper edge of No. 1 timing belt cover Using camshaft sprocket holder, slightly rotate left cam-
when timing mark on crankshaft pulley aligns with 0 mark shaft sprocket clockwise. Install timing belt on left cam-
on No. 1 timing belt cover. shaft sprocket. Ensure reference mark on timing belt aligns
with timing mark on camshaft sprocket. See Fig. 2.
Using puller, remove crankshaft pulley. Remove bolts, No. Using camshaft sprocket holder, slightly rotate left cam-
1 timing belt cover and gasket. Note direction of timing belt shaft sprocket and align timing mark on camshaft sprocket
guide installation for reassembly reference. See Fig. 1. Re- with timing mark on No. 3 timing belt cover. See Fig. 3.
move timing belt guide. Ensure tension exists on timing belt between crankshaft
If reusing timing belt, mark direction of timing belt rotation. sprocket and left camshaft sprocket.
Ensure reference mark exists on timing belt at reference
mark (dot) on crankshaft sprocket. See Fig. 2.
If reference mark does not exist, install reference mark on
timing belt in alignment with timing mark (dot) on crank-
shaft sprocket for reassembly reference. See Fig. 2.
Remove timing belt. Remove bolt, No. 1 idler pulley and
plate washer (if necessary). See Fig. 1.
Inspection:
nated.
Inspect timing belt tensioner for oil leakage. Replace tim-
ing belt tensioner if oil leakage exists. Hold timing belt
tensioner housing and press rod against solid surface.
Replace timing belt tensioner if rod moves.
rod to edge of housing on timing belt tensioner. See Fig. 4.
Replace timing belt tensioner if distance is not .394-.413"
(10.00-10.50 mm).
Inspect No. 1 and No. 2 idler pulleys and fan for smooth
rotation. Replace component if defective.
Installation:
Install plate washer and No. 1 idler pulley (if removed).
Install and tighten bolt to specification. See TORQUE SPECI-
FICATIONS. Ensure No. 1 idler pulley is clean and rotates
smoothly.
Install crankshaft pulley bolt in end of crankshaft. Rotate
crankshaft and align timing mark on crankshaft sprocket
with timing mark on oil pump body. See Fig. 3. Fig. 2: Identifying Timing Belt Reference Marks
554 TOYOTA
3.0L V6 3V-ZE (Cont.)

Install No. 2 idler pulley gasket. See Fig. 1. Install No. 2
Align reference mark on timing belt with timing mark on timing belt cover and gaskets. Install crankshaft pulley.
right camshaft sprocket. See Fig. 2. Ensure timing mark on To install remaining components, reverse removal proce-
right camshaft sprocket aligns with timing mark on No. 3 dure. Apply sealant on coolant outlet before installing.
timing belt cover. See Fig. 3. Tighten all bolts/nuts to specification. See TORQUE SPECI-
Using new gasket, install fan bracket. Install and tighten FICATIONS. Fill and bleed cooling system. Adjust drive belts
bolt/nuts to specification. See TORQUE SPECIFICATIONS. to proper tension. See page A-60 for belt tension ranges.
Using press, apply pressure on rod of timing belt tension
until rod is retracted and holes in rod and housing are TORQUE SPECIFICATIONS
aligned. See Fig. 5. Application Ft. Lbs. (N.m)
Install hexagon wrench through holes in housing and rod Alternator Bracket-To-Cylinder Head Bolt ................... 27 (37)
to hold rod in retracted position. See Fig. 5. Release press. Camshaft Sprocket Bolt ............................................ 80 (109)
Install dust boot on end of timing belt tensioner. Install tim- Crankshaft Pulley Bolt ........................................ 181 (245)
ing belt tensioner. Install and alternately tighten bolts. See Spark Plug .................................................................. 13 (18)
TORQUE SPECIFICATIONS. Timing Belt Tensioner Bolt ......................................... 20 (27)
INCH Lbs. (N.m)
CAUTION: Crankshaft must always be rotated clockwise. DO NOT Camshaft Housing Rear Cover Bolt .......................... 43 (4.9)
rotate crankshaft counterclockwise. Fan Retaining Nut ..................................................... 48 (5.4)
Remove hexagon wrench from timing belt tensioner. Ro- No. 3 Timing Belt Cover Bolt ...................................... 73 (8.3)
tate crankshaft 2 full revolutions clockwise from TDC to No. 4 Timing Belt Cover Bolt ...................................... 73 (8.3)
TDC. Ensure crankshaft pulley timing mark aligns with 0 Valve Cover Bolt ......................................................... 48 (5.4)
mark on No. 1 timing belt cover.
ing marks on No. 3 timing belt cover. See Fig. 3. If timing
marks are not aligned, remove timing belt and reinstall
using proper procedure.
TOYOTA 555
3.4L V6
Inspect idler pulley for oil leakage. Inspect idle pulley bear-
Application Labor Time Belt Part No. ing for smoothness. Replace if defective.
3.4L V6
Tacoma NOTE: DO NOT hold tensioner with push rod facing downward.
1995-01 ................ 1 2.4 Hours .................... T271 Inspect timing belt tensioner for oil leakage. Hold tensioner
T100 (push rod facing upward) with both hands and pushing
1995-98 ................ 1 2.4 Hours .................... T271 push rod against a hard surface. If push rod moves, re-
Tundra place tensioner. Measure protrusion of push rod. If protru-
2000-01 ................ 1 2.8 Hours .................... T271 sion is not .394-.425" (10.0-10.8 mm), replace tensioner.
See Fig. 4.
4Runner
1996-01 ................ 1 2.4 Hours .................... T271 NOTE: Only wipe timing belt pulleys and sprockets clean. Do
NOT use any cleaning agents or solvents.
1
Installation:
MANUFACTURERS SUGGESTED Ensure No. 1 cylinder is at TDC of compression stroke by
aligning crankshaft sprocket with mark on oil pump body.
SCHEDULED MAINTENANCE See Fig. 5. Ensure camshaft sprockets are still aligned at
1990-97 model years, the manufacturer recommends the belt TDC positions. See Fig. 6.
be replaced every 60,000 miles under severe driving condi-
NOTE: Install timing belt when engine is cold.
tions. For 1998-01 model years, the manufacturer recom-
mends the belt be replaced every 90,000 miles. Install timing belt on left (drivers side) camshaft pulley, No.
2 idler pulley, right (passengers side) camshaft pulley, wa-
REMOVAL & INSTALLATION ter pump pulley, crankshaft pulley and No. 1 idler pulley. If
reusing old belt, ensure all reference marks are aligned.
TIMING BELT Using a press, SLOWLY press in tensioner push rod with
Removal: pressure of 200-2205 lbs. (100-1000 N.m). Align holes of
Remove lower engine cover (if equipped). Drain cooling push rod and housing and insert a 1.27 mm hexagon
system. Disconnect upper radiator hose. Remove acces- wrench. Release pressure on push rod. See Fig. 7.
sory drive belts. Disconnect 2 power steering hoses from Install dust boot on tensioner. Install tensioner and alter-
the air intake chamber and resonator. Remove power steer- nately tighten 2 bolts to specification. See TORQUE SPECI-
ing pump driver belt. Remove power steering pump with FICATIONS table. Remove hexagon wrench from tensioner.
hoses attached and hang out of way. Remove A/C com- Ensure timing marks of crankshaft timing pulley and oil
pressor with hoses attached and hang out of way. pump body are aligned and check camshaft timing marks.
Loosen cooling fan with fluid coupling and fan pulleys. Re- See Fig. 1.
move lower fan shroud. Remove fan and fan pulleys. Install timing belt guide with cup facing outward. Install
Remove A/C compressor bracket from engine. Remove lower timing belt guide with new gaskets. Install crank-
engine oil dipstick and tube. Disconnect electrical connec- shaft pulley. Install crankshaft pulley bolt and tighten to
tors and clamps from upper timing belt cover. Remove up- specification.
per timing belt cover. See Fig. 2. Remove power steering Turn crankshaft clockwise 2 revolutions, from TDC to TDC.
pump adjusting strut. Remove fan bracket. Ensure V notch (TDC mark) on crankshaft pulley aligns
with 0 mark on lower timing belt cover. Ensure camshaft
NOTE: Always turn crankshaft clockwise as viewed from timing timing marks are still aligned with marks on rear cover.
belt end of engine. Install fan bracket. Install power steering adjusting strut.
Ensure No. 1 cylinder is set at TDC of compression stroke Install upper timing belt cover with new gasket. Install gen-
(crankshaft pulley groove aligned with zero mark on lower erator drive belt. Install oil dipstick tube. Install A/C com-
timing belt cover). Use Pulley Holder (SST 09213-54015)
or equivalent to hold crankshaft pulley. Remove crankshaft
pulley bolt. Use gear puller to remove crankshaft pulley.
Remove lower timing belt cover. Noting installed position
for reassembly reference, remove timing belt guide.
Check that the crankshaft sprocket timing mark is aligned
with mark on oil pump body. Check that camshaft sprocket
timing marks are aligned with timing marks on back cover.
See Fig. 1.
If marks are not aligned, temporarily install crankshaft pul-
ley. Turn crankshaft one revolution in direction of rotation
(clockwise). Recheck alignment of timing marks.
If reusing timing belt, check that there are 3 installation
marks and a front mark on belt. See Fig. 3. If marks are
missing, place 3 new marks on belt to match position of
belt on camshaft and crankshaft pulleys. Also place front
facing arrow on belt. Courtesy of Toyota Motor Sales, U.S.A., Inc.
Remove timing belt tensioner. DO NOT hold tensioner with Fig. 1: Aligning Crankshaft & Camshaft Timing Marks
push rod facing downward. Remove timing belt.
556 TOYOTA
3.4L V6 (Cont.)

TOYOTA 557
3.4L V6 (Cont.)

Fig. 3: Timing Belt Installation Marks Fig. 7: Retracting Timing Belt Tensioner Push Rod
pressor bracket and A/C compressor. Install power steer-

ing pump. Connect 2 power steering air hoses to air intake
chamber and resonator. Install fan and lower fan shroud.
Install accessory drive belts. Install engine under cover.
Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS table. Fill cooling system and bleed air
from system. Adjust drive belts to proper tension. See page
Fig. 4: Measuring Tensioner Push Rod Protrusion A/C Compressor-to-Bracket ......................................... 18 (25)
A/C Compressor Bracket-to-Engine ........................... 35 (47)
T100, 1995-98 Tacoma & 4Runner .......................... 184 (250)
1999-01 Tacoma & 4Runner .................................... 217 (295)
Tundra ...................................................................... 217 (295)
No. 1 Idler Pulley Bolt ..................................................... 25 (35)
No. 2 Idler Pulley Bolt ..................................................... 30 (40)
Power Steering Pump Bolt/Nut ..................................... 31 (43)
Spark Plug .................................................................. 13 (18)
Water Pump Bolt ............................................................ 14 (20)
INCH Lbs. (N.m)
Fan Retaining Nut ..................................................... 48 (5.4)
Upper Timing Belt Cover Bolt ....................................... 80 (9)
Courtesy of Toyota Motor Sales, U.S.A., Inc. Oil Dipstick Tube ............................................................ 71 (8)
Fig. 5: Aligning Crankshaft Sprocket Timing Mark

558 VOLKSWAGEN
1.5L, 1.6L & 1.7L 4-Cylinder
TIMING BELT APPLICATION termediate shaft sprocket aligns with V notch on crank-
shaft pulley. See Figs. 1 and 2.
Belt Use care not to move any sprocket. Fit belt on bottom first
Labor Component Part and then at top. There should be no slack between sprock-
Application Time Kit No. No. ets. Tighten tensioner so belt can just be twisted 90 de-
1.5L 4-Cyl. grees halfway between camshaft and intermediate sprock-
Dasher ets. Tighten adjuster lock nut.
1974-75 .......... 1.8 Hrs. ...... TCK017 .......... T017 Reverse removal procedure for remaining components.
Rabbit tension ranges.
1975-79 .......... 1.8 Hrs. ...... TCK017 .......... T017 TORQUE SPECIFICATIONS
Scirocco
1978 ............... 1.8 Hrs. ...... TCK017 .......... T017 Application Ft. Lbs. (N.m)
1.6L 4-Cyl. Crankshaft Pulley Bolts .............................................. 15 (20)
Crankshaft Sprocket Bolt ............................................ 59 (80)
Dasher Intermediate Sprocket Bolt 1 ....................................... 59 (80)
1976-80 .......... 1.8 Hrs. ...... TCK017 .......... T017 Timing Belt Tensioner Lock Nut ................................. 33 (45)
Jetta Water Pump Bolts ...................................................... 15 (20)
1980 ............... 1.8 Hrs. ...... TCK017 .......... T017 Water Pump Pulley Bolts ............................................ 15 (20)
Pickup 1
- Use Loctite.
1980 ............... 1.8 Hrs. ...... TCK017 .......... T017
Rabbit
1980 ............... 1.8 Hrs. ...... TCK017 .......... T017
Scirocco
1976-80 .......... 1.8 Hrs. ...... TCK017 .......... T017
1.7L 4-Cyl.
Jetta
1981-84 .......... 1.8 Hrs. ...... TCK017 .......... T017
Quantum
1982-83 .......... 1.8 Hrs. ...... TCK017 .......... T017
Rabbit
1981-84 .......... 1.8 Hrs. ...... TCK017 .......... T017
Rabbit Pickup
1981-83 .......... 1.8 Hrs. ...... TCK017 .......... T017
Scirocco
1981-83 .......... 1.8 Hrs. ...... TCK017 .......... T017

kits. Fig. 1: Aligning Crankshaft & Intermediate Sprockets

TIMING BELT
Removal:
Disconnect negative battery cable. Remove alternator belt,
water pump pulley, and upper and lower drive belt covers. If
equipped, remove air conditioning compressor drive belt.
Remove timing belt guide, if equipped. Loosen belt
tensioner, and work belt off sprockets toward front of en-
gine.
Installation:
Rotate camshaft sprocket until index punch mark on cam-
shaft sprocket is lined up with top surface of valve cover
mounting flange on spark plug side of head. Rotate crank- Fig. 2: Aligning Camshaft With Cylinder Head Flange
shaft and intermediate shaft until index punch mark on in-
VOLKSWAGEN 559
*1.5L & 1.6L 4-Cylinder Diesel & Turbo Diesel

Disconnect negative battery cable. Loosen alternator and
Application Labor Time Belt Part No. remove drive belt. Remove crankshaft drive belt pulley. Re-
1.5L 4-Cyl. Diesel move air cleaner and ducting. Remove timing belt and cyl-
Dasher inder head cover. Remove timing plug on top of bell hous-
1979-80 ..................... 1.5 Hours ................. T043 ing. Rotate engine to bring No. 1 cylinder to TDC. Check
Rabbit that TDC mark on flywheel is aligned with reference.
1977-80 ..................... 2.8 Hours ................. T043 Using Setting Bar (2065A for Vanagon, 2065 for other mod-
els) or equivalent, lock camshaft in position. See Fig. 1.
Rabbit Pickup Align tool by turning camshaft until one end of tool touches
1980 .......................... 2.8 Hours ................. T043 cylinder head. Measure gap at other end with feeler gauge.
1.6L 4-Cyl. Diesel & Turbo Diesel Insert feeler gauges of 1/2 thickness measured between
Dasher tool and cylinder head at each end of tool.
1981 .......................... 1.5 Hours ................ T043 Lock injection pump sprocket at TDC with Special Pin (2064)
Golf or equivalent. Loosen belt tensioner and remove timing
belt from sprockets.
1985-87 ..................... 2.8 Hours ................. T043
1988-92 (Canadian) .. 2.2 Hours ................. T043 CAUTION: DO NOT turn camshaft or crankshaft with drive belt
Jetta removed.
1981-86 ..................... 2.8 Hours ................. T043 Installation:
1986 (Canadian) ....... 2.8 Hours ................. T043 Ensure that flywheel is still aligned with TDC mark. With
1989-92 ..................... 2.2 Hours ................. T043 camshaft and injection pump locked in place, loosen cam-
1988-92 (Canadian) .. 2.2 Hours ................. T043 shaft sprocket bolt 1/2 turn. Lightly tap camshaft gear loose
Quantum from camshaft. Install drive belt so there is no slack be-
1982-86 ..................... 2.0 Hours ................. T043 tween camshaft sprocket and injection pump and injection
pump and crankshaft sprocket.
Rabbit Tighten tension adjuster to keep belt firmly in place. Remove
1981-84 ..................... 1.5 Hours ................. T043 injection pump locking pin. Adjust belt tension by turning
Rabbit Pickup tensioner until scale reads 12-13 on Tension Gauge (210) or
1981-83 ..................... 2.8 Hours ................. T043 equivalent. See Fig. 2. Tighten camshaft sprocket bolt and
Vanagon tensioner adjuster lock nut. Remove lock from camshaft.
1982 .......................... 2.8 Hours ................. T043 Turn crankshaft 2 revolutions in direction of engine rota-
tion. Using a rubber hammer, strike belt once between cam-
shaft sprocket and injection pump sprocket. Recheck belt
MANUFACTURERS SUGGESTED tension and install remaining components in reverse or-
SCHEDULED MAINTENANCE der of removal. Check injection pump timing. Adjust drive
ranges.
the belt be replaced at 60,000 mile intervals. TORQUE SPECIFICATIONS
* NOTE: This application is an interference engine. Camshaft Sprocket Bolt .............................................. 33 (45)
See page A-59 for interference engine cautions. Crankshaft Pulley Bolts .............................................. 15 (20)
REMOVAL & INSTALLATION Except Vanagon ...................................................... 81 (110)
Vanagon .............................................................. 110 (150)
TIMING BELT Intermediate Sprocket Bolt .......................................... 33 (45)
Timing Belt Tensioner Lock Nut ................................. 33 (45)
NOTE: Sprockets do not have to be removed to replace drive Water Pump Pulley Bolt .............................................. 15 (20)
belt.
560
VOLKSWAGEN
*1.5L & 1.6L 4-Cylinder Diesel & Turbo Diesel
(Cont.)
Fig. 1: Installing Camshaft Setting Bar

Fig. 2: Installing Timing Belt Tension Gauge
VOLKSWAGEN 561
*1.8L 4-Cylinder Beetle, 1999-01

Beetle (APH & AWV Engines)
1999-01 ................. 2.7 Hours ..................... T306
The manufacturer suggests the timing belt AND tensioner be
replaced at 105,000 mile intervals.

Courtesy of Volkswagen United States, Inc.
Fig. 2: Releasing Serpentine Drive Belt Tension
TIMING BELT
Removal:
Remove engine cover. Remove noise insulation pan from
under engine compartment.
Remove air duct pipe between turbocharger and charge air
cooler.
Mark rotation direction of serpentine drive belt. Move ser-
pentine drive belt tensioner as shown to release tension
on belt. See Fig. 1. Secure tensioner using a drift, about
.18 (4.5 mm) x 2.2 (55 mm). See Fig. 2. Remove serpen-
tine drive belt. Remove serpentine drive belt tensioner.
NOTE: On vehicles without headlight cleaning system, Connecting Fig. 3: Setting Crankshaft To TDC (Manual Transmission)
Rod Support (3090) can also be used to secure tensioner.
pression stroke. Ensure that TDC marks on flywheel and
bellhousing are aligned. See Figs. 3 and 4.
Remove coolant expansion tank and set aside. Label all
vacuum hoses for reassembly reference, and disconnect
vacuum hoses from fuel evaporative canister. Disconnect
vacuum hoses at throttle body.
Remove upper timing belt cover. See Fig. 7.
Attach Engine Support Bridge (10-222A) with Bracket
(10222) and engage retainer in right lifting eye bolt located
at cylinder head. Lift engine slightly to remove weight from
engine mounts. Engine may also be support from below
with a floor jack.

Fig. 4: Setting Crankshaft To TDC (Auto. Transmission)
CAUTION: Engine mount assembly is secured by torque-to-yield

bold. Crankshaft pulley CENTER bolt is also torque to yield bolt.
These bolts MUST be replaced if they are loosened or removed.
Remove bolts from engine mount assembly at timing belt
end of engine. Remove engine mount.
Remove crankshaft pulley outer bolts. Remove crankshaft
pulley. It is NOT necessary to remove crankshaft pulley center
bolt.
Remove lower and middle timing belt covers. Remove en-
gine bracket from engine block. See Fig. 6. If reusing old
timing belt, mark timing belt with arrow to indicate original
Fig. 1: Releasing Serpentine Drive Belt Tension
562 VOLKSWAGEN
*1.8L 4-Cylinder Beetle, 1999-01 (Cont.)

Fig. 6: Installing Timing Belt Tensioner Locking Pin
Screw Tensioning Bolt (T10092) or M5 x 55x 1 stud into

timing belt tensioner bracket. See Fig. 6. Install hex nut and
washer onto stud.
SLOWLY turn hex nut on stud to compress timing belt
tensioner. Compress tensioner just enough so that Lock-
ing Pin (T40011) or drill bit can be inserted through the
tensioner body, locking the tensioner in place.
Remove timing belt. Turn crankshaft back just slightly to
ensure that crankshaft is not at TDC for any cylinder. Courtesy of Volkswagen United States, Inc.
NOTE: When turning camshaft, crankshaft must not be at TDC Fig. 8: Locating Engine Bracket-To-Block Bolts
or there is a potential for valves to contact pistons. Install timing
belt when engine is cold or lukewarm. Turn crankshaft 2 revolutions and check that camshaft and
Installation: crankshaft marks align properly. See Fig. 5.
Ensure crankshaft is still at TDC of compression stroke for Install middle and upper timing belt covers. Tighten bolts
No. 1 cylinder. Align timing marks on camshaft sprocket to specification. See TORQUE SPECIFICATIONS.
with mark on cylinder head cover. See Fig. 5. Install engine mount bracket to block. Install engine mount
Install timing belt around crankshaft sprocket. If installing to engine bracket and body using NEW bolts. Adjust engine
used belt, ensure it is installed in original direction of rota- mount clearance. See Fig. 9.
tion. Install lower timing belt guard. Install crankshaft pul- Remove engine support bridge or floor jack. Install ser-
ley and tighten bolts to specification. See TORQUE SPECI- pentine drive belt tensioner. Install serpentine drive belt.
FICATIONS. Install the A/C compressor drive belt (if equipped). Ensure
Place timing belt on water pump, tensioner pulley and cam- used belts are installed in original direction of rotation.
shaft sprocket. To complete installation, reverse removal procedure.
Remove Locking Pin (T40011) or drill bit. Unscrew Tighten all fasteners to specification. See TORQUE SPECI-
Tensioning Bolt (T10092). See Fig. 6. FICATIONS.
VOLKSWAGEN 563
*1.8L 4-Cylinder Beetle, 1999-01 (Cont.)

Crankshaft Pulley Bolt ................................................... 18 (25)
Step 1 ........................................................................... 66 (90)
Step 2 ........................................... Plus 1/4 Turn (90 Degrees)
Engine Mount Bracket-To-Engine ................................... 33 (45)
Engine Mount-To-Body 1
Step 1 ........................................................................... 30 (40)
Engine Mount-To-Engine Bracket 1
Step 1 ........................................................................... 44 (60)
Serpentine Drive Belt Tensioner Bolt ............................ 18 (25)
Timing Belt Cover Bolt ................................................... 15 (20)
Timing Belt Tensioner Mount Bolt ................................... 11 (15)
Water Pump Bolt ............................................................ 11 (15)
1
Replace bolts if loosened or removed.

Fig. 9: Adjusting Engine Mount Clearance
564 VOLKSWAGEN
*1.8L 4-Cylinder Passat, 1998-2000
NOTE: Engine code is stamped on machined pad on left side (viewed
from flywheel end of engine) of engine block. Engine code is
also on vehicle data plate.

1.8L 4-Cylinder DOHC (AEB & ATW Engines)
Passat
1998-00
152 Tooth Belt ... 3.1 Hours ..................... T291
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. Courtesy of Volkswagen United States, Inc.
Fig. 1: Removing Timing Belt


TIMING BELT
NOTE: Front lock carrier (radiator support) must be moved forward
to remove timing belt.
Removal:
Raise and support vehicle. Remove front, lower engine
cover. Lower vehicle. Separate release lever from hood lock.
Remove front bumper cover. See Fig. 5. Remove bumper
carrier from impact damper.
Unbolt air duct between lock carrier and air cleaner on lock
carrier. Remove support bolt on passenger side of lock
carrier and insert one Lock Carrier Guide (3369) into hole.
See Fig. 6.
Remove lock carrier front support bolts. Remove lock car-
rier-to-side panel bolts. Insert Lock Carrier Guide (3369) Courtesy of Volkswagen United States, Inc.
into hole on drivers side of vehicle. Slide lock carrier for-
ward on lock carrier guides.
On vehicles with A/C, mark direction of rotation on belt, and Installation:
remove A/C drive belt. On all vehicles, rotate accessory drive Align timing marks on camshaft sprocket with mark on cyl-
belt tensioner clockwise to remove tension from belt. Mark inder head cover. See Fig. 2. Ensure crankshaft is still at
belt with rotation direction and remove accessory drive belt. TDC position. Install timing belt around crankshaft sprocket.
See Fig. 1. Temporarily install crankshaft pulley to ensure crankshaft
Remove accessory drive belt tensioner pulley and lever. is still at TDC of compression stroke for No. 1 cylinder.
Turn crankshaft to TDC of compression stroke on No. 1 Place timing belt on intermediate shaft sprocket, tensioner
cylinder. See Fig. 2. pulley and camshaft sprocket. To tension timing belt, use
Remove crankshaft pulley. It is NOT necessary to remove spanner wrench to rotate tensioner pulley clockwise until
center crankshaft pulley center bolt. Remove upper and tensioner piston No. 1 is fully extended, and tensioner pis-
lower timing belt covers. Loosen timing belt tensioner lever ton No. 2 lifts about .040 (1 mm). See Fig. 3.
bolt. Tighten tensioner pulley bolt to specification. See TORQUE
If reusing timing belt, mark belt with arrow to indicate direc- SPECIFICATIONS. Rotate crankshaft 2 revolutions. Make
tion of rotation. Remove timing belt. sure camshaft and crankshaft timing marks are aligned.
NOTE: When turning camshaft, crankshaft must not be at TDC
belt when engine is cold or lukewarm.
VOLKSWAGEN 565
*1.8L 4-Cylinder Passat, 1998-2000 (Cont.)
Fig. 6: Exploded View Of Lock Carrier Assembly
Belt tension is correct if edge of tensioner lever aligns with

piston upper edge (Area A), or piston No. 1 is extended
0.98-1.14 (25-29 mm) (dimension D). See Fig. 4. Check
for wear in Areas B and C is dimension is not correct.
Remove crankshaft pulley. Install lower and upper timing
belt covers. Install crankshaft pulley. Tighten bolts to speci-
fication. See TORQUE SPECIFICATIONS. Install accessory
drive belt tensioner. Install accessory drive belt. Install the
A/C compressor drive belt (if equipped). Ensure used belts
are installed in original direction of rotation.
Install lock carrier in original location. Install bumper and
bumper cover.
Courtesy of Volkswagen United States, Inc. Application Ft. Lbs. (N.m)
Fig. 4: Checking Timing Belt Tension Accessory Drive Belt Tensioner Bolt .............................. 18 (25)
A/C Drive Belt Tensioner Bolt ......................................... 22 (30)
Bumper Carrier-To-Impact Damper
Vertical Bolt ................................................................... 15 (20)
Crankshaft Pulley Bolt ................................................... 18 (25)
Impact Damper-To-Lock Carrier Bolt ............................. 68 (50)
Lock Carrier
Front Support Bolt ......................................................... 37 (50)
INCH Lbs. (N.m)
Bumper Guide-To-Side Panel Bolt ................................... 18 (2)
Lock Carrier-To-Side Panel Bolt ....................................... 71 (8)
Timing Belt Cover Bolt ................................................... 89 (10)

Fig. 5: Exploded View Of Bumper Assembly
566 VOLKSWAGEN
1.8L 4-Cylinder DOHC (AUG & AWM Engines)
Passat
2000-01
For 2000-01 model year, the manufacturer suggests the tim-
ing belt AND tensioner be replaced at 105,000 mile intervals.


TIMING BELT
NOTE: Front lock carrier (radiator support) must be moved forward
to remove timing belt.
Removal:
For vehicles manufacturered from up to September, 2000,
disconnect front turn signal light assembly wiring har- Courtesy of Volkswagen United States, Inc.
nesses. Separate hood release lever from bumper cover.
Fig. 2: Removing Front Bumper Cover (From October, 2000)
beam. Remove air intake duct from air cleaner housing. For vehicles manufacturered from October, 2000, remove
Remove support bolts from lock carrier assembly. See Fig. bumper cover from bumper carrier. See Fig. 2. Remove
3. Install Support Tool (3369) through lock carrier to body. noise insulation panel from under engine compartment.
Remove oil cooler from lock carrier assembly. Move lock Remove air intake duct at lock carrier. Remove bolts from
carrier forward on support tools. front of bumper carrier. See Fig. 4. Install guide rods on
right and left sides. Pull lock carrier forward about 4 (10
cm) on guide rods into service position.
CAUTION: DO NOT hang condenser or oil cooler from their lines.

On all vehicles, loosen bolts for air conditioning drive belt
and remove belt. Remove serpentine drive belt. Remove
serpentine drive belt tensioner.
Remove upper timing belt cover. See Fig. 6. Mark rotation
direction of timing belt with arrow. Rotate crankshaft to TDC
No. 1 cylinder. See Fig. 5.
CAUTION: Vibration damper outer bolts and center bolt are torque-
to-yield type. If loosened or removed, bolts must be replaced.
Remove vibration damper. It is NOT necessary to remove
center bolt from vibration damper. Remove lower and middle
timing belt covers. See Fig. 6.
NOTE: If necessary, align pressure piston using needle nose pliers

or a thin wire (hole in piston and hole in housing must align.
Align holes in timing belt tensioner piston rod and hous-
ing. Insert Tensioning Bolt (T10092) into timing belt
tensioner bracket. See Fig. 7. Turn tensioning bolt just
enough so that holes in tensioner piston rod and housing
align. Insert Locking Pin (T40011) into holes to secure
tensioner in place.
Remove timing belt. Turn crankshaft back just slightly to
ensure that crankshaft is not at TDC for any cylinder.
Fig. 1: Removing Front Bumper Cover (Up To Sept. 2000)
VOLKSWAGEN 567

NOTE: Engine must not be hotter than lukewarm when tensioning
timing belt.
Remove Locking Pin (T40011) and unscrew Tensioning
Bolt (T10092). See Fig. 7.
tion. Check that camshaft and crankshaft timing marks align
properly. See Fig. 5.
Install middle and upper timing belt covers. Tighten bolts
to specification. See TORQUE SPECIFICATIONS. Install
serpentine drive belt tensioner. Install serpentine drive belt.
Install the A/C compressor drive belt (if equipped). Ensure
used belts are installed in original direction of rotation.
Install lock carrier in original location. Install bumper and
bumper cover.
Bumper Carrier-To-Impact Absorber
Vertical Bolt ................................................................... 15 (20)
Crankshaft Pulley Center Bolt 1
Step 1 ........................................................................... 66 (90)
(Up To September, 2000)
Impact Damper-To-Lock
Carrier Bolt (From Oct. 2000) ......................................... 68 (50)
Lock Carrier
Front Support Bolt ......................................................... 37 (50)
Serpentine Drive Belt Tensioner Bolt ............................ 18 (25)
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)
1
Replace bolt if loosened or removed.

(From October, 2000)
NOTE: When turning camshaft, crankshaft must not be at TDC

belt when engine is cold or lukewarm.
Installation:
Align timing marks on camshaft sprocket with mark on cyl-
inder head cover. Ensure crankshaft sprocket is still aligned
with timing mark. See Fig. 5.
Install timing belt around crankshaft sprocket. Install lower
timing belt cover. Install vibration and tighten bolts to speci-
Set crankshaft pulley to TDC No. 1 cylinder. Place timing
belt on water pump, tensioner pulley and camshaft
sprocket.
568 VOLKSWAGEN
1.8L 4-Cylinder Passat, 2000-01

Fig. 7: Installing Timing Belt Tensioner Locking Pin

VOLKSWAGEN 569
1.8L 4-Cylinder SOHC, 1983-93

TIMING BELT APPLICATION With intermediate shaft/ignition rotor positioned, rotate crank-
shaft and align mark on crankshaft pulley with mark on
Belt intermediate shaft sprocket. Position camshaft sprocket
Labor Component Part mark even with valve cover surface. See Fig. 3. Install tim-
Application Time Kit No. No. ing belt.
1.8L 4-Cyl. SOHC Rotate tensioner clockwise to tighten belt and install lock
Cabriolet nut. Proper deflection is achieved when longest span of
belt between sprockets can be twisted 90 degrees. See
1985-93 .......... 1.8 Hrs. ...... TCK017 .......... T017 Fig. 4.
Corrado By hand, rotate crankshaft 2 turns and check timing mark
1990-92 .......... 1.8 Hrs. ...... TCK017 .......... T017 alignment. To complete installation, reverse removal pro-
Fox cedure. Adjust drive belts to proper tension. See page A-60
1987-93 .......... 1.8 Hrs. ...... TCK017 .......... T017 for belt tension ranges.
Golf TORQUE SPECIFICATIONS
1985-92 .......... 1.8 Hrs. ...... TCK017 .......... T017 Application Ft. Lbs. (N.m)
Golf (Canadian) A/C Bracket-To-Engine Bolt ........................................ 22 (30)
1993-95 .......... 1.8 Hrs. ...... TCK017 .......... T017 Crankshaft Timing Sprocket Bolt ................................ 66 (90)
GTI Intermediate Shaft Sprocket Bolt ................................. 59 (80)
1985-92 .......... 1.8 Hrs. ...... TCK017 .......... T017 Lower Pulley Bolt ........................................................ 15 (20)
Jetta Timing Belt Tensioner Nut .......................................... 33 (45)
1984-92 .......... 1.8 Hrs. ...... TCK017 .......... T017 INCH Lbs. (N.m)
Jetta (Canadian) Valve Cover Retaining Nut .......................................... 89 (10)
1993-95 .......... 1.8 Hrs. ...... TCK017 .......... T017 Water Pump-To-Housing ........................................... 89 (10)
Passat (Canadian)
1992-94 .......... 1.8 Hrs. ...... TCK017 .......... T017
Quantum
1985 ............... 1.8 Hrs. ...... TCK017 .......... T017
Rabbit
1983-84 .......... 1.8 Hrs. ...... TCK017 .......... T017
Scirocco
1983-89 .......... 1.8 Hrs. ...... TCK017 .......... T017

kits.
REMOVAL & INSTALLATION Fig. 1: Removing Timing Belt

TIMING BELT
Removal:
Disconnect negative battery cable. Match mark all compo-
nents to ensure reassembly in original position. See Fig.
1. DO NOT turn crankshaft with belt removed. Valve dam-
age may result. Remove upper drive belt cover, drive belt,
and pulley. Remove timing belt guide, if equipped. Loosen
belt tensioner. Remove vibration damper. Remove lower
belt cover. Remove timing belt.
Installation:
Align flywheel/flexplate 0 mark with pointer. This is TDC.
Remove distributor cap and check position of ignition rotor. Fig. 2: Aligning Ignition Rotor
Rotate intermediate shaft and position ignition rotor at No.
1 cylinder mark on housing. See Fig. 2.
570 VOLKSWAGEN
1.8L 4-Cylinder SOHC, 1983-93 (Cont.)
Fig. 4: Checking 1.8L Timing Belt Tension (8-Valve)
Fig. 3: Aligning 1.8L Timing Marks (8-Valve)

VOLKSWAGEN 571

1.8L 4-Cyl. - DOHC
Cabriolet
1985-89 ................. 1.8 Hours ..................... T292
Golf & GTI
1985-89 ................. 1.8 Hours ..................... T292
Jetta
1985-89 ................. 1.8 Hours ..................... T292
Scirocco (Canadian)
1988-89 ................. 1.8 Hours ..................... T292
Scirocco
1985-88 ................. 1.8 Hours ..................... T292
2.0L 4-Cyl. - DOHC
GTI
1990-92 ................. 1.8 Hours ..................... T292
Jetta
1990-92 ................. 1.8 Hours ..................... T292
Passat
1990-92 ................. 1.8 Hours ..................... T292
*NOTE: This application is an interference engine. Fig. 2: Aligning Ignition Rotor

See page ...for interference engine cautions.

TIMING BELT
Removal:
Disconnect negative battery cable. Match mark all compo-
nents to ensure reassembly to original position. Remove
accessory drive belts.
pression stroke. Remove fan belt and water pump pulleys.
See Fig. 1. Remove timing belt covers. Remove tensioner
pulley. Remove timing belt.
Installation:
Install timing belt around crankshaft and intermediate shaft
sprockets. Install lower timing belt cover. Install vibration
damper, noting offset holes. If valve cover is installed, mark
on front of camshaft sprocket must align with mark on valve
cover. If valve cover is removed, place camshaft sprocket
mark even with valve cover surface. See Fig. 3.
Align crankshaft sprocket mark with mark on lower timing
belt cover. See Fig. 3. Install timing belt around camshaft
sprocket. Rotate tensioner clockwise until Timing Belt Ten-
sion Scale (VW 210) or equivalent, reads 13-14.
Rotate crankshaft 2 revolutions and check timing mark align-
ment. To complete installation, reverse removal procedure. Fig. 3: Timing Mark Alignment
tension ranges.
572 VOLKSWAGEN
Crankshaft Pulley Nut ................................................. 15 (20)
16-Valve ................................................................ 148 (200)
Intermediate Shaft Sprocket Bolt
16-Valve .................................................................... 48 (65)
Water Pump Pulley ..................................................... 15 (20)
INCH Lbs. (N.m)
Upper & Lower Timing Belt Cover Bolt ......................... 53 (6)
Water Pump-To-Housing ........................................... 84 (10)
Fig. 4: Proper Timing Belt Tension

VOLKSWAGEN 573
*1.9L 4-Cylinder Turbo Diesel, 1993-98

TIMING BELT APPLICATION mension between setting bar and one side of cylinder
head.
Application Labor Time Belt Part No. Turn camshaft until setting bar contacts feeler gauge. Place
1.9L 4-Cylinder Turbo Diesel second feeler gauge of same dimension between other
Golf (Engine Code AAZ, AHU & 1Z) 1 end of bar and cylinder head.
1993-95 ................. 2.8 Hours ..................... T242 Lock injection pump in place using Lock Pin (2064). See
1996-97 ................. 2.2 Hours ..................... T242 Fig. 5. Loosen timing belt tensioner. Remove crankshaft
vibration damper. Remove the lower timing belt cover. See
Jetta (Engine Code AAZ, AHU & 1Z) 1 Fig. 3.
1993-95 ................. 2.8 Hours ..................... T242 If reusing old timing belt, mark belt with arrow to indication
1996-98 ................. 2.2 Hours ..................... T242 original direction of rotation. Move timing belt tensioner,
Passat (Engine Code AAZ, AHH & 1Z) 1 and remove timing belt.
1994-99 ................. 2.2 Hours ..................... T242 Installation (Golf & Jetta w/AAZ Engine, Up To Sept., 1994):
Ensure TDC mark on flywheel and transmission mating
1
- Code is stamped on pad on engine block flange are still aligned. See Fig. 2.
between diesel injection pump and exhaust
manifold. Engine code is also included on NOTE: Use spanner wrench to hold camshaft sprocket while loosening
vehicle data plate and timing belt cover. center bolt. Do not use camshaft setting bar to hold camshaft
sprocket.
MANUFACTURERS SUGGESTED Loosen camshaft sprocket bolt about 1/2 turn. Insert pin
SCHEDULED MAINTENANCE punch through hole in rear of timing belt cover until it con-
The manufacturer recommends the belt AND tensioner be tacts rear of camshaft sprocket. LIGHTLY tap pin punch
replaced at 60,000 mile intervals. with hammer to loosen camshaft sprocket on camshaft
taper.
*NOTE: This application is an interference engine. With Camshaft Setting Bar (2065A) in place on rear of cam-
shaft and crankshaft at TDC, install timing belt on engine. If
See page A-59 for interference engine cautions. reusing old belt, ensure belt is installed in original direc-
tion of rotation. Remove Lock Pin (2064) from injection pump
REMOVAL & INSTALLATION sprocket.
TIMING BELT
Removal (Golf, Jetta & Passat w/AAZ Engine, Up To Sept.,
1994):
On models with tensioner, install Tensioner Tool (3299)
and rotate clockwise. Mark serpentine belt with arrow to
indicate rotation direction, and remove belt. See Fig. 1. Re-
move tensioner pulley. On models without serpentine belts,
remove accessory drive belts.
On all models, remove upper timing belt cover. See Fig. 3.
Remove valve cover.
pression stroke. Flywheel TDC mark must be aligned to
mark on transmission mating flange. See Fig. 2.
Lock camshaft in place with Setting Bar (2065A) installed
on rear of camshaft. See Fig. 4. Center setting bar by turn-
ing camshaft so one side of setting bar contacts cylinder
head. Using feeler gauge, measure distance between other
end of setting bar and cylinder head.
Divide this feeler gauge dimension in half. Place a feeler
gauge corresponding to half the bar-to-cylinder head di-
Tensioner Tool (3299)

Fig. 2: Locating TDC Mark On Flywheel/Flexplate
95B59106
Fig. 1: Removing Serpentine Belt
574 VOLKSWAGEN
*1.9L 4-Cylinder Turbo Diesel, 1993-98 (Cont.)
(2065A)

Fig. 4: Locking Camshaft With Setting Bar (2065A)
On models without semiautomatic timing belt tensioner,

apply tension to timing belt using Tension Pin Wrench
(Matra V159). See Fig. 6. Turn tensioner clockwise to ten-
sion belt. Install Tension Tool (VW210) set to 12 to 13. Mea-
sure tension midway between camshaft sprocket and in- Courtesy of Volkswagen United States, Inc.
jection pump sprocket. Tighten lock nut on timing belt Fig. 5: Locking Diesel Fuel Injection Pump Sprocket
tensioner to 33 ft. lbs. (45 N.m). (AHU & 1Z Engines; AAZ Engines Up To Sept. 1994)
On models with semiautomatic timing belt tensioner, in-
stall idler pulley and tighten center nut to 15 ft. lbs. (20 On models with semiautomatic tensioner, apply thumb
N.m). Using Tension Pin Wrench (Matra V159), turn pressure to timing belt. Notched and raised portions of
tensioner clockwise until notch aligns with raised portion timing belt tensioner must move apart. Release thumb pres-
of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft. sure on belt. Tensioner must back to its original position
lbs. (20 N.m). (raised and notched portions aligned). If not, replace
On all models, tighten camshaft sprocket bolt. See TORQUE tensioner.
SPECIFICATIONS. Remove setting bar from camshaft. On all models, install timing belt covers. Install vibration
Turn crankshaft 2 revolutions in normal direction of rota- damper and belt pulleys (if removed). Install accessory drive
tion. Recheck timing belt tension. belts. To prevent damage to serpentine belt, install in origi-
nal direction of rotation.
VOLKSWAGEN 575

Fig. 6: TensioningTiming Belt (AAZ Engines Up To Oct.
1994, Without Semi-Automatic Tensioner) Fig. 8: Locking Diesel Fuel Injection Pump Sprocket
(AHH Engine & AAZ Engines From Oct. 1994)
Lock injection pump in place using lock pin. See Figs. 5

and 8. Loosen injection pump sprocket mounting bolt(s).
Loosen timing belt tensioner. On Passat with 1Z engine,
remove water pump pulley and power steering pump pul-
ley.
On all models, remove crankshaft vibration damper. Re-
move the lower timing belt cover. See Fig. 3.
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):
Ensure TDC mark on flywheel and transmission mating
flange are still aligned. See Fig. 2.
Courtesy of Volkswagen United States, Inc. NOTE: Use spanner wrench to hold camshaft sprocket while loosening
Fig. 7: Adjusting Timing Belt Tension center bolt. Do not use camshaft setting bar to hold camshaft
(Semi-Automatic Timing Belt Tensioner) sprocket.
Install valve cover. On engine code AAZ, check fuel injection Loosen camshaft sprocket bolt about 1/2 turn. Insert pin
delivery. Consult service information for procedure. punch through hole in rear of timing belt cover until it con-
tacts rear of camshaft sprocket. LIGHTLY tap pin punch
CAUTION: Timing belt replacement for Passat (1Z engine) requires with hammer to loosen camshaft sprocket on camshaft
using factory scan tool VAG 1551/1552 to check injection pump taper.
start of delivery after timing belt is installed. With Camshaft Setting Bar (2065A) in place on rear of cam-
shaft and crankshaft at TDC, install timing belt on engine. If
Removal (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ reusing old belt, ensure belt is installed in original direc-
Engine, From Oct., 1994): tion of rotation.
On models with tensioner, install Tensioner Tool (3299) Install idler pulley and tighten center nut to 15 ft. lbs. (20
and rotate clockwise. Mark serpentine belt with arrow to N.m). Using Tension Pin Wrench (Matra V159), turn
indicate rotation direction, and remove belt. See Fig. 1. Re- tensioner clockwise until notch aligns with raised portion
move tensioner pulley. On models without serpentine belts, of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft.
remove accessory drive belts. lbs. (20 N.m).
On all models, remove upper timing belt cover. See Fig. 3. Tighten camshaft sprocket bolt. See TORQUE SPECIFICA-
Remove valve cover. TIONS. Tighten injection pump sprocket mounting bolt(s).
Rotate crankshaft so that No. 1 cylinder is at TDC of com- Remove setting bar from camshaft. Remove lock pin from
pression stroke. Flywheel TDC mark must be aligned to injection pump.
mark on transmission mating flange. Rotate crankshaft 2 revolutions in normal direction of rota-
Lock camshaft in place with Setting Bar (2065A) installed tion. Set No. 1 cylinder to TDC of compression stroke.
on rear of camshaft. See Fig. 4. Center setting bar by turn- On models with semiautomatic tensioner, apply thumb
ing camshaft so one side of setting bar contacts cylinder pressure to timing belt. Notched and raised portions of
head. Using feeler gauge, measure distance between other timing belt tensioner must move apart. Release thumb pres-
end of setting bar and cylinder head. sure on belt. Tensioner must back to its original position
Divide this feeler gauge dimension in half. Place a feeler (raised and notched portions aligned). If not, replace
gauge corresponding to half the bar-to-cylinder head di- tensioner.
mension between setting bar and one side of cylinder
head.
576 VOLKSWAGEN
On engine codes AHU and 1Z, ensure injection pump
sprocket can be locked using Lock Pin (2064). See Fig. 5.
On engine code AAZ, ensure injection pump sprocket can
be locked using Lock Pin (3359). See Fig. 8. If injection
pump cannot be locked using correct lock pin, loosen in-
jection pump sprocket mounting bolt(s), and turn sprocket
until lock pin can be inserted in place. Tighten mounting
bolt(s).
Install timing belt covers. Install vibration damper and belt
pulleys (if removed). Install valve cover. Install accessory
drive belts. To prevent damage to serpentine belt, install in
For Passat with 1Z engine, check injection pump start of
delivery. Consult service information for procedure using
VAG 1551/1552 factory scan tool.
CAUTION: Timing belt replacement for 1998 Passat (AHH engine)

requires using factory scan tool VAG 1551/1552 to check injection
pump start of delivery after timing belt is installed.
Removal (1998 Passat, w/AHH Engine):
Disconnect front turn signal light assembly wiring har-
nesses. Separate hood release lever from bumper cover.
beam.
Remove air intake duct from air cleaner housing. Remove
support bolts from lock carrier assembly. See Fig. 10. In-
stall Support Tool (3369) through lock carrier to body. Re-
move oil cooler from lock carrier assembly. Move lock car- Courtesy of Volkswagen United States, Inc.
rier forward on support tools. Fig. 9: Exploded View Of Bumper Assembly (1998 Passat)
Mark serpentine drive belt with arrow to indicate direction of
rotation. Rotate tensioner counterclockwise, and remove With Camshaft Setting Bar (2065A) in place on rear of cam-
serpentine drive belt. Remove upper timing belt cover. See shaft and crankshaft at TDC, install timing belt on engine. If
Fig. 2. reusing old belt, ensure belt is installed in original direc-
Lock camshaft in place with Setting Bar (2065A) installed tion of rotation.
on rear of camshaft. See Fig. 4. Center setting bar by turn- Install idler pulley and tighten center nut to 15 ft. lbs. (20
ing camshaft so one side of setting bar contacts cylinder N.m). Using Tension Pin Wrench (Matra V159), turn
head. Using feeler gauge, measure distance between other tensioner clockwise until notch aligns with raised portion
end of setting bar and cylinder head. of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft.
Divide this feeler gauge dimension in half. Place a feeler lbs. (20 N.m).
gauge corresponding to half the bar-to-cylinder head di- Tighten camshaft sprocket bolt. See TORQUE SPECIFICA-
mension between setting bar and one side of cylinder TIONS. Tighten injection pump sprocket mounting bolts.
head. Remove setting bar from camshaft. Remove lock pin from
Remove timing belt tensioner. Lock injection pump in place injection pump.
using lock pin. See Fig. 8. Loosen injection pump sprocket Rotate crankshaft 2 revolutions in normal direction of rota-
mounting bolts. tion. Set No. 1 cylinder to TDC of compression stroke.
Remove crankshaft vibration damper. Remove lower tim- Apply thumb pressure to timing belt. Notched and raised
ing belt cover. See Fig. 3. portions of timing belt tensioner must move apart. Release
If reusing old timing belt, mark belt with arrow to indication thumb pressure on belt. Tensioner must back to its origi-
original direction of rotation. Move timing belt tensioner, nal position (raised and notched portions aligned). If not,
and remove timing belt. replace tensioner.
Installation (1998 Passat w/AHH Engine): Ensure injection pump sprocket can be locked using Lock
Ensure TDC mark on flywheel and transmission mating Pin (3359). See Fig. 8. If injection pump cannot be locked
flange are still aligned. See Fig. 2. using correct lock pin, loosen injection pump sprocket
mounting bolt(s), and turn sprocket until lock pin can be
NOTE: Use spanner wrench to hold camshaft sprocket while loosening inserted in place. Tighten mounting bolts.
center bolt. Do not use camshaft setting bar to hold camshaft Install timing belt covers. Install vibration damper. Install
sprocket. valve cover. To prevent damage to serpentine belt, install in
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.
VOLKSWAGEN 577

TORQUE SPECIFICATIONS (GOLF & JETTA)
Step 1 ........................................................................... 66 (90)
Injection Pump Sprocket Mounting Bolt
Center Mounting Bolt .................................................... 33 (45)
Three Mounting Bolts ................................................... 18 (25)
Intermediate Shaft Sprocket Bolt ................................... 33 (45)
Timing Belt Tensioner Pulley Lock Nut
With Semi-Automatic Tensioner ................................... 15 (20)
Without Semi-Automatic Tensioner .............................. 33 (45)
INCH. Lbs. (N.m)
Lower Timing Belt Cover Bolt ......................................... 89 (10)
Valve Cover Nut .............................................................. 89 (10)
1
ALWAYS replace if loosened or removed.
TORQUE SPECIFICATIONS (PASSAT)

Bumper Beam-To-Impact
Fig. 10: Exploded View Of Lock Carrier Assembly Absorber Bolt (1998) .................................................... 15 (20)
(1998 Passat) Camshaft Sprocket Bolt .............................................. 33 (45)
Step 1 ........................................................................... 66 (90)
Injection Pump Sprocket Mounting Bolts 1
Step 1 .......................................................................... 15 (20 )
Intermediate Shaft Sprocket Bolt ................................... 33 (45)
Timing Belt Tensioner Pulley Lock Nut ....................... 18 (25)
INCH. Lbs. (N.m)
Bumper Cover Bolt (1998) ................................................ 18 (2)
Lower Timing Belt Cover Bolt ......................................... 89 (10)
Valve Cover Nut .............................................................. 89 (10)
1
ALWAYS replace with new bolts if loosened or removed.
TECHNICAL SERVICE BULLETIN

TIMING BELT RUNS TOWARD OUTSIDE,
Fig. 11: Injection Pump Mounting Bracket
WEARS OUT, JUMPS OFF SPROCKET OR
(1994-97 Golf, Jetta & Passat w/AAZ & 1Z Engines) CRACKS
1994-97 Golf, Jetta & Passat (AAZ & 1Z Engines):
Place lock carrier in original position on body. Install front If this condition exists, replace timing belt and semiauto-
bumper assembly. matic tensioner (part No. 028 109 243F).
Check injection pump start of delivery. Consult service in- BEFORE installing new timing belt, clean all timing belt
formation for procedure using VAG 1551/1552 factory scan sprockets. Install new belt. Before installing vibration
tool. damper, start and run engine at idle for a few seconds.
Turn off engine
Belt must not protrude past edge of crankshaft sprocket. If
it does, remove diesel injection pump. Loosen 3 injection
pump bracket mount bolts. Tighten bolts to 18 ft. lbs. (25
N.m) while pressing mount down at A and lifting mount at
B. See Fig. 11.
Start and run engine at idle for a few seconds. Turn off
engine. Belt must not protrude past edge of crankshaft
sprocket.
NOTE: This information is from Volkswagen technical service

bulletin Group 15, No. 97-01; June 4, 1997.
578 VOLKSWAGEN
*1.9L 4-Cylinder Turbo Diesel, 1998-01
TIMING BELT APPLICATION NOTE: The 3 diesel injection pump bolts are torque-to-yield type.
Application Labor Time Belt Part No. Manufacturer recommends replacing bolts during final assembly.
1.8L 4-Cylinder Turbo Diesel Loosen, but do not remove, the 3 diesel injection pump
Beetle (Engine Code ALH) 1 sprocket mounting bolts. Manufacturer recommends re-
1998-01 ................. 4.0 Hours ..................... T301 placing these torque-to-yield bolts during final assembly.
Golf (Engine Code ALH) 1 Support engine weight from above or below with floor jack.
1999-01 ................. 2.7 Hours ..................... T301 NOTE: On Beetle models, engine mount bolts are torque-to-yield
Jetta (Engine Code ALH) 1 type. Manufacturer recommends replacing bolts if they are loosened
1999-01 ................. 2.7 Hours ..................... T301 or removed.
1
- Code is stamped on pad on engine block Remove engine mount from timing belt end of engine. Re-
between diesel injection pump and exhaust move 4 crankshaft pulley bolts and remove crankshaft pul-
manifold. Engine code is also included on ley (it is not necessary to remove center bolt). Remove tim-
vehicle data plate and timing belt cover. ing belt covers.
If reusing old timing belt, mark belt with arrow to indication
MANUFACTURERS SUGGESTED original direction of rotation. Loosen, but do not remove,
SCHEDULED MAINTENANCE timing belt tensioner nut, and remove timing belt.
The manufacturer suggests the belt AND tensioner be replaced CAUTION: DO NOT turn camshaft or crankshaft with drive belt
at 40,000 mile intervals for automatic transmission model, removed.
and 60,000 mile intervals on manual transmission models.
NOTE: Timing belt installation procedure requires using a factory
*NOTE: This application is an interference engine. scan tester (VAG 1551/1552) to adjust injection pump timing
Golf & Jetta:
REMOVAL & INSTALLATION Remove upper engine cover. Remove right sound damper
cover. Rotate serpentine belt tensioner clockwise to relieve
TIMING BELT REMOVAL belt tension, and remove serpentine belt. Remove serpen-
tine belt tensioner.
NOTE: Timing belt installation procedure requires using a factory
scan tester (VAG 1551/1552) to adjust injection pump timing.
Beetle:
Remove tube between charge air cooler and air intake pipe.
Disconnect and plug fuel supply and return lines at fuel
filter. Remove fuel filter from bracket.
Remove upper timing belt cover. Remove valve cover. Re-
move brake booster vacuum pump. Remove pipe between
charge air cooler and turbocharger.
Remove right side insulation tray. Rotate tensioner clock-
wise, and remove serpentine drive belt. If reusing serpen-
tine drive belt, mark belt with direction of rotation.
pression stroke. TDC mark can be viewed through access
hole in engine-to-transmission mating flange. See Fig. 1.
Lock camshaft in place with Camshaft Setting Bar (3418)
installed on rear of camshaft. See Fig. 2. Center setting bar
by turning camshaft so one side of setting bar contacts
cylinder head. Using feeler gauge, measure distance be-
tween other end of setting bar and cylinder head.
Divide this dimension in half. Place a feeler gauge corre-
sponding to half the bar-to-cylinder head dimension be-
tween setting bar and cylinder head. Turn camshaft until
setting bar contacts feeler gauge. Place second feeler
gauge of same dimension between other end of bar and
cylinder head.
Lock the injection pump in place using Lock Pin (3359).
See Fig. 3.
CAUTION: DO NOT loosen diesel injection pump center hub nut.

This will alter injection pump basic setting.
Fig. 1: Locating TDC Mark On Flywheel/Flexplate

VOLKSWAGEN 579

Lock camshaft in place with Camshaft Setting Bar (3418)
installed on rear of camshaft. See Fig. 2. Center setting bar
by turning camshaft so one side of setting bar contacts
cylinder head. Using feeler gauge, measure distance be-
tween other end of setting bar and cylinder head.
Divide this dimension in half. Place a feeler gauge corre-
sponding to half the bar-to-cylinder head dimension be-
tween setting bar and cylinder head. Turn camshaft until
setting bar contacts feeler gauge. Place second feeler
gauge of same dimension between other end of bar and
cylinder head.
Lock injection pump in place using Lock Pin (3359). See
Fig. 3.
CAUTION: DO NOT loosen diesel injection pump center hub nut.

Courtesy of Volkswagen United States, Inc. This will alter injection pump basic setting.
Fig. 2: Locking Camshaft With Setting Bar Loosen, but do not remove, the 3 diesel injection pump
sprocket mounting bolts. Support engine weight from above
or below with floor jack. Remove coolant reservoir bottle
and power steering reservoir (both with hoses attached)
and set aside.
Remove engine mount from timing belt end of engine. Re-
move 4 crankshaft pulley bolts and remove crankshaft pul-
ley (it is not necessary to remove center bolt). Remove
middle and lower timing belt covers. If reusing old timing
belt, mark belt with arrow to indicate original direction of
rotation. Move timing belt tensioner, and remove timing belt.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt

removed.

Beetle, Golf & Jetta:
Ensure cylinder No. 1 is at TDC. Check reference mark on
flywheel and bellhousing.
Fig. 3: Locking Diesel Fuel Injection Pump Sprocket NOTE: Use spanner wrench to hold camshaft sprocket while loosening
center bolt. DO NOT use camshaft setting bar to hold camshaft
sprocket.
Holding camshaft stationary, loosen camshaft sprocket bolt
1/2 turn. Place drift punch through rear timing belt cover
and LIGHTLY tap camshaft sprocket loose from tapered
end of camshaft. Gear puller may also be used to remove
sprocket. Remove camshaft sprocket.
Fig. 4: Adjusting Timing Belt Tension (Beetle, Golf & Jetta

With Manual Transaxle)
Remove brake booster vacuum pump. Remove upper tim-
ing belt cover. Remove engine valve cover. Remove tube
between charge air cooler and intake manifold.
pression stroke. TDC mark can be viewed through access Courtesy of Volkswagen United States, Inc.
hole in engine-to-transmission mating flange. See Fig. 1.
Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta
With Automatic Transaxle)
580 VOLKSWAGEN
Install timing belt onto crankshaft sprocket, idler pulley, water
pump, injection pump sprocket, and tensioner pulley. If in-
stalling old belt, note direction of rotation mark.
Install camshaft sprocket together with timing belt. Install
camshaft sprocket bolt finger tight. Camshaft sprocket
should still be free to turn.
On Golf and Jetta with manual transaxle and Beetle, install
Tension Pin Wrench (MATRA V159) on timing belt tensioner
pulley. See Fig. 4. Turn wrench clockwise until notch and
raised mark are aligned. Tighten tensioner pulley center
nut.
On Golf and Jetta with automatic transaxle, turn timing belt
tensioner clockwise until notch and pointer align. See Fig.
5. If tensioner is turned too far and correct tension is ex- Courtesy of Volkswagen United States, Inc.
ceeded, tension must be fully released, and then read-
justed. Tighten center lock nut on tensioner pulley.
On all models, ensure tensioner is correctly installed in TORQUE SPECIFICATIONS (BEETLE)
rear timing belt cover. See Fig. 6. Ensure TDC marks on
flywheel are still aligned. Tighten camshaft sprocket center Application Ft. Lbs. (N.m)
bolt to specification. See TORQUE SPECIFICATIONS. Camshaft Sprocket Bolt .............................................. 33 (45)
NOTE: Timing belt installation procedure requires using a factory Diesel Injection Pump Sprocket 1
scan tester (VAG 1551/1552) to adjust injection pump timing. Bolts .................................................... 15 (20 ) + 90 Degrees
Engine Mount Bracket-to-Engine
Install NEW torque-to-yield mounting bolts in diesel injec- Bolt ...................................................... 1 30 (40) + 90 Degrees
tion pump sprocket. Tighten injection pump bolts to 15 ft. Engine Mount-To-Bracket
lbs. (20 N.m). Before final tightening injection pump mount- Bolt ...................................................... 1 44 (60) + 90 Degrees
ing bolts, perform start of injection procedure (dynamic tim- Idler Pulley Bolt ........................................................... 15 (20)
ing) using factory scan tester (VAG 1551/1552). Final tighten Timing Belt Tensioner Pulley Nut ............................... 15 (20)
injection pump sprocket mounting bolts about 90 degrees. Water Pump Bolts ...................................................... 11 (15)
If not already done, remove camshaft setting bar from rear INCH. Lbs. (N.m)
of camshaft. Remove lock pin from injection pump. Timing Belt Cover Bolt .................................................... 89 (10)
Rotate crankshaft 2 complete revolutions. Place crankshaft Valve Cover Nut .............................................................. 89 (10)
at TDC and ensure belt timing is correct. Ensure timing
belt tensioner pulley marks are still aligned.
1
Replace with new torque-to-yield bolts on installation.
Install engine mount bracket to engine block. Install timing
belt covers. Install crankshaft pulley. TORQUE SPECIFICATIONS (GOLF & JETTA)
Tighten nuts and bolts to specification. See TORQUE
SPECIFICATIONS. Check fuel lines for leaks. Adjust drive
belts to proper tension. On Beetle models, check injection
Diesel Injection Pump Sprocket 1
pump start of delivery with scan tool.
Bolts .................................................... 15 (20 ) + 90 Degrees
Engine Mount Bracket-to-Engine Bolt ............................ 33 (45)
Idler Pulley Bolt ............................................................ 15 (20)
Serpentine Drive Belt Tensioner .................................... 18 (25)
Vacuum Pump Bolt ....................................................... 15 (20)
Water Pump Bolts ........................................................ 16 (22)
INCH. Lbs. (N.m)
Valve Cover Nut .............................................................. 89 (10)
1
Replace with new torque-to-yield bolts on installation.
VOLKSWAGEN 581
*2.0L 4-Cylinder ABA Engine

NOTE: Engine code (ABA) is stamped into machined pad on front
Install timing belt around crankshaft, intermediate shaft,
tensioner, and camshaft sprockets.
of cylinder block above crankcase breather, near cylinder head
mating surface.
Loosen timing belt tensioner center nut. Using spanner
wrench, rotate tensioner pulley clockwise to tension belt.
TIMING BELT APPLICATION Belt tension is correct when it is possible to rotate belt 90
degrees with thumb and forefinger, half-way between cam-
Application Labor Time Belt Part No. shaft and intermediate shaft sprockets. See Fig. 4.
2.0L 4-Cyl., ABA Engine
Cabrio
1995-01 ................. 1.9 Hours ..................... T262
Golf (Canadian)
1995 ...................... 1.9 Hours ..................... T262
Golf
1993-99 ................. 1.9 Hours ..................... T262
GTI (Canadian)
1993-95 ................. 1.9 Hours ..................... T262
GTI
1996-99 ................. 1.9 Hours ..................... T262
Jetta
1993-99 ................. 1.9 Hours ..................... T262
Passat
1993-96 ................. 1.9 Hours ..................... T262
SCHEDULED MAINTENANCE Fig. 1: Removing Timing Belt


TIMING BELT
Removal:
Remove accessory drive belts. Remove accessory drive
belt tensioner bracket. See Fig. 1.
Remove crankshaft pulley bolts and pulley (it is NOT nec-
essary to remove center bolt).
Remove water pump pulley. Remove upper and lower tim-
ing belt covers.
NOTE: DO NOT turn crankshaft with belt removed. Valve damage

may result.
If reusing timing belt, mark belt with arrow to indicate origi-
nal direction of rotation.
CAUTION: To prevent valves from contacting piston, DO NOT

rotate camshaft or crankshaft with timing belt removed.
Place crankshaft at TDC by aligning flywheel (M/T) or drive
plate (A/T) TDC marks. See Fig. 2. Ensure camshaft timing
Fig. 2: Aligning Crankshaft & Distributor Timing Marks
mark is aligned with mark on belt guard. See Fig. 3. Loosen
belt tensioner. Remove timing belt.
Installation:
Ensure crankshaft is still at TDC position. See Fig. 2. Re-
move distributor cap. Rotate intermediate shaft counter-
clockwise until rotor is pointed at No. 1 cylinder mark. See
Fig. 2. Ensure camshaft timing mark is still aligned with
mark on belt guard. See Fig. 3.
582 VOLKSWAGEN
*2.0L 4-Cylinder ABA Engine (Cont.)
While holding tensioner pulley stationary, tighten tensioner
pulley center nut to specification. Rotate crankshaft 2 revo-
lutions and recheck check belt tension. Adjust tension as
necessary. Recheck all timing marks again.
Install timing belt covers. Install drive belt tensioner bracket.
tension ranges.
Crankshaft Pulley Bolt ................................................. 18 (25)
Crankshaft Sprocket
Center Bolt .......................................... 1 66 (90) + 90 Degrees
Drive Belt Tensioner Bracket Bolt .................................. 15 (20)
Fig. 3: Aligning Camshaft Timing Marks Intermediate Shaft Sprocket Bolt ................................. 59 (80)
INCH Lbs. (N.m)
Valve Cover Retaining Nut .......................................... 89 (10)
1
- Replace torque-to-yield bolt on installation.

VOLKSWAGEN 583
*2.0L 4-Cylinder AEG Engine

NOTE: Engine code (AEG) is stamped into machined pad on front
On all models, remove engine mount from timing belt end
of engine. Remove crankshaft pulley from crankshaft
of cylinder block above crankcase breather, near cylinder head
sprocket. It is NOT necessary to remove center bolt (center
mating surface.
bolt is torque-to-yield type that must be replaced if removed).
TIMING BELT APPLICATION Remove timing belt covers. Remove engine support from
front of engine. See Fig. 1.
2.0L 4-Cyl., AEG Engine CAUTION: To prevent valves from contacting piston, DO NOT
rotate camshaft or crankshaft with timing belt removed.
Beetle
1998-01 ................. 2.7 Hours ..................... T296 If reusing old belt, mark belt with arrow to indicate original
Cabrio direction of rotation. Rotate timing belt tensioner away from
belt and remove timing belt.
1999 ..................... 1 1.9 Hours .................... T296 Installation:
Golf Ensure crankshaft and camshaft timing marks are still
1999 ..................... 1 1.9 Hours .................... T296 aligned. See Figs. 2 and 3.
1999-00 ................ 2 3.1 Hours .................... T296 Install timing belt around crankshaft and water pump
GTI sprockets. Install engine support on front of engine block.
1999 ..................... 1 1.9 Hours .................... T296 Tighten mounting bolts to specification. See TORQUE
Jetta SPECIFICATIONS.
1999 ................... 1 1.9 Hours .................... T296 Install timing belt lower and center covers. Install crank-
shaft pulley and tighten bolts to specification. Install en-
1999-00 ................ 2 3.1 Hours .................... T296 gine mount-to-body and engine support. Remove floor jack
1
Early 1999 model. 8th character of VIN is H. or engine support bar from engine.
2
Late 1999 model. 8th character of VIN is M Install timing belt on camshaft sprocket and timing belt
tensioner. Make sure there is no slack in timing belt.
for Cabrio and Jetta; 8th character of VIN To tension timing belt, engine must be at most warm to the
is J for Golf. touch. Rotate tensioner pulley counterclockwise until
tensioner arrow is aligned with cut-out on cylinder head.
MANUFACTURERS SUGGESTED See Fig. 4.
mile intervals.
For 2001 model year, the manufacturer recommends the belt


TIMING BELT
Removal:
Remove right hand insulation tray from engine compart-
ment. Remove engine cover. Rotate serpentine belt
tensioner clockwise to relieve belt tension. Remove ser-
pentine belt.
Remove serpentine belt tensioner assembly. See Fig. 1.
Turn crankshaft to TDC position. See Fig. 2. On Golf and
Jetta, align TDC marks visible in bellhousing access hole.
See Fig. 3. On all models, remove upper timing belt cover.
Ensure camshaft sprocket timing mark aligns with mark
on rear cover. See Fig. 2. Courtesy of Volkswagen United States, Inc.
Support engine from above or below with floor jack to take Fig. 1: Exploded View Of Timing Belt Components
engine weight off of mounts. Remove coolant reservoir and
set aside. On Golf and Jetta, remove power steering reser-
voir (hoses attached), and set aside. On Beetle, pull off
EVAP hoses at EVAP canister and throttle valve housing.
584 VOLKSWAGEN
*2.0L 4-Cylinder AEG Engine (Cont.)
Tighten tensioner pulley center nut to specification. Rotate
crankshaft 2 revolutions in normal direction of rotation, and
recheck check belt tension. Adjust tension as necessary.
Recheck all timing marks again.
Install upper timing belt cover. Install serpentine belt
tensioner. Install engine mount. To complete installation,
reverse removal procedure.
Beetle ........................................................................... 18 (25)
Golf & Jetta .................................................................. 30 (40)
Crankshaft Sprocket
Center Bolt .......................................... 1 66 (90) + 90 Degrees
Engine Support-To-Engine Block .................................. 33 (45)
Serpentine Belt Tensioner Bolt .................................... 15 (20)
Water Pump Bolt ........................................................ 11 (15)
INCH Lbs. (N.m)
Valve Cover Retaining Nut .......................................... 89 (10)
1
- Replace torque-to-yield bolt on installation.


Fig. 3: Locating TDC Mark On Transaxle (Golf & Jetta)

VOLKSWAGEN 585
*2.8L V6
2.8L V6, 30-Valve
Passat
1998-01 ................. 3.1 Hours ..................... T297
mile intervals for 1998 models, and 75,000 mile intervals for
1999 models.
On 2000-01 models, replace timing belt and belt tensioner at
105,000 miles.


TIMING BELT
NOTE: Obtain radio anti-theft code before disconnecting battery.
Removal:
Disconnect negative battery cable. Remove engine top cover.
Remove noise insulation panel from under front of vehicle.
Hold cooling fan pulley with spanner wrench. Unscrew and
remove viscous cooling fan clutch from pulley. Viscous cool-
ing fan is LEFT-HAND threaded.
Use a 17 mm box wrench to turn serpentine belt tensioner
counterclockwise. Relieve belt tension and remove ser-
pentine belt. If reusing belt, mark belt rotation direction with
arrow for reassembly reference.
Unclip timing belt guard on front of both camshafts and
remove. Turn crankshaft in normal direction of rotation until
TDC marks on crankshaft pulley and timing belt cover are
Note securing plate on front end of each camshaft sprocket.
If large hole in each plate does not face inward, toward
center of engine, rotate crankshaft one revolution. See Fig.
2. Ensure crankshaft timing marks are still aligned.
Remove sealing plug from left side of engine block. TDC
mark on crankshaft must be visible or be felt through seal-
ing hole. Install Crankshaft Holding Tool (Audi 3242) into
sealing plug hole. See Fig. 3.
Remove serpentine belt tensioner. Remove center and left
timing belt covers.
Using an 8 mm hex wrench, SLOWLY turn timing belt
tensioner pulley clockwise to compress timing belt
tensioner. See Fig. 4. Compress timing belt tensioner just
enough so a 2 mm pin can be inserted through the holes in
top of tensioner body and push rod. This will hold the
tensioner in the compressed position.
CAUTION: If reusing old timing belt, mark an arrow indicating Courtesy of Audi of America, Inc.
direction of rotation on accessory drive belt or timing belt. Damage Fig. 2: Locating Camshaft Sprocket Holes
Remove crankshaft vibration damper from crankshaft. It is
NOT necessary to remove center bolt. If center bolt is re-
moved, manufacturer recommends using NEW bolt on re-
assembly. Remove serpentine belt idler pulley.
Remove lower timing belt guard (if equipped). Remove tim-
ing belt.
586 VOLKSWAGEN
*2.8L V6 (Cont.)
Installation:
Install Camshaft Locator Bar (3391) into locking plates of
camshafts. See Fig. 5. Loosen camshaft sprocket bolts
about 5 turns. Remove locator bar.
Leaving camshaft sprocket bolts in place, use gear puller
to loosen camshaft sprockets on camshaft taper.
NOTE: Camshaft sprockets must be loose enough to ro-
tate on camshaft, but not loose enough to tilt.
Ensure all timing marks are still aligned. Install timing belt
on engine. Ensure belt routing is correct and there is no
slack in belt. See Fig. 6. Install Camshaft Locator Bar (3391)
into locking plates of camshafts.
Using an 8 mm hex wrench, SLOWLY compress timing
belt tensioner so that 2 mm pin can be removed from
tensioner.
Using 8 mm hex socket, place torque wrench on timing belt
tensioner pulley. Apply 11 ft. lbs. (15 N.m) to tensioner in
direction of tension (clockwise). This will pre-load belt ten-
sion.
Tighten camshaft sprocket bolts to specification. Remove
camshaft locator bar. Remove crankshaft holder. Install
sealing plug.
Fig. 3: Installing Crankshaft Holding Tool Install timing belt cover. Install crankshaft pulley. Install ser-
pentine drive belt
To complete installation, reverse removal procedure. When
installing crankshaft pulley, ensure notches in pulley are
aligned with locating lugs in crankshaft.
Crankshaft Pulley
Center Bolt ................................... 1 148 (200) + 180 Degrees
Crankshaft Pulley-To-Crankshaft Hex Bolt .................... 18 (25)
Lock Carrier-To-Body Bolts ........................................... 37 (50)
INCH Lbs. (N.m)
Timing Belt Tensioner Bolt/Nut ................................... 89 (10)
Water Pump Bolt ......................................................... 89 (10)
1
If removed, manufacturer recommends using NEW bolt.

VOLVO 587
*1.9L 4-Cylinder Turbo

1.9L 4-Cyl. Turbo
S40 & V40
2000-01
Up To Engine VIN
1219110 ............ 1 2.4 Hours .................... T252
From Engine VIN
1219111 ............ 1 2.4 Hours .................... T311
1
timing belt and belt tensioner be replaced every 105,000 miles.
Courtesy of Volvo Cars of North America
*NOTE: This application is an interference engine. Fig. 2: Removing Timing Gear Covers

TIMING BELT
CAUTION: DO NOT turn crankshaft or camshafts while belt is
removed.
Removal:
Remove right engine compartment cover and cover above
right headlight unit. Release serpentine drive belt by turn-
ing tensioner clockwise. Remove serpentine drive belt. See
Fig. 1.
Remove two screws securing upper timing belt covers.
Remove upper cover by releasing the two clips then re-
move the screw and the cover. See Fig. 2.
Use an appropriate engine lifting tool to support the weight
of the engine at timing belt end of engine.
Remove engine mount bolts and nuts on timing end of Courtesy of Volvo Cars of North America
engine. Remove engine mount. See Figs. 3 and 7. Fig. 3: Locating Engine Mount (2000)

Fig. 4: Removing Lower Timing Gear Cover
Fig. 1: Removing Accessory Drive Belt
588 VOLVO
*1.9L 4-Cylinder Turbo (Cont.)
Courtesy of Volvo Cars of North America Courtesy of Volvo Cars of North America
Fig. 5: Locating Engine Bracket Bolts Fig. 7: Locating Engine Mount (2001)

Fig. 6: Locating Upper Rear Timing Belt Cover
VOLVO 589

Fig. 8: Locating Snow Cap & Bolts

Fig. 10: Installing New Timing Belt
Loosen timing belt tensioner pulley bolt. See Fig. 11. Hold-
ing tensioner pulley bolt stationary, rotate pulley eccentric
clockwise with a 6 mm Allen wrench. Remove timing belt
from tensioner pulley, camshaft sprockets and water pump.
Remove splashguards from under engine compartment.
Remove bolts and snow cap. See Fig. 8. Remove timing
belt with a turning motion. Remove timing belt tensioner.
Inspection:
Spin tensioner and idler pulleys and listen for bearing noise.
Ensure pulley surfaces in contact with belt are clean and
smooth.
Installation:
Place timing belt between vibration damper and engine
block, and route belt upwards. Reinstall the lower snow
cap and replace the bolts. Install splashguards under en-
gine compartment.
aligned. Position new timing belt tensioner, and finger
tighten bolt A. See Fig. 9. Turn eccentric from tensioner in
Fig. 9: Installing New Tensioner
lowest position.
Remove lower timing gear cover by releasing the bottom Install timing belt in correct sequence. See Fig. 10. Install
cover and moving it backwards. See Fig. 4. On 2000 mod- upper rear timing cover on engine (do not tighten).
els, engine bracket may have to be removed for clearance
NOTE: Timing belt tension MUST be adjusted when the engine
to remove belt. See Fig. 5.
is cold. Around 68F (20C) is the best temperature.
On all models, remove right front wheel. Turn crankshaft
clockwise until camshaft sprocket timing marks align with,
inner timing gear cover, and crankshaft sprocket aligns with
the oil pump housing. See Fig. 6.
590 VOLVO
With timing belt installed, turn crankshaft clockwise until
timing belt is tensioned. Belt must be tensioned between
intake camshaft sprocket, idler pulley and crankshaft.
Holding tensioner bolt stationary, use a 6 mm hex wrench
to turn tensioner counterclockwise until tensioner indicator
passes marked position. See Fig. 11.
Turn tensioner eccentric back so that indicators position is
in center of window. See Fig. 11. Holding eccentric in this
position, tighten bolt B to 15 ft. lbs (20 N.m) without mov-
ing tensioner. See Fig. 11.
Recheck adjustment by pressing pin A clockwise and coun-
terclockwise to check. Rotate crankshaft two complete revo-
lutions and check that markings on crankshaft pulley and
timing gears align with marks on timing gear cover. Ensure
indicator pin A is in middle. Readjust if necessary. See
Fig. 12. After readjustment, always turn crankshaft 2 com-
plete revolutions to check if tensioner indicator returns to
correct position.
NOTE: Timing belt tensioner indicator will be in different positions

depending on engine temperature. At very low or high temperatures,
tensioner indicator will be to the left or right of center. See Fig.
13.

VOLVO 591

Install engine bracket (if removed), timing belt covers, and
snow cap.
NOTE: Close lid in side cover and move wheels straight.

Install serpentine drive belt. Reinstall engine mount and
body support. Install power steering hose. Install right front
wheel. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS.
Engine Bracket-To-Engine Block Bolt Fig. 13: Timing Belt Tension Positions
Step 1 ........................................................................... 26 (35)
Step 2 ..................................................... Plus 75 Degree Turn
Engine Mount (2000)
To-Body Through-Bolt .................................................. 72 (98)
To-Engine Bolt ............................................................. 50 (67)
Engine Mount (2001)
To-Body Nut ................................................................. 37 (50)
To-Engine Bolt ............................................................. 50 (67)
Water Pump Bolt ............................................................ 13 (17)
Wheel Lug Nut ............................................................. 81 (110)
INCH. Lbs. (N.m)
Power Steering Hose Bolt .............................................. 89 (10)
Snow Cap Bolt ............................................................ 89 (10)
Timing Belt Cover
Front ........................................................................... 106 (12)
Upper ........................................................................... 89 (10)
592 VOLVO
*2.1L & *2.3L 4-Cylinder B21 & B23
Belt TIMING BELT REMOVAL
Application Time 1 Kit No. No. Disconnect negative battery cable. Remove fan shroud and
2.1L 4-Cyl. B21 accessory drive belts. Remove timing belt cover. Rotate crank-
242, 244 & 245 shaft until timing marks are aligned. See Fig. 1. Loosen belt
1976-79 .......... 1.3 Hrs. ...... TCK032 .......... T032 tensioner and pull belt outward until tensioner spring is com-
DL, GL, GLT pressed. Tighten tensioner nut. Remove timing belt.
Installation:
1980-83 .......... 1.3 Hrs. ...... TCK032 .......... T032 Ensure that timing marks are still aligned. See Fig. 1. In-
DL (Canadian) stall belt around crankshaft and intermediate shaft so that
1983 ............... 1.3 Hrs. ...... TCK032 .......... T032 lines on belt are aligned with timing mark on crankshaft.
GLT Install belt over camshaft pulley and tensioner roller. Loosen
1981-83 .......... 1.3 Hrs. ...... TCK032 .......... T032 tensioner nut to release spring tension. Tighten tensioner
Turbo nut.
1984-85 .......... 1.3 Hrs. ...... TCK032 .......... T032 To complete installation, reverse removal procedure. Ad-
2.3L 4-Cyl. B23 tension ranges.
DL & GL
1982-85 .......... 2.0 Hrs. ...... TCK032 .......... T032
GLE (Canadian) Application Ft. Lbs. (N.m)
1984 ............... 2.0 Hrs. ...... TCK032 .......... T032 Camshaft Sprocket ..................................................... 37 (50)
Crankshaft Sprocket ................................................. 22 (166)
GLT (Canadian) Drive Belt Tensioner Nut ............................................. 37 (50)
1983 ............... 2.0 Hrs. ...... TCK032 .......... T032 Fan Bolt ...................................................................... 33 (45)
760 GLE Intermediate Shaft Sprocket ....................................... 37 (50)
1984 ............... 2.2 Hrs. ...... TCK032 .......... T032
1

kits.
On 1976-85 engines, the manufacturer recommends the belt
Fig. 1: Timing Marks For Crankshaft, Intermediate Shaft &
be replaced every 40,000 miles.
Camshaft
On 1986-88 engines, the manufacturer recommends the belt
be replaced every 50,000 miles.

VOLVO 593
*2.3L 4-Cylinder B230, B230F, B230FT

TIMING BELT APPLICATION reference.
Belt
Place mark on timing belt to indicate direction of belt rota-
Labor Component Part tion. Loosen belt tensioner nut one turn. Pull on timing belt
to compress belt tensioner spring. Tighten belt tensioner
Application Time1 Kit No. No. nut.
2.3L 4-Cyl. SOHC Install a 3 mm drill bit through hole of belt tensioner bolt to
Coupe lock belt tensioner spring in place. Remove timing belt from
1991 ............... 2.0 Hrs. ...... TCK032 .......... T032 camshaft sprocket.
240 Series Inspection:
1986-92 .......... 2.0 Hrs. ...... TCK032 .......... T032 Check belt teeth for cracks, damage or oil contamination.
1993 ............... 2.0 Hrs. ................................ T234 Inspect all sprockets for damage. Check belt tensioner for
roughness in rotation. Replace components if damaged.
740 Series Installation:
1986-92 .......... 2.2 Hrs. ...... TCK032 .......... T032 Install belt tensioner if previously removed. Ensure all tim-
760 Series ing marks align. See Fig. 1.
1985-90 .......... 2.2 Hrs. ...... TCK032 .......... T032 Outer side of timing belt has 2 lines, which should fit to-
780 Series ward crankshaft marks. Install belt over crankshaft sprocket
1989-90 .......... 2.2 Hrs. ...... TCK032 .......... T032 first, then over intermediate shaft. Stretch belt on tension
side and fit over camshaft sprocket. Slide back of belt onto
940 Series belt tensioner.
1991-92 .......... 2.2 Hrs. ...... TCK032 .......... T032 Loosen bolt on belt tensioner to apply spring tension
1993-95 .......... 2.2 Hrs. ................................ T234 against drive belt. Tighten belt tensioner nut. Ensure tim-
1
- With Air Cond. add .5 hours. ing marks align. To install remaining components, reverse
removal procedure.
NOTE: A timing belt component kit is available for CAUTION: Readjust timing belt when engine reaches normal operating
temperature.
kits.
Warm engine to normal operating temperature. Remove
plug from front timing belt cover. Loosen belt tensioner bolt
one turn and allow for belt tensioner spring to apply pres-
MANUFACTURERS SUGGESTED sure on timing belt. This readjusts timing belt to allow for
SCHEDULED MAINTENANCE belt stretch. Tighten belt tensioner nut. Install rubber plug.
The manufacturer recommends the belt be replaced every Adjust drive belts to proper tension. See page A-60 for belt
50,000 miles, except for 1994 and later B230FT engines with tension ranges.
EGR. On these engines, the manufacturer recommends the TORQUE SPECIFICATIONS
timing belt be replaced at 100,000 mile intervals.
* NOTE: This application is an interference en- Camshaft Sprocket Bolt .............................................. 37 (50)
gine. See page A-59 for interference engine cau- Step 1 ....................................................................... 44 (60)
tions. Step 2 ............................................... Additional 60 degrees
REMOVAL & INSTALLATION 1
- Apply light coat of oil to bolts before installation.
TIMING BELT REMOVAL
CAUTION: Ensure timing marks align before removing timing
belt. DO NOT rotate crankshaft or camshaft with timing belt removed,
or valves may contact pistons.
Removal:
Disconnect negative battery cable. Loosen adjusters and
remove all drive belts and water pump pulley. Remove fan,
preheater hose (below fan shroud) and fan shroud.
Using center bolt on crankshaft, rotate crankshaft so mark
on camshaft pulley aligns with timing mark on inner timing
belt cover, and crankshaft pulley mark aligns with TDC mark
on timing belt cover.
Remove nut and washer from belt tensioner. Install Crank-
shaft Holder (5284) or equivalent, on crankshaft pulley and
belt tensioner stud. Install nut on stud. Remove crankshaft
center bolt, crankshaft pulley and lower timing belt cover.
Ensure timing marks are aligned. See Fig. 1.
NOTE: If reusing timing belt, mark direction of rotation for installation

594 VOLVO
*2.3L 4-Cylinder B234
TIMING BELT APPLICATION Install balance shaft belt around left (upper) balance shaft
with marking C opposite marking on pulley. See Fig. 4.
Belt Part No. Install balance shaft belt on right (lower) balance shaft with
2.3L 4-Cyl. B234 marking A opposite marking on pulley. Install balance shaft
740 Series (Canadian) belt around tensioner. Ensure that markings are still
1986-88 aligned.
Balance Shaft ........... 2 ............................ T174 Tighten balance shaft belt tensioner, using an Allen key
inserted in adjusting hole in tensioner. See Fig. 5. Carefully
Camshaft ............ 2.5 Hours ..................... T173 rotate crankshaft a few degrees on either side of TDC posi-
1989 (With Automatic Tensioner) tion to ensure that balance shaft belt engages properly in
Balance Shaft ........... 2 ............................ T174 pulleys. Return crankshaft to TDC position.
Camshaft ............ 2.5 Hours ..................... T198 Ensure that adjusting hole in balance shaft belt tensioner
1989 (With Manual Tensioner) is below 3 oclock position when tightening locking bolt.
Balance Shaft ........... 2 ............................ T174 Torque locking bolt to 29.5 ft. Ibs. (40.5 N.m), using an Allen
Camshaft ............ 2.5 Hours ..................... T173 key inserted in adjusting hole as counter hold. See Fig. 5.
Check balance shaft belt tension using Volvo Gauge Tool
1990 (No. 998 8500) or equivalent.
Balance Shaft ........... 2 ............................ T174 Position gauge above idler. See Fig. 7. Balance shaft belt
Camshaft ............ 2.5 Hours ..................... T173 tension should be within 1 to 4 unit range. Align double line
940 Series (Canadian) marking on camshaft timing belt with top marking on belt
1991-92 guide plate. See Fig. 6. Ensure that single line markings
Balance Shaft ........... 2 ............................ T174 align with pulley markings.
Camshaft ............ 2.5 Hours ..................... T198 Place camshaft timing belt around oil pump drive pulley,
then install belt onto left hand idler. Ensure that timing marks
1
- With Air Cond. add .5 hours. are aligned properly and No. 1 cylinder is at TDC position.
2
Balance shaft labor included in camshaft. Rotate crankshaft clockwise until pulley markings align with
those on transmission mounting plate. See Fig. 8.
MANUFACTURERS SUGGESTED Rotate crankshaft clockwise until pulley markings are 1 1/2
SCHEDULED MAINTENANCE teeth past markings on housing. Tighten camshaft timing
belt tensioner lock nut. Start engine and allow to reach nor-
The manufacturer recommends the belt be replaced every mal operating temperature, then shut engine off.
50,000 miles. To check balance timing belt tension, start engine and al-
low to reach normal operating temperatures. Turn engine
* NOTE: This application is an interference engine. off. Position gauge above location of dismantled idler. Belt
See page A-59 for interference engine cautions. tension should be within 4.7 to 5.1 unit range.
If belt tension is low, rotate tensioner slightly clockwise,
REMOVAL & INSTALLATION then rotate crankshaft clockwise one revolution. Belt ten-
sion should be within 4.7 to 5.1 unit range. If belt tension is
TIMING BELT high, repeat procedure. Install idler pulley and timing cov-
ers.
CAUTION: Ensure timing marks align before removing timing To check timing belt tension, rotate crankshaft until No.1
belt. DO NOT rotate crankshaft or camshaft with timing belt removed, cylinder is at TDC position, then position Volvo Belt Gauge
as it is possible valves may contact pistons. Tool (No. 998 8500) or equivalent, between exhaust cam-
shaft pulley and idler. Belt tension should be within 5.3 to
Removal: 5.7 unit range. See Fig. 9. Torque tensioner lock nut to 37 ft.
Disconnect negative battery cable. Remove radiator fan and Ibs. (51 N.m). Replace protective cap in measuring zone.
pulley. Remove fan shroud and servo pump. Remove A/C See Fig. 10.
compressor drive belts, if equipped. Remove timing cover Torque tensioner lock nut to 37 ft. lbs. (51 N.m). Replace
attaching bolts, then all three covers starting with top cover. protective cap. If belt tension reading is outside above range,
Rotate crankshaft until No. 1 cylinder is at TDC position. remove protective cap, then loosen tensioner locknut. Po-
Check that marks on camshaft pulleys align with those on sition Volvo Gauge (998 8500) or equivalent in measuring
transmission mounting plate. Marking on belt guide plate zone. See Fig. 10. If belt tension is low, move roller to adjust
on crankshaft should be opposite TDC marking on cylinder belt tension to 5.8 to 6.2 units.
block. See Fig. 1. If belt tension is high, adjust to obtain a reading of 4.8 to 5.2
Loosen tensioner lock nut, then compress tensioner spring. units. Torque tensioner lock nut to 37 ft. Ibs. (51 N.m), and
Tighten tensioner lock nut and remove camshaft timing rotate crankshaft clockwise. Measure belt tension. Belt ten-
belt. sion should be 5.3 to 5.7 unit range.
Do not turn crankshaft and camshafts while timing belt is Torque tensioner lock nut to 37 ft. Ibs. (51 N.m). Remove
removed. Remove balance shaft belt idler pulley. Loosen protective cap, then loosen tensioner. To complete instal-
locknut and remove balance shaft belt. See Fig. 2. lation, reverse procedure. Adjust drive belts to proper ten-
Installation: sion. See page A-60 for belt tension ranges.
Check that balance shaft marking aligns with markings on TORQUE SPECIFICATIONS
transmission mounting plate. See Fig. 3. Ensure that crank-
shaft marking is opposite TDC marking on cylinder head. Application Ft. Lbs. (N.m)
Install balance shaft belt under crankshaft pulley assem- Tensioner Locking Bolt ............................................ 29.5 (40)
bly. Ensure that blue dot (marking B) is opposite bottom Tensioner Lock Nut ................................................. 37.0 (49)
TDC marking on belt guide plate at bottom of crankshaft.
See Fig. 4.
VOLVO 595
*2.3L 4-Cylinder B234 (Cont.)
Fig. 1: Aligning Camshaft & Crankshaft Markings
Fig. 3: Aligning Balance Shaft & Crankshaft Markings
Fig. 4: Installing Balance Shaft Belt
Fig. 2: Removing Balance Shaft Belt

596 VOLVO
Fig. 7: Checking Balance Shaft Belt Tension
Fig. 5: Adjusting Tensioner
Fig. 8: Rotating Crankshaft

VOLVO 597
Fig. 9: Checking Belt Tension
Fig. 10: Adjusting Belt Tension

598 VOLVO
2.3L 5-Cyl. Turbo
C70, S70 & V70 CAUTION: DO NOT turn crankshaft or camshafts while belt is
1998-01, Up To Engine VIN removed.
1266127 ............. 1 2.4 Hours .................... T252 Removal:
1998-01, From Engine VIN Remove key from ignition switch. On S60 models, remove
1266128 ............. 1 2.4 Hours .................... T311 the cross brace between the front shock towers.
S60 On all models, remove upper timing belt cover. Remove
2001, Up To Engine VIN power steering pump reservoir with hoses attached and
1266127 ............. 1 2.0 Hours .................... T252 set aside. Remove coolant reservoir and set aside. Re-
move accessory drive belt.
2001, From Engine VIN Remove front timing belt cover. Raise and support vehicle.
1266128 ............. 1 2.0 Hours .................... T311 Remove right front wheel. Remove nut from fender liner
2.4L 5-Cyl. cover. Remove upper timing belt cover.
C70, S70 & V70 Turn crankshaft clockwise (as viewed from timing belt end
1998-01, Up To Engine VIN of engine) to align the timing marks on the crankshaft pul-
1266127 ............. 1 2.4 Hours .................... T252 ley and camshaft sprockets. See Fig. 1. Turn crankshaft an
additional 1/4 turn clockwise, and then back again until the
1998-01, From Engine VIN timing marks align.
1266128 ............. 1 2.4 Hours .................... T311 Loosen timing belt tensioner pulley center bolt. Holding
S60 center bolt, turn the tensioner eccentric clockwise with a 6
2001, Up To Engine VIN mm Allen wrench. Turn eccentric until the hole for the Allen
1266127 ............. 1 2.0 Hours .................... T252 wrench is at the 10 oclock position.
1998-01, From Engine VIN
CAUTION: Vibration damper pulley bolts are torque-to-yield
1266128 ............. 1 2.0 Hours .................... T311 type. If vibration damper pulley bolts are removed so that Counterhold
1
- With Air Cond. add .5 hours. (999 5433) or equivalent can be installed, pulley bolts MUST be
replaced.
MANUFACTURERS SUGGESTED Raise and support vehicle. Holding vibration damper sta-
SCHEDULED MAINTENANCE tionary with Counterhold (999 5433) or equivalent, remove
vibration damper center bolt. Remove vibration damper.
For 1998 model year, the manufacturer recommends the belt Lower vehicle. Remove timing belt.
be replaced every 70,000 miles. For 1999-01 model years, Inspection:
the manufacturer recommends the belt be replaced every Spin tensioner and idler pulleys and listen for bearing noise.
105,000 miles. In addition, manufacturer recommends replac- Ensure pulley surfaces in contact with belt are clean and
ing timing belt tensioner on 2001 C70. smooth.
Installation:
*NOTE: This application is an interference engine. If timing belt tensioner was remove, ensure tensioner fork
See page A-59 for interference engine cautions. is installed with fork centered over rib on engine block.

Fig. 1: Aligning Crankshaft & Camshaft Timing Marks Fig. 2: Timing Belt Routing
VOLVO 599

Holding the timing belt tensioner eccentric steady, tighten
the center bolt to 15 ft. lbs. (20 N.m). Ensure tensioner
needle is still in correct position. Press timing belt to see if
the indicator on the tensioner moves easily.
Turn crankshaft clockwise 2 turns. Align camshaft and crank-
shaft timing marks. Ensure the timing belt tensioner indi-
cator is within the correct area.
tion. Ensure camshaft and crankshaft sprocket timing
marks are still aligned. Ensure timing belt tensioner indi-
Courtesy of Volvo Cars of North America cator is in the correct position for engine temperature.
Install front and upper timing belt covers. Install accessory
drive belt. Install power steering reservoir. Check power
steering fluid level. Refill, if necessary.
Place timing belt around crankshaft pulley. Install vibration Install coolant reservoir. Install fender liner cover. Install
damper. Install vibration damper center bolt. Hold vibration front wheel. On S60 models, install shock tower brace.
damper stationary with Counterhold (999 5433) or equiva-
lent, and tighten center bolt to specification. See TORQUE TORQUE SPECIFICATIONS
SPECIFICATIONS. Install NEW vibration damper pulley bolts Application Ft. Lbs. (N.m)
(if removed). Shock Tower Brace (S60)
Place timing belt around idler pulley, intake camshaft pul- Engine Bracket Bolt .................................................... 37 (50)
ley, exhaust camshaft pulley, water pump and timing belt Shock Tower Bolt ....................................................... 59 (80)
tensioner. Timing Belt Idler Pulley Bolt ............................. 17-18 (24-25)
NOTE: Timing belt tension MUST be adjusted when the engine Vibration Damper Center Bolt .................................... 133 (180)
is cold. Around 68F (20C) is the best temperature.
Vibration Damper Pulley Bolts 1
Slowly turn crankshaft clockwise (as viewed from timing Step 1 ........................................................................... 18 (25)
belt end of engine) until the timing belt is tensioned. The Step 2 ........................................................... Plus 30 Degrees
belt should be tight between the intake camshaft sprocket, Water Pump Bolt ............................................................ 13 (17)
idler pulley and crankshaft sprocket. Wheel Lug Nut ........................................................... 100 (130)
Hold timing belt tensioner pulley bolt secure and turn INCH Lbs. (N.m)
tensioner eccentric counterclockwise until the tensioner Front Timing Belt Cover Bolt ..................................... 106 (12)
needle passes to the right of center position. See Fig. 3. Upper Timing Belt Cover Bolt ........................................... 71 (8)
Turn tensioner eccentric back until the needle reaches the 1
Always replace bolts if loosened or removed.
marked position corresponding to engine temperature. At
68F (20C), the needle must be centered in the window.
600 VOLVO
*2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder
TIMING BELT APPLICATION Remove right front wheel and release wheel arch liner to
gain access to vibration damper. Remove vibration damper
Application Labor Time Belt Part No. guard. Turn crankshaft clockwise until all timing marks are
2.3L 5-Cyl. Turbo aligned. See Fig. 1.
850 Remove tensioner upper mounting bolt and loosen
1994 ..................... 1 2.4 Hours .................. 2 T217 tensioner lower bolt. Twist tensioner to free pulley. Remove
1994 ..................... 1 2.4 Hours .................. 3 T252 lower bolt, tensioner, upper timing belt cover. If reusing old
timing belt, mark belt with arrow to indicate rotation direc-
1995-97 ................ 1 2.4 Hours ................... T252 tion. Remove timing belt.
850 (Canadian) Removal (6-Cylinder):
1996 ..................... 1 2.4 Hours .................... T252 Remove auxiliary drive belt, front transmission cover splash
2.4L 5-Cyl. guard under engine, vibration damper guard, and ignition
850 coil cover.
1993 ..................... 1 2.4 Hours .................. 2 T217 Turn crankshaft clockwise until timing marks on camshaft
1993 ................... 1 2.4 Hours .................. 3 T252 pulleys/transmission plate and crankshaft pulley/oil pump
housing are aligned. See Fig. 1. Remove upper transmis-
1994-97 ................ 1 2.4 Hours .................... T252 sion cover.
850 (Canadian) Remove tensioner upper mounting bolt and loosen lower
1995 ..................... 1 2.4 Hours .................. 2 T217 mounting bolt. Twist tensioner to free plunger/pulley. If re-
1995 ..................... 1 2.4 Hours .................. 3 T269 using old timing belt, mark belt with arrow to indicate rota-
2.9L 6-Cyl. tion direction. Remove lower bolt, tensioner, and timing
S90 & V90 belt.
1997-98 ................ 1 2.2 Hours .................... T270 CAUTION: DO NOT turn crankshaft or camshafts while belt is
960 removed.
1992-93 ................ 1 2.2 Hours .................... T217
Inspection:
1994 ................... 1 2.2 Hours .................... T252 Spin tensioner and idler pulleys and listen for bearing noise.
1995-97 ................ 1 2.2 Hours .................... T270 See Fig. 2. Ensure pulley surfaces in contact with belt are
1
- With Air Cond. add .5 hours. With shimmed Air clean and smooth. Check tensioner pulley arm and idler
Cond. belt add .5 hours. pulley mountings, and tighten bolts as necessary. See
TORQUE SPECIFICATIONS. Check tensioner for signs of
2
Through engine number 131034. leakage, no resistance when depressed, or a plunger that
3
From engine number 131035. cannot be depressed.
On 1992 960 models, the manufacturer recommends the belt
be replaced every 30,000 mile intervals, starting at the first
40,000 mile service.
be replaced at 30,000 mile intervals, starting at the first 30,000
mile service.
to be replaced every 50,000 miles.
On 1993 850 models, with engine number 131034 and ear-
lier, the manufacturer suggests the belt be replaced every
50,000 miles. On 1994 850 models, and 1993 850 models
from engine number 131035, the manufacturer recommends
On ALL 1995-98 models, the manufacturer recommends the
belt be replaced every 70,000 miles.


TIMING BELT
Removal (5-Cylinder):
Disconnect negative battery cable. Remove spark plug cover Fig. 1: Aligning Camshaft & Crankshaft Timing Marks
and 2 fuel line clips. Lift out expansion tank and place on
top of engine. Remove front timing belt cover. Remove aux-
iliary drive belt.
VOLVO 601
*2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder (Cont.)

Installation:
Compress tensioner and tighten center nut. Wait until com-
pression has taken place and insert a 2 mm locking pin in
plunger. Install tensioner and tighten mounting bolts to
specification.
Place timing belt around crankshaft pulley and right idler.
Place belt over camshaft pulleys. Position belt around wa-
ter pump and press over tensioner pulley.
Remove tensioner locking pin. To complete installation,
reverse removal procedure. Turn crankshaft 2 revolutions
to ensure timing marks on crankshaft and camshaft pul-
leys are aligned. See Fig. 1. Adjust drive belts to proper
Camshaft Cover Bolt .................................................. 13 (17)
Spark Plug .................................................................. 18 (25)
Timing Belt Pulley Bolt ................................................ 30 (40)
Fig 2: Checking Tensioner & Idler Pulleys 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 Degree Turn
6-Cylinder
Step 1 ........................................................................ 26 (35)
Step 2 .................................................. Plus 50 Degree Turn
Water Pump Bolt ........................................................ 13 (17)
Wheel Lug Nut ............................................................. 81 (110)
602 VOLVO
TIMING BELT APPLICATION Remove center bolt from idler pulley. Using Idler Pulley
Removal Tool (5202) or equivalent, remove idler pulley. Re-
Application Labor Time Belt Part No. place and tap new idler pulley into position. Using Spanner
2.4L 6-Cyl. Diesel Wrench Tool (5199) or equivalent, hold front camshaft drive
DL gear in place and remove center retaining bolt. See Fig. 2.
1982
NOTE: Idler pulley must be replaced when replacing timing gear
Camshaft ............ 13.6 Hours .................... T083 belt. Use Puller (5202) to remove pulley.
GL NOTE: Camshaft MUST NOT rotate or damage to valves and
1982-84 pistons may result.
Camshaft ............ 13.6 Hours .................... T083
Injection Pump ... 1.9 Hours ..................... T082 Tap gear loose from camshaft tapered end. Remove injec-
tion pump drive belt by loosening retaining bracket bolts.
740 Series Tighten one screw to hold pump in upper position. Use
1985-86 Spanner Wrench Tool (5199) or equivalent to hold rear cam-
Camshaft ............ 13.6 Hours .................... T083 shaft sprocket and Wrench (5201) or equivalent to remove
Injection Pump ... 1.9 Hours ..................... T082 center retaining bolt. Tap gear loose from camshaft. See
760 GLE Fig. 2.
Camshaft ............ 13.6 Hours .................... T083 Check that No. 1 cylinder is at TDC, timing mark on fly-
wheel is at 0 and camshaft lobes for No. 1 cylinder are
Injection Pump ... 1.9 Hours ..................... T082 facing up with equally large angles in comparison with cyl-
760 Series inder head. See Fig. 1. Place Camshaft Lock Gauge Tool
1985 (5190) or equivalent in camshaft groove at rear of cylinder
Camshaft ............ 13.6 Hours .................... T083 head.
Injection Pump ... 1.9 Hours ..................... T082 Place a .008" (.2 mm) feeler gauge under left side of Cam-
shaft Locking Gauge Tool (5190) or equivalent. See Fig. 3.
1
- With Air Cond. add .5 hours. Install timing gear belt and damper pulley. Replace 4
damper pulley bolts and torque to 15 ft. lbs. (20 N.m).
MANUFACTURERS SUGGESTED NOTE: Feeler gauge placed under Camshaft Lock Gauge Tool
SCHEDULED MAINTENANCE (5190) or equivalent is to compensate for timing gear clearance.
The manufacturer recommends the belt be replaced every Using Damper Pulley Wrench Tools (5187 and 5188) or
75,000 miles. equivalent, install and torque center bolt (use sealing agent
on center bolt threads) of damper pulley to 255 ft. lbs. (350
* NOTE: This application is an interference engine. N.m). Install front timing gear belt and camshaft timing gear
See page A-59 for interference engine cautions. (ensuring camshaft does not turn). Torque to 33 ft. lbs. (45
N.m) after setting timing marks.
REMOVAL & INSTALLATION Remove Camshaft Gauge Locking Tool (5190) and feeler
gauge from rear of camshaft. Install rear camshaft gear
TIMING BELT and injection pump belt. Set injection pump timing. See
Removal: Fig. 4.
Disconnect negative battery cable. Remove splash guard, Position Belt Tension Gauge Tool (5197) or equivalent on
cooling fan, spacer, and pulley. Remove fan and power timing and injection pump belt, set gauge to .50" (12.5 mm).
steering pump belts, power steering pump and expansion Place tension on belt until mark on plunger is flush with
tank cap. Drain and remove radiator. Disconnect battery gauge sleeve and tighten bolts.
ground cable. Using coolant pump to adjust timing gear belt tension, place
Remove valve cover and front and rear timing belt covers. tension on belt until mark on plunger is flush with gauge
Using a 1 1/16" (27 mm) socket on damper pulley bolt, set sleeve. Install valve cover and new gaskets. Install front
No. 1 cylinder at TDC (timing mark on flywheel at 0). Loosen and rear timing gear covers. Install lower belt shield. Re-
water pump and idler pulley bolts to remove timing belt verse removal procedure to complete installation. Adjust
from camshaft gear. See Fig. 1. drive belts to proper tension. See page A-60 for belt tension
Using Damper Pulley Wrench (5187) or equivalent, and ranges.
Damper Pulley Bolt Tool (5188) or equivalent, remove TORQUE SPECIFICATIONS
damper pulley bolt. Using a (6 mm) socket, remove 4 screws
from damper pulley and pulley (it may be necessary to tap
Camshaft Gear Bolt
pulley from shaft). Remove lower belt shield and timing
Front ......................................................................... 33 (45)
gear belt.
Rear ....................................................................... 74 (100)
Crankshaft Pulley Nut ............................................. 258 (350)
Injector Pump Gear .................................................... 33 (45)
VOLVO 603
Fig. 3: Setting Timing Using Camshaft Locking Gauge
Fig. 1: Camshaft Timing & Injection Timing At TDC
Fig. 4: Injection Pump Alignment Marks

Fig. 2: Using Camshaft Gear Retaining Wrench
604 YUGO
1.1L 4-Cyl.
GV Series
1986-89 ................. 2.5 Hours ..................... T018
1.3L 4-Cyl.
GV Series
1987 ...................... 2.5 Hours ..................... T018
The manufacturer recommends inspection of the timing belt
every 15,000 miles. Although the manufacturer does not rec-
ommend a specific scheduled replacement interval, belt manu-
facturers suggest the belt be replaced at 60,000 mile inter-
vals.


TIMING BELT
Removal:
Disconnect negative battery cable. Position No. 1 cylinder
at TDC of compression stroke. Disconnect positive battery
cable. Remove accessory drive belt. Remove cooling fan
and shroud. Remove crankshaft pulley. Remove timing belt
Fig. 1: Camshaft-To-Crankshaft Alignment
covers.
Align camshaft sprocket with timing mark. See Fig. 1.
Loosen tensioner lock nut and move tensioner pulley to-
ward engine mount. Tighten nut to secure tensioner in slack
position. Remove and discard timing belt.
CAUTION: Timing belts cannot be reused. DO NOT readjust belt

tension following initial installation of a new belt.
Installation:
Align camshaft sprocket with timing mark. Align crankshaft
sprocket with reference index. See Fig. 2. Position timing
belt tensioner to its !imit of travel toward engine mount and
partially tighten lock nut. Install a new timing belt with slack
on tensioner side. Loosen tensioner lock nut to apply ten-
sion. Tighten tensioner lock nut to 33 ft. Ibs. (45 N.m).
To apply equal tension to each side of timing belt, turn
crankshaft 2 revolutions in direction of travel. Tighten
tensioner lock bolt. Check for proper alignment of timing
marks. Reverse removal procedure to complete installa-
tion. Adjust drive belts to proper tension. See page A-60 for Fig. 2: Exploded View Of Timing Belt & Related Components
Camshaft Housing Bolts ............................................ 14 (19)
Crankshaft Pulley Nut ............................................. 101 (137)
Tensioner Pulley Support Nut ..................................... 33 (45)

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Limited Warranty for the Life of the Merchandise

To help your customer avoid costly

Todays Timing Belts are

*An interference engine is an engine in which the valves and the

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

G.M.C. (SEE CHEVROLET/G.M.C.)

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

1997-98 2.4L 4-Cyl. (SOHC, VIN G)

Make Timing Belt Recommended

1997-98 2.4L 4-Cyl. (SOHC, VIN G)

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

Make Timing Belt Recommended

CONTINENTAL CONTITECH - Cont. CONTITECH - Cont. DAYCO - Cont. DAYCO - Cont.

TEXACO ULTRALAST - Cont. UNIROYAL - Cont. VERA - Cont. VERA - Cont.

Belts should be kept in their original packaging until

Installation Tips Belt Cracking

Tensioners and idlers (when applicable) should be

IMPORTANT: Avoid crimping the belt when installing

Overhead Valve (OHV) Double Overhead Cam

However, interference engines usually sustain damage if synchronization is lost. As illustrated,

V- Belt Tension Ranges for Manual Tensioners

Suggested Installation Installation Suggested Installation Installation

Micro-V Belt Tension Ranges for Manual Tensioners

Suggested Installation Installation Suggested Installation Installation

Courtesy of American Honda Motor Co. , Inc.

Courtesy of American Honda Motor Co. , Inc.

*1.6L 4-Cylinder EL (Cont.)

Courtesy of American Honda Motor Co. , Inc.

Fig. 4: Timing Belt Installation Sequence

Courtesy of American Honda Motor Co. , Inc.

Fig. 5: Locating Timing Belt Adjuster Bolt

* NOTE: This application is an interference engine.

REMOVAL & INSTALLATION

ley. Fig. 1: Exploded View of Timing Belt & Components

REMOVAL & INSTALLATION

Fig. 1: Exploded View Of Timing Belt Components

Fig. 3: Locating Timing Belt Adjuster Bolt

Fig. 2: Aligning Timing Marks

NOTE: Some vehicles may be equipped with radio/cassette or

* NOTE: This application is an interference engine.

REMOVAL & INSTALLATION

Fig. 2: Aligning Timing Marks

Fig. 4: Positioning Camshaft

Fig. 3: Engine/Transaxle Mount Location & Tightening

*2.2L & 2.3L 4-Cylinder

* NOTE: This application is an interference engine.