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Table of Contents
Timing Component Kits . . . . . . . . . . . . . . . I-IV Alphabetical/Application Listings with recommended replacement intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1 Changeover Listing . . . . . . . . . . . . . . . . . . A-43 Manufacturers Part Numbers . . . . . . . . . A-54 Troubleshooting Guide . . . . . . . . . . . . . . . A-56 Overhead Valve Engine Identification . . A-58 Interference Engine Information . . . . . . . A-59 Belt Tensioning . . . . . . . . . . . . . . . . . . . . . .A-60 Replacement Instructions . . . . . . . . . . . . . . . . 1
WARNING Be safe! Do not use NAPA Belts/Hose (Gates) belts, pulleys or sprockets on any aircraft propeller or rotor drive systems or in-flight accessory drives. Those NAPA Belts/Hose (Gates) products are not designed or intended for aircraft use. CAUTION Use NAPA Belts/Hose (Gates) products only on applications specified in NAPA Belts/Hose (Gates) literature. Install and maintain products according to the vehicle manufacturer's recommended procedures and with recommended tools. Failure to follow these instructions could result in injury or property damage. NAPA Belts/Hose (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. NAPA Belts/Hose (The Gates Rubber Company) will, at its option, replace or repair any merchandise proved defective in material or workmanship,or both, during the warranty period. This is the exclusive remedy. For warranty service, please contact the Service Department, The NAPA Belts/Hose (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 CONSEQUENTIAL 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 connected 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, without 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. Prepared Expressly for NAPA Belts/Hose by Mitchell Repair Information Company Copyright 2002 MITCHELL REPAIR INFORMATION COMPANY, LLC All Right Reserved Printed in the U.S. of America
NEW! Timing Component Kits
Do the complete job and reduce your warranty returns!
Why Replace Timing Belt Drive Components?

Worn idlers and tensioners damage new timing belts resulting in costly warranty returns. Idler and tensioner wear, however, is difficult to detect. Bearing wear, grease degradation due to increased underhood temperatures, seal erosion and tensioner plate seizure all reduce component life. In some cases, the lifespan of the belt tensioner or idler may already be exceeded by the time the belt is due for replacement. The cost of a labor claim associated with a timing belt system failure on an interference engine can be over $1,000 when valves are bent and pistons are damaged. Why take a chance? Avoid the warranties and comebacks by replacing critical system components.
NAPA Timing Component Kits Are The Perfect Solution

With NAPAs new Timing Component Kits, you dont have to shop for more components, buy from multiple sources or hassle with returning components that dont fit. NAPA Timing Component Kits provide a complete system replacement solution, so you can do a complete timing belt system replacement right the first time, every time. The benefits dont stop there. You also get
Reduced Labor Claims and Comebacks

By replacing all the timing belt system components, service technicians will reduce costly labor claims and comebacks.
Greater Convenience Eliminate the frustration of limited aftermarket availability of components. Kits contain the exact components needed for the most popular and critical belt replacement jobs. Ease of Parts Sourcing
You save time with kits that contain all the NAPA parts needed to do the joball under a single part number.
Save Your Customers Money

By replacing the idler, tensioner and belt at the same time, you save your customers extra labor charges.
Detailed Installation Instructions

NAPA Timing Component Kits are unique in the market. Each kit contains a complete replacement solution, plus detailed installation instructions specific to each application, so theres no guesswork required to get the right fit.
II
OE Quality Components In Each Kit

NAPA Timing Component Kits are built with quality you can depend on. Tamper-evident packaging assures you that all the parts you need are in each box. NAPA timing belts are manufactured to the toughest specifications, assuring customers a replacement belt to match the capabilities of the original belt. NAPA timing belts have positioning marks to make installation fast and easy. You wont find that with many competitive belts, which require you to count individual teeth to correctly position belts.
More Support From NAPA Belts/Hose

NAPAs Timing Belt Replacement Manual contains all the information needed for any car or light truck timing belt installation. Over 400 illustrated pages of detailed instructions. Covers domestic and imported vehicles 1970 and newer. NAPA replacement belts are listed with each application. Includes average technician labor time as well.
III
Tooth profiles arent interchangeable

The earliest timing belts had a trapezoidal profile. Competition and more demanding applications led to the development of a curvilinear profile. This, in turn, evolved to a modified curvilinear profile. Belts with different tooth profiles are not interchangeable. NAPAs complete line of more than 250 timing belt numbers continues to grow and set the industry standard. Our timing belts include the popular tooth profiles pictured at right.
Trapezoidal
Curvilinear
Modified Curvilinear
Dont be mislead by initial cost

The cost of the belt is only 5 10 percent of the cost of replacement. Changing any timing belt can be labor intensive and costly. In the case of interference engines*, the repair bill for a failed timing belt can be up to 10 times the cost of replacing the belt.
NOTE: Trapezoidal, curvilinear and modified curvilinear tooth profiles will not interchange, and a neoprene belt will not replace HSN (Highly Saturated Nitrile). Replacing a high performance timing belt with a non-OE equivalent belt may severely shorten the belt life. NAPA offers OE equivalency in timing belt replacements. Many engines from other countries use different timing belts and sprockets than like engines designed for the North American market. While these engines may look identical and fit exactly the same in similar vehicles, the belts may be vastly different. Please take special care to look for these differences if you suspect your engine may have been replaced with an imported engine.
NAPA first to use HSN

Neoprene, an excellent material in its own right, was standard until 1985, when Gates introduced the first belts made of highly-saturated nitrile (HSN). In short supply, and difficult to engineer, HSN is the material of choice for most new engine timing belts. An HSN-constructed belt appears no different than a neoprene belt, but significantly outperforms in the high-temperature engine compartments of modern vehicles.
Easy installation every time

NAPA timing belts have positioning marks to make installation fast and easy. You wont find that with many competitive belts, which require you to count individual teeth to correctly position the belt.
HSN belts are worth the price

They cost more than neoprene belts, but theyre a small percentage of the total cost of replacing a belt and theyre absolutely necessary for acceptable service life. The fact is, theyre worth every penny. Todays engines require high-performance belts. Thats why car manufacturers use HSN in so many new engines.
*In interference engines, the valves and the piston may contact each other if the timing is not set correctly.
IV
ALPHABETICAL MODEL LISTING

Make Model/ Year Engine Belt Part No. Timing Belt Component Interference Driven Water Kit Part No. Engine* Pump Recommended Replacement Interval (Miles)
A-1
Page
ACURA
Passenger Cars EL (Canadian) 1997-00 1.6L 4-Cyl. Integra 1986-89 1.6L 4-Cyl. 1992-93 1.7L 4-Cyl. 1990-94 1.8L 4-Cyl. (Exc. VTEC) 1995-96 1.8L 4-Cyl. (Exc. VTEC) 1997-01 1991-94 1995-96 1997-01 Legend 1986-87 1988-89 1990 1991-94 1995 MDX 2001 Vigor 1992-94 2.2CL 1997 1.8L 4-Cyl. (Exc. VTEC) 1.8L 4-Cyl. (VTEC) 1.8L 4-Cyl. (VTEC) 1.8L 4-Cyl. (VTEC) 2.5L V6 2.7L V6 2.7L V6 3.2L V6 (C32A1) 3.2L V6 (C32A1) 3.5L V6 (J35A3) 2.5L 5-Cyl. 2.2L 4-Cyl. Balance Shaft Camshaft 2.3CL 1999-98 2.5TL 1995-96 1997-98 3.0CL 1997-99 3.2CL 2001 3.2TL 1996 1997-98 1999-01 3.5RL 1996 2.3L 4-Cyl. Balance Shaft Camshaft 2.5L 5-Cyl. 2.5L 5-Cyl. 3.0L V6 (J30A1) 3.2L V6 (J32A1/A2) 3.2L V6 (C32A6) 3.2L V6 (C32A6) 3.2L V6 (J32A1) 3.5L V6 (C35A1) Balance Shaft Camshaft
250224 250130 250227 250184 250184 250184 250247 250247 250247 250129 250129 250129 250193 250193 250286 250211 250186 250244
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
105,000 3 60,000 1 90,000 90,000 90,000 Normal 60,000 Severe 105,000 3 90,000 90,000 Normal 60,000 Severe 105,000 3 60,000 1 60,000 1 90,000 90,000 90,000 Normal 60,000 Severe 105,000 3 90,000 90,000 Normal 2 60,000 Severe 90,000 Normal 2 60,000 Severe 105,000 3 105,000 3 90,000 Normal 60,000 Severe 105,000 3 105,000 3 105,000 3 90,000 Normal 60,000 Severe 105,000 3 105,000 3 90,000 Normal 2 60,000 Severe 90,000 Normal 2 60,000 Severe
1 4 5 7 7 7 7 7 7 13 13 13 19 19 19 15 11 9 9 9 9 9 11 11 11 15 15 19 19 19 15 22 22 22 22
250186 250244 250211 250211 250286 250286 250193 250193 250286 250280 250279
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
* - 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
Make Model/ Year 3.5RL (Cont.) 1997-01 Light Trucks SLX 1996-97 1999-98
ALPHABETICAL MODEL LISTING (Cont.)

Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles) Page
ACURA (Cont.)
3.5L V6 Balance Shaft Camshaft 3.2L V6 (SOHC) 3.5L V6 (DOHC) 250280 250279 250221 250303 Yes Yes Yes Yes Yes Yes 105,000 3 105,000 3 60,000 75,000 22 22 28 26
164L, LS & S 1991-93 3.0L V6 AMERICAN MOTORS Concord 1978-79 2.0L 4-Cyl. Gremlin 1977-78 2.0L 4-Cyl. Spirit 1979 2.0L 4-Cyl.
ALFA ROMEO
250120 250017 250017 250017 2520170 2520170 2520170
50,000 60,000 1 60,000 1 60,000 1
30 32 32 32
ASUNA
Passenger Cars Sunfire (Canadian) 1993 1.8L 4-Cyl. Light Trucks Sunrunner (Canadian) 1989-95 1.6L 4-Cyl. (8-Valve) California Except California 1994-98 1.6L 4-Cyl. (16-Valve) California Except California 1999-01 1.6L 4-Cyl. (16-Valve) Allroad 2000 A4 1997-99 1996 1997 1998 1999 A4 Quattro 1997-99 1996 1997 1998 1999 2000 A6 1995-96 1997 1998 1999 2000
250205
Yes
60,000
209
250212 250164 250212 250164 250212
60,000 60,000 60,000 60,000 60,000
215 215 217 217 217
AUDI
2.7L V6 DOHC 1.8L 4-Cyl. Turbo 2.8L V6, 12-Valve 2.8L V6, 12-Valve 2.8L V6, 30-Valve 2.8L V6, 30-Valve 1.8L 4-Cyl. Turbo 2.8L V6, 12-Valve 2.8L V6, 12-Valve 2.8L V6, 30-Valve 2.8L V6, 30-Valve 2.7L V6 DOHC 2.8L V6, 12-Valve 2.8L V6, 12-Valve 2.8L V6, 30-Valve 2.8L V6, 30-Valve 2.8L V6, 30-Valve
250297 250291 250218 250218 250297 250297 250291 250218 250218 250297 250297 250297 250218 250218 250297 250297 250297
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
105,000 90,000 60,000 1 90,000 90,000 75,000 90,000 60,000 1 90,000 90,000 75,000 105,000 60,000 1 90,000 90,000 75,000 105,000
57 38 62 62 64 64 38 62 62 64 64 57 62 62 64 64 64
* - 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.

Make Model/ Year Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
A-3
Page
AUDI (Cont.)
A6 Quattro & Quattro Turbo 1995-96 2.8L V6, 12-Valve 1997 2.8L V6, 12-Valve 1998 2.8L V6, 30-Valve 1999 2.8L V6, 30-Valve 2000 2.8L V6, 30-Valve A8 1997-98 3.7L V8 (AEW) 1999 3.7L V8 (AEW) A8 Quattro 1997-98 3.7L V8 (AEW) 1999 3.7L V8 (AEW) 2000 4.2L V8 (AKB, AUX & AYS) Cabriolet 1994-96 2.8L V6, 12-Valve 1997-98 2.8L V6, 12-Valve Coupe 1981-83 2.2L 5-Cyl. 1984-85 2.2L 5-Cyl. 113 Tooth Belt 120 Tooth Belt Coupe GT 1986-87 2.2L 5-Cyl. Coupe Quattro 1990-91 2.3L 5-Cyl. Fox 1973-79 1.6L 4-Cyl Quattro 1983 2.2L 5-Cyl. 1984-85 2.2L 5-Cyl. 113 Tooth Belt 120 Tooth Belt S4 Quattro 2001 2.7L V6 DOHC S4 Sedan 1992-94 2.2L 5-Cyl. Turbo S6 1995 2.2L 5-Cyl. Turbo S6 Quattro 1995 2.2L 5-Cyl. Turbo TT Coupe & Roadster 1.8L 4-Cyl. Turbo V8 Quattro 1990-91 3.6L V8 (PT Engine) 1992-94 4.2L V8 (ABH Engine) 80 1988-90 2.0L 4-Cyl. 1991-92 2.3L 5-Cyl. 80 Quattro 1988 2.3L 5-Cyl. 90 1988-90 2.0L 4-Cyl. 1988 2.3L 5-Cyl. 250218 250218 250297 250297 250297 250207 250207 250207 250207 250297 250218 250218 250065 250065 250127 250127 250197 250017 250065 250065 250127 250297 250225 250225 250225 250306 250207 250207 250017 250170 250127 250017 250127 2520170 2520170 Yes Yes 2520170 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 60,000 1 90,000 90,000 75,000 105,000 90,000 75,000 90,000 75,000 105,000 60,000 1 90,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 105,000 60,000 1 60,000 1 60,000 1 120,000 60,000 90,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 62 62 64 64 64 72 72 72 72 76 62 62 79 79 79 79 47 34 79 79 79 53 49 49 49 40 67 67 43 51 51 43 51
A-4
Make Model/ Year

AUDI (Cont.)
90 (Cont.) 1989 2.3L 5-Cyl. Up To Chas. 89J396702 From Chas. 89J396703 2.3L 5-Cyl. 2.8L V6, 12-Valve 2.3L 5-Cyl. 2.3L 5-Cyl. Up To Chas. 89J394742 From Chas. 89J394743 2.3L 5-Cyl. 2.8L V6 (12-Valve) 2.3L 5-Cyl. Thru Chas. 063969 From Chas. 063970 2.3L 5-Cyl. 2.8L V6 (12-Valve) 2.3L 5-Cyl. Thru Chas. 063969 From Chas. 063970 2.3L 5-Cyl. 2.8L V6 (12-Valve) 2.2L 5-Cyl. Up To Chas. 44K400000 2.2L 5-Cyl. From Chas. 44K400001 2.2L 5-Cyl. 2.2L 5-Cyl. Thru Chas. 44K004457 From Chas. 44K004458 2.2L 5-Cyl. 250127 250170 250170 250218 250127 250127 250170 250170 250218 250127 250170 250170 250218 250127 250170 250170 250218 250127 250170 250170 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 51 51 51 62 51 51 51 51 62 51 51 51 62 51 51 51 62 79 79 79
1990-91 1993-95 90 Quattro 1988 1989 1990-92 1993-95 100 1988-91 1990-91 1992-94 100 Quattro 1988-91 1990-91 1992-94 200 1989 1989 1990-91 200 Quattro 1989
Yes
Yes
Yes
Yes
1990-91 4000 1980-83 1.7L 4-Cyl. 1982-83 1.6L 4-Cyl. Diesel 1980-81 2.2L 5-Cyl. 4000CS 1986-87 2.2L 5-Cyl. 4000CS Quattro 1987 2.2L 5-Cyl. 4000S 1984-87 1.8L 4-Cyl. 4000S Quattro 1984-85 2.2L 5-Cyl. 113 Tooth Belt 120 Tooth Belt 1986 2.2L 5-Cyl.
250127 250170 250170 250017 250043 250065 250127 250127 250017 250065 250127 250127 2520170 Yes 2520170
Yes Yes Yes Yes Yes Yes Yes
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1
79 79 79 34 33 79 79 79 36 79 79 79
Yes Yes Yes
60,000 1 60,000 1 60,000 1

A-5
Page
AUDI (Cont.)
5000 1979-83 1979-83 2.0L 5-Cyl. Diesel Camshaft Injection Pump 2.0L 5-Cyl.Turbo Diesel Camshaft Injection Pump 2.2L 5-Cyl. Turbo 250083 250082 250083 250082 250065 250127 250127 250127 250065 250127 250127 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 60,000 60,000
1, 2 1, 2
45 45 45 45 79 51 79 51 79 79 79
1978-83 5000 Quattro 1988 2.3L 5-Cyl. 5000CS Quattro 1987-88 2.2L 5-Cyl. 5000S 1987-88 2.3L 5-Cyl. 1984-85 2.2L 5-Cyl. 113 Tooth Belt 120 Tooth Belt 1986-87 2.2L 5-Cyl.
60,000 1, 2 60,000 1, 2 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1
BMW
325 Series 1987-88 1989-91 1984-88 525i 1989-95 528e 1982-88
2.5L 6-Cyl. 127 Tooth Belt 128 Tooth Belt 2.5L 6-Cyl. 2.7L 6-Cyl. 127 Tooth Belt 128 Tooth Belt 2.5L 6-Cyl. 2.7L 6-Cyl. 127 Tooth Belt 128 Tooth Belt
250131 250106 250131 250131 250106 250131 250131 250106
Yes Yes Yes Yes Yes Yes Yes Yes
60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000
81 81 81 81 81 81 81 81
BUICK
Skyhawk 1982-86 1987-88
1.8L 4-Cyl. 2.0L 4-Cyl.
250081 250081
Yes Yes
60,000 1 60,000 1
228 229
CADILLAC
Catera 1997-01
CHEVROLET
3.0L V6 (DOHC)
250285
Yes
Yes
100,000
231
Passenger Cars Chevette 1976 1.4L 4-Cyl. 1977 1.4L 4-Cyl. 1976 1.6L 4-Cyl. 1977-78 1.6L 4-Cyl. 1979-87 1.6L 4-Cyl. 1981-86 1.8L 4-Cyl. Diesel Lumina (Exc. Van) 1991-95 3.4L V6 1996-97 3.4L V6
250037 250039 250037 250039 250061 250076 250192 250273
Yes Yes Yes Yes Yes
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000
221 221 221 221 221 226 238 238
A-6
Make Model/ Year Metro 1989-00 1998-01 Monte Carlo 1995 1996-97 Nova 1988 1985-88 Spectrum 1985-87 1988-89 Sprint 1985-88 1989-91

CHEVROLET (Cont.)
1.0L 3-Cyl. 1.3L 4-Cyl. 3.4L V6 3.4L V6 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (SOHC) 1.5L 4-Cyl Up To 4/30/87 From 5/1/87 1.5L 4-Cyl. 1.0L 3-Cyl. 1.0L 3-Cyl. 250194 250194 250192 250273 250112 250070 250118 250162 250162 250095 250166 2520700 Yes Yes Yes Yes Yes Yes 2521941 2521941 Yes Yes Yes Yes 100,000 100,000 60,000 60,000 60,000 1 60,000 1 60,000 60,000 60,000 60,000 60,000 211 213 238 238 224 224 219 219 219 211 211
CHEVROLET/G.M.C.
Light Trucks LUV 1981-82 2.2L 4-Cyl. Diesel S10 & S15 Pickups 1983-85 2.2L 4-Cyl. Diesel Tracker 1998 1.6L 4-Cyl. (16-Valve) California Except California 1999-01 1.6L 4-Cyl. (16-Valve)
250075 250075 250212 250164 250212
Yes Yes
60,000 60,000 60,000 60,000 60,000
323 323 217 217 217
CHRYSLER
Cirrus 2000 2.0L 4-Cyl. (SOHC, VIN C) 2.4L 4-Cyl. (DOHC, VIN X) 2.4L 4-Cyl. (DOHC, VIN X) 2.5L V6 3.2L V6 3.2L V6 3.5L V6 3.5L V6 3.5LV6 250245 250265 250265 250259 250295 250295 250219 250255 250295 250071 250071 250295 250295 2520710 2520710 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 100,000 Federal 105,000 Calif. 105,000 100,000 Federal 105,000 California 60,000 3 105,000 100,000 Federal 105,000 California 105,000 105,000 100,000 Federal 105,000 California 60,000 1 60,000 1 105,000 100,000 Federal 105,000 California 105,000 105,000 93 93 106 106 106 108 123 123 123 123 123 123 123 101 101 123 123 123 123 123
1995-99 2000 1995-00 Concorde 1998-99 2000 1993-94 1995-97 2000
E Class 1983-84 2.2L 4-Cyl. Executive Limo (Canadian) 1986 2.2L 4-Cyl. Intrepid (Canadian) 1998-99 3.2L V6 2000 3.2L V6
1993-94 3.5L V6 250219 Yes 1995-97 3.5L V6 250255 Yes * - 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-7
Page
CHRYSLER (Cont.)
Laser 1984-86 2.2L 4-Cyl. 1986 2.5L 4-Cyl. LeBaron & LeBaron GTS 1982-88 2.2L 4-Cyl. 1989-90 2.2L 4-Cyl. 1986-87 2.5L 4-Cyl. 1988 2.5L 4-Cyl. 1989-94 2.5L 4-Cyl. 1990-93 3.0L V6 (SOHC) 1994-95 3.0L V6 (SOHC) LHS 1994 3.5L V6 1995-97 3.5L V6 1998-99 3.5LV6 2000 3.5LV6 New Yorker 1983-88 2.2L 4-Cyl. 1986-87 2.5L 4-Cyl. 1988 2.5L 4-Cyl. 1988-89 3.0L V6 (SOHC) 1994 3.5L V6 1995-96 3.5L V6 Sebring Coupe 1995-99 2.0L 4-Cyl. (DOHC, VIN Y) 1995-00 2.5L V6 Sebring Convertible 1996-99 2.4L 4-Cyl. (DOHC, VIN X) 1997-00 2.5L V6 TC 1990 2.2L 4-Cyl. (DOHC, VIN R) 1990-91 3.0L V6 (SOHC) Town & Country 1982-88 2.2L 4-Cyl. 1986-87 2.5L 4-Cyl. 1988 2.5L 4-Cyl. 300M 1998-99 3.5LV6 2000 3.5LV6
250071 250114 250071 250153 250114 250132 250153 250139 250139 250219 250255 250295 250295 250071 250114 250132 250139 250219 250255 250246 250259 250265 250259 250153 250139 250071 250114 250132 250295 250295
2520710 2520710 2521530 2521530 2521390 2521390 Yes Yes Yes Yes 2520710 2521390
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 1 105,000 105,000 105,000 100,000 Federal 105,000 California 60,000 1 60,000 1 60,000 1 60,000 105,000 105,000 60,000 3 60,000 3 105,000 60,000 3 60,000 1 60,000 60,000 1 60,000 1 60,000 1 Yes Yes 105,000 100,000 Federal 105,000 California
101 101 101 101 101 101 101 110 110 123 123 123 123 123 101 101 101 110 123 123 133 108 106 108 98 110 101 101 101 123 123 123
Yes Yes Yes Yes Yes Yes Yes Yes Yes
2521530 2521390 2520710
DAEWOO
Laganza 1999-01 2.2L 4-Cyl. (DOHC) 1.6L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 250305 250310 250309 Yes Yes Yes Yes Yes Yes 72,000 Federal 102,000 Federal 3 60,000 Federal 102,000 Federal 3 72,000 Federal 102,000 Federal 3 150 150 145 145 148 148
Lanos 1999-01 Nubira 1999-01
A-8
Make Model/ Year

DAEWOO (Cont.)
Optima (Canadian) 1988-91 1.6L 4-Cyl. 1988-89 2.0L 4-Cyl. 1990-91 2.0L 4-Cyl. 250081 250081 250163 Yes Yes Yes 60,000 1 60,000 1 60,000 1 147 147 147
DAIHATSU
2521630
Passenger Cars Charade 1988-92 1.0L 3-Cyl. 1988-92 1.3L 4-Cyl. Light Trucks Rocky 1990-92 1.6L 4-Cyl.
250178 250181 250182
Yes Yes Yes
60,000 60,000 60,000
152 154 154
Passenger Cars Aries 1981-88 2.2L 4-Cyl. 1989 2.2L 4-Cyl. 1986-87 2.5L 4-Cyl. 1988 2.5L 4-Cyl. 1989 2.5L 4-Cyl. Avenger 1995-99 2.0L 4-Cyl. (DOHC, VIN Y) 1995-00 2.5L V6 Challenger 1978-79 (RWD) 1.6L 4-Cyl. w/o Bal. Shaft 1978-79 1.6L 4-Cyl. Balance Shaft Camshaft Charger 1983 1.7L 4-Cyl 1983-87 2.2L 4-Cyl. Colt 1979-84 1.4L 4-Cyl. 1985-86 1.5L 4-Cyl. 1987-90 1.5L 4-Cyl. 1991-94 1.5L 4-Cyl. 1978-79 (RWD) 1.6L 4-Cyl. w/o Bal. Shaft 1979-82 (FWD)1.6L 4-Cyl. w/o Bal. Shaft 1983-89 1.6L 4-Cyl. w/o Bal. Shaft 1977-80 1.6L 4-Cyl. Balance Shaft Camshaft 1989-90 1.6L 4-Cyl. (DOHC) 1989-90 1.8L 4-Cyl. (VIN T) 1992-94 1.8L 4-Cyl. (VINs C & D) Colt (Canadian) 1985-86 1.5L 4-Cyl. 1989-91 1.5L 4-Cyl. 1992 & 1995 1.5L 4-Cyl.
DATSUN (SEE NISSAN) DODGE
250071 250153 250114 250132 250153 250246 250259 250064 250062 250013 250017 250071 250073 250073 250128 250191 250064 250064 250093 250062 250013 250165 250093 250201 250073 250128 250191
2520710 2521530 2521530 Yes Yes Yes Yes
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 3 60,000 3 60,000 60,000 2 60,000 2
101 101 101 101 101 133 108 87 85 85 89 101 83 114 114 114 87 87 87 85 85 125 91 131 114 114 114
2520170 2520710 Yes Yes Yes
60,000 1 60,000 1 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 2 60,000 2 60,000 60,000 60,000 60,000 60,000 60,000
2521280 2521910
Yes Yes 2521280 2521910 Yes Yes

A-9
Page
DODGE (Cont.)
Colt Vista (Includes Canadian) 1992-94 1.8L 4-Cyl. (VINs C & D) 1984-86 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 1987-91 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 1992 2.4L 4-Cyl. Balance Shaft Camshaft 1993 2.4L 4-Cyl. Balance Shaft Camshaft 1994 2.4L 4-Cyl. Balance Shaft Camshaft Colt Wagon (Includes Canadian) 1989-90 1.8L 4-Cyl. (VIN T) 1992 2.4L 4-Cyl. Balance Shaft Camshaft 1993 2.4L 4-Cyl. Balance Shaft Camshaft 1994 2.4L 4-Cyl. Balance Shaft Camshaft Colt 100 (Canadian) 1989-90 1.6L 4-Cyl. (DOHC) Colt 200 (Canadian) 1989-90 1.6L 4-Cyl. (DOHC) Daytona & Daytona Shelby 1984-88 2.2L 4-Cyl. 1989-93 2.2L 4-Cyl. 1992-93 2.2L 4-Cyl. (DOHC, VIN A) 1986-87 2.5L 4-Cyl. 1988 2.5L 4-Cyl. 1989-93 2.5L 4-Cyl. 1990-93 3.0L V6 (SOHC) Dynasty 1989-93 2.5L 4-Cyl. 1988-93 3.0L V6 (SOHC) Expo (Canadian) 1987-88 2.2L 4-Cyl. 1989 2.2L 4-Cyl. Intrepid 1998-99 3.2L V6 2000 3.2L V6 1993-94 1995-97 2000 3.5L V6 3.5L V6 3.5L V6 250201 250090 250089 250159 250158 250159 250204 250159 250230 250168 250230 250093 250159 250204 250159 250230 250168 250230 250165 250165 250071 250153 250206 250114 250132 250153 250139 250153 250139 250071 250153 250295 250295 250219 250255 250295 2520710 2521530 Yes Yes 2521581 2521581 Yes 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 1 60,000 60,000 1 60,000 1 Yes Yes Yes Yes 105,000 100,000 Federal 105,000 California 105,000 105,000 100,000 Federal 105,000 California 131 121 121 121 121 136 136 136 136 136 136 91 136 136 136 136 136 136 125 125 101 101 96 101 101 101 110 101 110 101 101 123 123 123 123 123 123 123
2521530 2521390 2521530 2521390 2520710 2521530
A-10
Make Model/ Year Lancer 1985-88 1989 1986-87 1988 1989 Neon 1995-99 1995-00 Omni 1978-83 1981-88 1989-90 Rampage 1982-84 Shadow 1987-88 1989-94 1988 1989-94 1992-93 1994 Spirit 1991-92 1989-95 1989-93 1994-95 Stealth 1991-96 1991-93 1994-96 Stratus 2000 1995-99 2000

DODGE (Cont.)
2.2L 4-Cyl. 2.2L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 2.0L 4-Cyl. (DOHC, VIN Y) 2.0L 4-Cyl. (SOHC, VIN C) 1.7L 4-Cyl. 2.2L 4-Cyl. 2.2L 4-Cyl. 2.2L 4-Cyl. 2.2L 4-Cyl. 2.2L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 3.0L V6 (SOHC) 3.0L V6 (SOHC) 2.2L 4-Cyl. (DOHC, VIN A) 2.5L 4-Cyl. 3.0L V6 (SOHC) 3.0L V6 (SOHC) 3.0L V6 (DOHC) 3.0L V6 (SOHC) 3.0L V6 (SOHC) 2.0L 4-Cyl. (SOHC, VIN C) 2.4L 4-Cyl. (DOHC, VIN X) 2.4L 4-Cyl. (DOHC, VIN X) 250071 250153 250114 250132 250153 250246 250245 250017 250071 250153 250071 250071 250153 250132 250153 250139 250139 250206 250153 250139 250139 250195 250139 250139 250245 250265 250265 250259 250017 250071 250071 250071 250114 250132 250159 250155 2520170 2520710 2520710 2520710 Yes 2520170 2520710 2521530 2520710 2520710 2521530 2521530 2521390 2521390 2521530 2521390 2521390 2521390 2521390 Yes 2520710 2521530 2521530 Yes Yes Yes Yes 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 105,000 105,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 3 60,000 1 60,000 1 60,000 60,000 3 60,000 3 60,000 60,000 3 100,000 Federal 105,000 Calif. 105,000 100,000 Federal 105,000 California 60,000 3 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 2 60,000 2 101 101 101 101 101 133 93 89 101 101 101 101 101 101 101 110 110 96 101 110 110 142 110 110 93 93 106 106 106 108 89 101 101 101 101 101 121 121
Yes Yes Yes
Yes
Yes Yes Yes Yes
1995-00 2.5L V6 024 1981-82 1.7L 4-Cyl. 1981-82 2.2L 4-Cyl. 400 1982-83 2.2L 4-Cyl. 600 1983-88 2.2L 4-Cyl. 1986-87 2.5L 4-Cyl. 1988 2.5L 4-Cyl. 2000 GTX (Canadian) 1989-92 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft

Make Model/ Year Light Trucks Caravan 1982-88 1986-87 1988 1989-95 1996-00 1987-93 1994-96 1997-00 Dakota 1987-88 1989-95 Mini Ram Van 1984-87 1987 1988 1987-93 Raider 1989 Ram 50 1983-86 1987-89 1983-85 1990-92 1993 1990-91 Scamp Pickup 1983 Light Trucks Voyager 1982-88 1986-87 1988 1989-95 1987-93 1994-96 1997-00 1996-00 Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
A-11
Page
DODGE/PLYMOUTH
2.2L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 2.4L 4-Cyl. (DOHC, VIN B) 3.0L V6 (SOHC) 3.0L V6 (SOHC) 3.0L V6 (SOHC) 2.2L 4-Cyl. 2.5L 4-Cyl. 2.2L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 3.0L V6 (SOHC) 3.0L V6 (SOHC) 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.3L 4-Cyl. Diesel Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft 3.0L V6 (SOHC) 2.2L 4-Cyl. 2.2L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 3.0L V6 (SOHC) 3.0L V6 (SOHC) 3.0L V6 (SOHC) 2.4L 4-Cyl. (DOHC, VIN B) 250071 250114 250132 250153 250265 250139 250139 250139 250071 250153 250071 250114 250132 250139 250139 250090 250089 250159 250158 250092 250091 250159 250124 250168 250229 250139 250071 250071 250114 250132 250153 250139 250139 250139 250265 2521240 2521240 2521581 2521581 Yes Yes 2520710 2521530 2521390 2521390 2521390 2520710 2521530 2520710 2521390 2521390 Yes 60,000 60,000 1 60,000 1 60,000 1 120,000 60,000 60,000 3 60,000 3 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 60,000 2 60,000 2 60,000 2 60,000 2 50,000 2 50,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 3 60,000 3 120,000 101 101 101 101 104 110 110 110 101 101 101 101 101 110 110 121 121 121 121 138 138 140 140 140 140 110 101 101 101 101 101 110 110 110 104
Yes Yes Yes Yes
2521390 2520710 2520710 2521530 2521390 2521390 2521390
Yes Yes Yes Yes
EAGLE
Medallion 1989
2.2L 4-Cyl.
250140
60,000 1
156
A-12
Make Model/ Year

EAGLE (Cont.)
Summit 1989-90 1991-96 1989-90 1992-96 1992 1993-96 1.5L 4-Cyl. 1.5L 4-Cyl. 1.6L 4-Cyl. (DOHC) 1.8L 4-Cyl. (VINs C & D) 2.4L 4-Cyl. Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft 250128 250191 250165 250201 250159 250204 250168 250230 250201 250159 250158 250246 250168 250167 250219 250255 250128 250191 250165 250093 250159 250158 250168 250167 250159 250155 2521280 2521910 Yes Yes 2521580 2521580 2521670 2521670 Yes 2521280 2521910 Yes Yes Yes 60,000 60,000 60,000 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 2 60,000 2 60,000 3 60,000 2 60,000 2 Yes Yes 105,000 105,000 60,000 60,000 60,000 60,000 60,000 2 60,000 2 Yes Yes 60,000 2 60,000 2 60,000 2 60,000 2 114 114 125 131 136 136 136 136 131 128 128 133 116 116 123 123 114 114 125 87 121 121 116 116 121 121
Summit Wagon 1992-96 1.8L 4-Cyl. (VINs C & D) Talon 1993-94 1.8L 4-Cyl. Balance Shaft Camshaft 1995-98 2.0L 4-Cyl. (DOHC, VIN Y) 1990-99 2.0L 4-Cyl. (DOHC) Balance Shaft Camshaft Vision 1993-94 3.5L V6 1995-97 3.5L V6 Vista (Canadian) 1989-91 1.5L 4-Cyl. 1992 1.5L 4-Cyl. 1989-90 1.6L 4-Cyl. (DOHC) 1989 1.6L 4-Cyl. w/o Bal. Shaft 1989-91 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 2000GTX (Canadian) 1989-93 2.0L 4-Cyl. (DOHC) Balance Shaft Camshaft 1989-92 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft
Yes Yes Yes
Yes
2521581 2521581 2521670 2521670
FIAT
Brava 1974-78 1979-83 Spider 2000 1979-82 Strada 1979-82 X1/9 1974-78 1979-83
1.8L 4-Cyl. 2.0L 4-Cyl. 2.0L 4-Cyl. 1.5L 4-Cyl. 1.3L 4-Cyl. 1.5L 4-Cyl.
250020 250068 250068 250069 250018 250069
Yes Yes Yes Yes Yes Yes
25,000 30,000 30,000 30,000 36,000 30,000
158 160 160 157 157 157

A-13
Page
FIAT (Cont.)
124 Series 1971-74 1974-78 128 Series 1973-79 131 Series 1975-78 1.6L 4-Cyl. 1.8L 4-Cyl. 1.3L 4-Cyl. 1.8L 4-Cyl. 250020 250020 250018 250020 Yes Yes Yes Yes 25,000 25,000 36,000 25,000 158 158 157 158
FORD
Passenger Cars Aspire 1994-97 1.3L 4-Cyl. Contour 1995-97 1998-00 Escort 1981-85 1991-96 1985-90 1991 1992-96 1984-87 1997-00 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) 1.6L 4-Cyl. (SOHC) 1.8L 4-Cyl. (DOHC) 1.9L 4-Cyl. 1.9L 4-Cyl. Before 3/25/1991 After 3/26/1991 1.9L 4-Cyl. 2.0L 4-Cyl. Diesel Camshaft Injection Pump 2.0L 4-Cyl. (SOHC, VIN P)
250185 250258 250294 250067 250179 250067 250067 250194 250194 250103 250102 250283 250283 250294 250294 250067 250067 250014 250141 250185 250294 250294 250283 250283 250014 250014 2520140 2520140 2520670 2520670 2520140 TCK141 Yes Yes Yes Yes 2520670 TCK179 2520670 2520670 2521940 2521940 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
60,000 Federal 105,000 California 60,000 1 Inspect at 120,000; Replace if needed 60,000 60,000 60,000 60,000 60,000 60,000 100,000 2 100,000 2 Inspect at 120,000; Replace if needed 120,000 Inspect at 120,000; Replace if needed 120,000 60,000 60,000 60,000 1 60,000 60,000 Inspect at 120,000; Replace if needed 120,000 Inspect at 120,000; Replace if needed 120,000 60,000 1 60,000 1
161 161 178 180 165 169 165 165 165 165 172 172 184 184 180 180 165 165 189 161 161 180 180 184 184 189 189
2001 2.0L 4-Cyl. (SOHC, VIN P) Escort Coupe & ZX2 1998-00 2.0L 4-Cyl. (DOHC, VIN 3) 2001 EXP 1981-85 1985-90 Fairmont 1978-83 Festiva 1988-89 1990-93 Focus 2000 2001 2000 2001 Granada 1981-82 LTD 1983-86 2.0L 4-Cyl. (DOHC, VIN 3) 1.6L 4-Cyl. (SOHC) 1.9L 4-Cyl. 2.3L 4-Cyl. 1.3L 4-Cyl. 1.3L 4-Cyl. 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (SOHC, VIN P) 2.0L 4-Cyl. (SOHC, VIN P) 2.3L 4-Cyl. 2.3L 4-Cyl.
A-14
Make Model/ Year

FORD (Cont.)
Mustang 1974-91 1992 1993 Pinto 1971-74 1974-80 Probe 1989-92 1993-97 1993-97 Taurus SHO 1989-95 1993-95 Tempo 1984-86 Thunderbird 1983-88 Light Trucks Aerostar 1987 Courier 1977-82 Escape 2001 Ranger 1983-88 1983-91 1992 1993-94 1995-97 1985-87 1998-00 2001 2.3L 4-Cyl. 2.3L 4-Cyl. Square Tooth Sprocket Round Tooth Sprocket 2.3L 4-Cyl. 2.0L 4-Cyl. 2.3L 4-Cyl. 2.2L 4-Cyl. 2.0L 4-Cyl. 2.5L V6 3.0L V6 3.2L V6 2.0L 4-Cyl. Diesel Camshaft Injection Pump 2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. Square Tooth Sprocket Round Tooth Sprocket 2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. Diesel Camshaft Balance Shaft 2.5L 4-Cyl. 2.5L 4-Cyl. 250014 250014 250210 250210 250013 250014 250134 250228 250214 250248 250248 250103 250102 250014 250014 250014 250294 250014 250014 250014 250210 250210 250276 250091 250092 250276 250276 2520140 2520140 2520140 2520140 2520140 Yes Yes Yes Yes 2520140 2520140 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 Yes Yes Yes 60,000 60,000 Federal 105,000 California 60,000 Federal 105,000 California 100,000 100,000 100,000 2 100,000 2 60,000 1 60,000 1 60,000 1 120,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 Yes Yes 60,000 1 60,000 1 Inspect At 120,000; Replace, if needed 120,000 189 189 189 189 168 189 186 186 186 196 196 200 200 172 172 189 189 189 175 189 189 189 189 189 194 192 192 195 195
2520140 TCK134 TCK228
G.M.C. (SEE CHEVROLET/G.M.C.)
GEO
Passenger Cars Metro 1989-92 1.0L 3-Cyl. 1993 1.0L 3-Cyl. 4-Bolt Sprocket 5-Bolt Sprocket
250166 250166 250241
60,000 60,000 60,000
211 211 211

A-15
Page
GEO (Cont.)
Metro (Cont.) 1994-95 1.0L 3-Cyl. 1996 1.0L 3-Cyl. 1997-00 1.0L 3-Cyl. 1992-93 1.3L 4-Cyl. 1994 1.3L 4-Cyl. 1995-97 1.3L 4-Cyl. Metro (Canadian) 1992-93 1.3L 4-Cyl. 1994 1.3L 4-Cyl. Prizm 1937-97 1.6L 4-Cyl. (DOHC, VIN 6) 1993-97 1.8L 4-Cyl. (DOHC, VIN B) Prizm GSI 1990-92 1.6L 4-Cyl. (DOHC) Spectrum 1985 1.5L 4-Cyl. 1986-87 1.5L 4-Cyl Up To 6/30/1986 From 7/1/1986 1988-89 1.5L 4-Cyl. Storm 1990-91 1.6L 4-Cyl. (DOHC) 1990-93 1.6L 4-Cyl. (SOHC) 1992-93 1.8L 4-Cyl. (DOHC) Light Trucks Tracker 1989-95 1.6L 4-Cyl. (8-Valve) California Except California 1994-98 1.6L 4-Cyl. (16-Valve) California Except California 1999-01 1.6L 4-Cyl. (16-Valve) 250241 250194 250194 250095 250243 250272 250095 250243 250236 250235 250176 250118 250118 250162 250162 250169 250177 250205 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes TCK236 Yes Yes 2521940 2521940 60,000 60,000 100,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 30,000 60,000 211 211 211 213 213 213 213 213 207 207 203 219 219 219 219 209 205 209
250212 250164 250212 250164 250212
60,000 1 60,000 1 60,000 60,000 60,000
215 215 217 217 217
HONDA
Passenger Cars Accord 1976-83 1.6L 4-Cyl. (SOHC) 1979-83 1.8L 4-Cyl. 1984-85 1.8L 4-Cyl. 1986-89 2.0L 4-Cyl. 1990-93 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 1994 (EX) 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 1994 (Exc. EX) 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft
250041 250041 250094 250160 250186 250187 250186 250244 250186 250187
TCK160 TCK160 TCK186 TCK186 TCK186 TCK186 TCK186 TCK186
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
60,000 1 60,000 1 60,000 1 60,000 1 90,000 2 90,000 2 90,000 2 90,000 2 90,000 2 90,000 2
253 263 263 269 278 278 278 278 278 278
A-16
Make Model/ Year

HONDA (Cont.)
Accord (Cont.) 1995 (EX) 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 1995 (Exc. EX) 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 1996 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft (w/o VTEC) Camshaft (w/ VTEC) 1997 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft (w/o VTEC) Camshaft (w/ VTEC) 2.3L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.7L V6 2.7L V6 3.0L V6 1.2L 4-Cyl. 1.3L 4-Cyl. Canada USA 1.3L 4-Cyl. 1.3L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 250186 250244 250186 250187 250186 250187 250244 250186 250187 250244 250186 250244 250263 250263 250286 250028 250028 250073 250099 250161 250041 250099 250161 250143 250143 250143 250145 250145 250145 250224 250224 250224 250224 TCK186 TCK186 TCK186 TCK186 TCK186 TCK186 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 2, 3 90,000 Normal 60,000 Normal 105,000 3 105,000 3 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 90,000 90,000, Normal 60,000, Severe 60,000 1 90,000 90,000 90,000 90,000 90,000 Normal 60,000 Severe 90,000 Normal 60,000 Severe 278 278 278 278 278 278 278 278 278 278 278 278 278 278 278 278 278 282 282 287 287 287 288 241 243 243 243 243 246 246 246 246 246 246 246 253 253 253 253 253 253 253 257 257
TCK186
1998-01 1996 1997 1998-01 Civic 1973-79 1980-83 1984-85 1986-87 1980-83 1984-85 1986-87 1988-89 1990-94 1995 1988-89 1991 1992 Except Si Si 1993-94 1995 1996
TCK161 TCK161 TCK143 TCK143 TCK143
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

A-17
Page
HONDA (Cont.)
Civic (Cont.) 1997-00 1.6L 4-Cyl. (SOHC) 2001 1.7L 4-Cyl. (SOHC) Civic CVCC 1975 1.5L 4-Cyl. 1976-79 1.5L 4-Cyl. Civic CRX 1984 1.3L 4-Cyl. 1984-85 1.5L 4-Cyl. 1986-87 1.5L 4-Cyl. 1988-89 1.6L 4-Cyl. (SOHC) 1990-91 1.6L 4-Cyl. (SOHC) Civic del Sol (Except VX) 1993-94 1.5L 4-Cyl. 1995 1.5L 4-Cyl. 1993-94 1995 1996 1997 1994 1995-95 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (DOHC) 250224 250312 250036 250041 250099 250099 250161 250145 250145 250143 250143 250224 250224 250224 250224 250227 250227 250227 250223 250223 250223 250223 250041 250041 250094 250160 250094 250160 250144 250144 250142 250141 250142 250186 250226 250186 250226 TCK036 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 105,000 3 110,000 3 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 90,000 90,000 90,000, Normal 60,000, Severe 90,000 90,000 Normal 60,000 Severe 90,000 Normal 60,000 Severe 105,000 3 90,000 90,000 Normal 60,000 Severe 105,000 3 90,000 90,000, Normal 60,000, Severe 90,000 90,000, Normal 60,000, Severe 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 90,000 60,000 1 90,000 90,000 90,000 2 90,000 2 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 257 260 246 246 243 246 246 253 253 246 246 246 253 253 253 257 257 257 251 251 251 251 246 246 246 246 246 246 253 263 263 263 269 269 269 269 271 271 271 273 273 273 273 273 273
TCK161
TCK143 TCK143
1997 1.6L 4-Cyl. (DOHC) Civic del Sol VX 1993-94 1.5L 4-Cyl. 1995 1.5L 4-Cyl. Civic VX 1992-94 1995 Prelude 1980-82 1979-82 1983-85 1986-87 1985 1986-87 1988-89 1990 1988-89 1990-91 1990-91 1993-94 1995-96 1.5L 4-Cyl. 1.5L 4-Cyl. 1.6L 4-Cyl. (SOHC) 1.8L 4-Cyl. 1.8L 4-Cyl. 1.8L 4-Cyl. 2.0L 4-Cyl. 2.0L 4-Cyl. (SOHC) 2.0L 4-Cyl. (SOHC) 2.0L 4-Cyl. (SOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.1L 4-Cyl. (DOHC) 2.2L 4-Cyl. (DOHC) Balance Shaft Camshaft 2.2L 4-Cyl. (DOHC) Balance Shaft Camshaft
TCK160 TCK160 TCK160 TCK160
A-18
Make Model/ Year

HONDA (Cont.)
Prelude (Cont.) 1997-01 2.2L 4-Cyl. (DOHC) Balance Shaft Camshaft 1992-94 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 1995-96 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 1992-94 1995-96 2.3L 4-Cyl. (DOHC) Balance Shaft Camshaft 2.3L 4-Cyl. (DOHC) Balance Shaft Camshaft Light Trucks CR-V 1997-01 Odyssey 1995-96 1997 1998 1999-01 Passport 1994-96 1994-97 1998-99 2000-01 250186 250226 250186 250187 250186 250187 250186 250216 250186 250216 TCK186 TCK186 TCK186 TCK186 TCK186 TCK186 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 105,000 2, 3 105,000 2, 3 90,000 2 90,000 2 90,000 2, Normal 60,000 2, Severe 90,000 2, Normal 60,000 2, Severe 90,000 2 90,000 2 90,000 2, 60,000 2, 90,000 2, 60,000 2, Normal Severe Normal Severe 273 273 278 278 278 278 278 278 278 278 278 278 278 278 266 276 276 276 276 282 282 288 285 28 291 291
2.0L 4-Cyl. 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.3L 4-Cyl. (SOHC) Balance Shaft Camshaft 3.5L V6 2.6L 4-Cyl. 3.2L V6 (SOHC) 3.2L V6 (DOHC) 3.2L V6 (DOHC)
250184 250186 250187 250186 250187 250186 250244 250286 250147 250221 250303 250303 TCK186 TCK186 TCK186 TCK186
105,000 3 90,000 2 90,000 2 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 3 60,000 60,000 75,000 105,000 3
HYUNDAI
Accent 1995-96 1997 1995-96 1997-01 2001 Elantra 1992-95 1993-95 1.5L 4-Cyl. (DOHC) 1.5L 4-Cyl. (DOHC) 1.5L 4-Cyl. (SOHC) 1.5L 4-Cyl. (SOHC) 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (DOHC) Balance Shaft Camshaft 1.8L 4-Cyl. (DOHC) Balance Shaft Camshaft 250282 250282 250191 250191 250282 250168 250165 250168 250167 2521670 2521670 Yes Yes Yes Yes Yes Yes Yes Yes 60,000 60,000 3 60,000 60,000 3 60,000 3 60,000 60,000 60,000 60,000
2 2
2521910 2521910
293 293 294 294 296 297 297 297 297
2 2

Make Model/ Year Elantra (Cont.) 1996-98 1999-01 Excel 1986-89 1990-94 Scoupe 1991-93 1994-95 Sonata 1992-98 1989-91 1990-98 Tiburon 1997 1999-01 Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
A-19
Page
HYUNDAI (Cont.)
1.8L 4-Cyl. 2.0L 4-Cyl. 1.5L 4-Cyl. (SOHC) 1.5L 4-Cyl. (SOHC) 1.5L 4-Cyl. (SOHC) 1.5L 4-Cyl. (SOHC) 2.0L 4-Cyl. (DOHC) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 3.0L V6 1.8L 4-Cyl. 2.0L 4-Cyl. 250278 250284 250073 250128 250128 250128 250168 250167 250159 250124 250139 250278 250284 2521280 2521280 2521910 2521670 2521670 2521240 2521240 2521390 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 60,000 3 60,000 3 60,000 60,000 60,000 60,000 60,000 2, 3 60,000 2, 3 60,000 2 60,000 2 60,000 3 60,000 3 60,000 3 301 301 294 294 294 294 302 302 305 305 308 301 301
INFINITI
Passenger Cars J30 1993 3.0L V6 1994-97 3.0L V6 M30 1990-92 3.0L V6 Light Trucks QX4 1997-01 3.3L V6 (SOHC)
250180 250251 250104 250249
Yes Yes Yes
60,000 60,000 60,000 105,000
310 310 313 456
ISUZU
Passenger Cars I-Mark 1981-84 1.8L 4-Cyl. Diesel 1985-87 1.5L 4-Cyl. Up To 6/30/86 From 7/1/86 1988-89 1.5L 4-Cyl. 1989 1.6L 4-Cyl. (DOHC) Impulse 1985-89 2.0L 4-Cyl. Turbo 1988-89 2.3L 4-Cyl. 1990-92 1.6L 4-Cyl. (DOHC) 1991-93 1.6L 4-Cyl. Turbo 1992 1.8L 4-Cyl. Stylus 1991 1.6L 4-Cyl. (DOHC) 1991-93 1.6L 4-Cyl. (SOHC) 1992-93 1.8L 4-Cyl. Light Trucks Amigo 1998 2.2L 4-Cyl.
250076 250118 250162 250162 250169 250121 250122 250169 250169 250205 250169 250177 250205 250305
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 75,000
318 219 219 219 315 320 315 315 315 315 315 315 315 325
Yes Yes Yes Yes Yes
Yes
Yes
A-20
Make Model/ Year

ISUZU (Cont.)
Amigo (Cont.) 1999-00 1989-93 1989-94 1998 1999 Oasis 1996 1997 1998 Pickup & PUP 1981-87 1986-95 1988-95 Rodeo 1998 1999-00 2001 1991-97 1993-97 1998 1999-01 Trooper 1990-91 1992-95 1992-97 1998 1999-01 Trooper II 1984-87 1986-87 1988-89 VehiCROSS 1999-01 2.2L 4-Cyl. 2.3L 4-Cyl. 2.6L 4-Cyl. 3.2L V6 3.2L V6 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.2L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.3L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.2L 4-Cyl. Diesel 2.3L 4-Cyl. 2.6L 4-Cyl. 2.2L 4-Cyl. 2.2L 4-Cyl. 2.2L 4-Cyl. 2.6L 4-Cyl. 3.2L V6 (SOHC) 3.2L V6 3.2L V6 2.6L 4-Cyl. 3.2L V6 (DOHC) 3.2L V6 (SOHC) 3.5L V6 3.5L V6 2.2L 4-Cyl. Diesel 2.3L 4-Cyl. 2.6L 4-Cyl. 3.5L V6 250305 250122 250147 250303 250303 Yes Yes Yes Yes 100,000, Normal 75,000, Severe 60,000 60,000 75,000 100,000 Normal 75,000 Severe 90,000 2 90,000 2 105,000 2, 3 105,000 2, 3 105,000 2, 3 105,000 2, 3 60,000 60,000 60,000 Yes Yes Yes Yes Yes Yes 75,000 100,000, Normal 75,000, Severe 75,000, Normal 60,000, Severe 60,000 60,000 75,000 100,000 Normal 75,000 Severe 60,000 60,000 60,000 75,000 100,000 Normal 75,000 Severe 60,000 60,000 60,000 Yes 100,000 Normal 75,000 Severe 325 325 320 320 334 334 334 327 327 327 327 329 329 323 320 320 325 325 325 325 325 320 332 334 334 334 320 332 332 334 334 334 323 320 320 334 334
Yes Yes
250186 250187 250186 250187 250186 250244 250075 250122 250147 250305 250305 250305 250147 250221 250303 250303 250147 T220 250221 250303 250303 250075 250122 250147 250303
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes
Yes Yes Yes Yes
Yes Yes Yes
KIA
Passenger Cars Sephia 1994-95 1.6L 4-Cyl. (SOHC) 1994-95 1.6L 4-Cyl. (SOHC) 1996-97 1.6L 4-Cyl. (DOHC) 1996-97 1.6L 4-Cyl. (DOHC)
250185 250185 250179 250179
TCK179 TCK179
Yes Yes Yes Yes
105,000 (Calif.) 3 60,000 (Exc. Calif.) 105,000 (Calif.) 3 60,000 (Exc. Calif.)
337 337 336 336

A-21
Page
KIA (Cont.)
Sephia (Cont.) 1995-97 1995-97 1998-01 1998-01 1996-97 1996-97 Spectra 2000-01 2000-01 Light Trucks Sportage 1995-01 1995-01 1995 1995
1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (SOHC) 1.8L 4-Cyl. (SOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (SOHC) 2.0L 4-Cyl. (SOHC)
250179 250179 250302 250302 250185 250185 250302 250302 250281 250281 250264 250264
TCK179 TCK179
105,000 (Calif.) 3 60,000 (Exc. Calif.) 105,000 (Calif.) 3 60,000 (Exc. Calif.) 105,000 (Calif.) 3 60,000 (Exc. Calif.) 105,000 (Calif.) 3 60,000 (Exc. Calif.) 105,000 (Calif.) 3 60,000 (Exc. Calif.) 105,000 (Calif.) 3 60,000 (Exc. Calif.)
336 336 339 339 337 337 339 339 341 341 343 343
LANCIA LEXUS
Beta 1976-78 ES250 1990-91 ES300 1992-93 1994-98 1999-01 GS300 1993-97 1998-01 GS400 1998-00 LS400 1990-94 1995-97 1998-00 SC300 1993-97 1998-00 SC400 1992-94 1995-97 1998-00 Light Trucks LX470 1998-01 RX-300 1999-01
1.8L 4-Cyl.
250020
Yes
25,000
344
2.5L V6 3.0L V6 3.0L V6 3.0L V6 3.0L 6-Cyl. 3.0L 6-Cyl. 4.0L V8 4.0L V8 4.0L V8 4.0L V8 3.0L 6-Cyl. 3.0L 6-Cyl. 4.0L V8 4.0L V8 4.0L V8 4.7L V8 3.0L V6
250157 250200 250257 250257 250215 250215 250298 250190 250190 250298 250215 250215 250190 250190 250298 250298 250257 Yes
Yes Yes Yes Yes
60,000 1, 3 60,000 1, 3 60,000 1, 3 90,000 60,000 1, 3 90,000
345 345 345 349 353 355 362 358 358 358 362 353 355 358 358 358 362 366 349
Yes Yes Yes Yes
90,000 60,000 1, 3 90,000, Normal 60,000, Severe 90,000 60,000 1, 3 90,000
Yes Yes Yes Yes Yes
60,000 1, 3 90,000, Normal 60,000, Severe 90,000 90,000 90,000
A-22
Make Model/ Year

MAZDA
Passenger Cars Miata & MX-5 Miata 1990-92 1.6L 4-Cyl. (DOHC) 1993 1.6L 4-Cyl. (DOHC) 1994-96 1997-00 1997-00 2001 Millenia 1995-96 1997-00 1997-00 1995-96 1997-00 1997-00 2001 MX-3 (Includes 1988-89 1994-95 1992 1993 1992 1993-95 MX-6 1993 1994-96 1997 1997 1988-92 1993 1994-96 1997 1997 Protege 1995-97 1995-97 1998 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 2.3L V6 (Miller Cycle) 2.3L V6 (Miller Cycle) 2.3L V6 (Miller Cycle) 2.5L V6 2.5L V6 2.5L V6 2.5L V6 Canadian) 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.8L V6 1.8L V6 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.2L 4-Cyl. 2.5L V6 2.5L V6 2.5L V6 2.5L V6 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. Up To Eng. No. 19472 From Eng. No. 19473 1999-00 2001 1990-92 1993-95 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC)
250179 250179 250179 250179 250179 250179 250267 250267 250267 250214 250214 250214 250214 250149 250179 250185 250185 250214 250214 250228 250228 250228 250228 250134 250214 250214 250214 250214 250266 250266 250266 250308 250308 250308 250179 250179
TCK179 TCK179 TCK179 TCK179 TCK179 TCK179
60,000 60,000 Federal 105,000 Calif. 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 60,000 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 105,000 3
373 373 373 376 376 376 376 376 396 396 396 396 399 399 399 399 399 373 373 373 373 373 373 393 393 393 382 382 382 382 382 387 399 399 399 399 399 370 370
TCK179
Yes Yes TCK228 TCK228 TCK228 TCK228 TCK134 Yes Yes Yes Yes Yes
60,000 60,000 Federal 105,000 Calif. 60,000 60,000 Federal 105,000 Calif. 60,000 60,000 Federal 105,000 Calif. 60,000 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 60,000 60,000 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 60,000 (Ex. CA & MA) 105,000 (CA & MA) 3
TCK179
60,000 (Ex. CA & MA) 370 105,000 (CA & MA) 3 370 60,000 (Ex. CA & MA) 370 105,000 (CA & MA) 3 370 371 60,000 3 371 105,000 3 60,000 373 60,000 Federal 373 105,000 Calif. 373

A-23
Page
MAZDA (Cont.)
Protege (Cont.) 1995-96 1.8L 4-Cyl. (DOHC) 1997-98 1997-98 1999-00 1999-00 1990-92 1993-94 2001 323 1988-89 1986 1987-89 1990-92 1993-94 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (SOHC) 1.8L 4-Cyl. (SOHC) 2.0L 4-Cyl. (DOHC) 1.6L 4-Cyl. (DOHC) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.8L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 2.0L 4-Cyl. (SOHC) 2.0L 4-Cyl. Square Tooth Sprocket Round Tooth Sprocket 2.0L 4-Cyl. 2.0L 4-Cyl. Diesel Camshaft Injection Pump 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.0L 4-Cyl. (DOHC) 2.2L 4-Cyl. 2.5L V6 2.5L V6 2.5L V6 2.5L V6 2.5L V6 3.0L V6 (DOHC) 3.0L V6 (DOHC) 3.0L V6 (SOHC) 2.0L 4-Cyl. (SOHC) Up To Chas. 568707 From Chas. 568708 2.0L 4-Cyl. (SOHC) 2.2L 4-Cyl.
250179 250179 250179 250316 250316 250185 250185 250228 250149 250123 250141 250185 250185 250088 250088 250113 250117 250103 250102 250228 250228 250228 250228 250228 250134 250214 250214 250214 250214 250214 250183 250183 250146
TCK179 TCK179 TCK179
TCK228
Yes
60,000 Federal 105,000 Calif. 60,000 3 105,000 3 60,000 3 105,000 3 60,000 60,000 Federal 105,000 Calif. 105,000 3 60,000 60,000 60,000 60,000 60,000 Federal 105,000 Calif.
376 376 376 376 380 380 373 373 373 382 373 373 373 373 373 373 387 387 387 387 389 389 382 382 382 382 382 382 387 399 399 399 399 399 399 402 402 402 404
TCK141
626 1983 1984-85 1986-87 1984-85 1993 1994-96 1997-00 1997-00 2001 1988-92 1993 1994-96 1997-00 1997-00 2001 929 1990-93 1994-95 1988-91 Light Trucks B2000 1986 1987 B2200 1987-93
60,000 60,000 60,000 60,000 100,000 100,000 60,000 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 105,000 3 60,000 60,000 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 105,000 3 60,000 60,000 Federal 105,000 Calif. 60,000
TCK228 TCK228 TCK228 TCK228 TCK228 TCK134
Yes Yes TCK146 Yes
250113 250117 250117 250134 TCK134
Yes Yes Yes Yes
60,000 60,000 60,000 60,000
387 387 387 387
A-24
Make Model/ Year B2300 1994 1997-95 B2500 1998-00 MPV 1988-93 1994-96 1997-98 1997-98 Tribute 2001

MAZDA (Cont.)
2.3L 4-Cyl. 2.3L 4-Cyl. 2.5L 4-Cyl. 3.0L V6 (SOHC) 3.0L V6 (SOHC) 3.0L V6 (SOHC) 3.0L V6 (SOHC) 2.0L 4-Cyl. (DOHC) 250210 250276 250276 250146 250146 250146 250146 250294 TCK146 TCK146 TCK146 TCK146 Yes Yes Yes Yes 60,000 60,000 120,000 60,000 60,000 Federal 105,000 Calif. 105,000 3 60,000 3 120,000 391 391 392 404 404 404 404 404 384
MERCURY
Passenger Cars Bobcat 1974-80 2.3L 4-Cyl. Capri 1972 1.6L 4-Cyl. 1971-74 2.0L 4-Cyl. 1991-94 1.6L 4-Cyl. (DOHC) 1976-86 2.3L 4-Cyl. Cougar 1981-86 2.3L 4-Cyl. 1998-00 2.0L 4-Cyl. (DOHC, VIN 3) 2001 LN7 1981-85 1981-85 1985-87 1984-87 Marquis 1983-86 Mystique 1995-97 1998-00 Topaz 1984-86 Tracer 1987-90 1991-96 1991 1992-96 2.0L 4-Cyl. (DOHC, VIN 3) 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (SOHC) 1.9L 4-Cyl. 2.0L 4-Cyl. Diesel Camshaft Injection Pump 2.3L 4-Cyl. 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. (DOHC, VIN 3) 2.0L 4-Cyl. Diesel Camshaft Injection Pump 1.6L 4-Cyl. (SOHC) 1.8L 4-Cyl. (DOHC) 1.9L 4-Cyl. Before 3/25/1991 After 3/26/1991 1.9L 4-Cyl.
250014 250013 250013 250179 250014 250014 250294 250294 250067 250067 250067 250103 250102 250014 250258 250294
2520140
60,000 1 60,000 1 60,000 1 60,000 60,000 1 60,000 1 Inspect at 120,000, Replace if needed 120,000 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 60,000 60,000 60,000 100,000 2 100,000 2 60,000 1 60,000 1000 Inspect at 120,000, Replace if needed Yes Yes Yes Yes Yes Yes Yes Yes 100,000 2 100,000 2 60,000 60,000 60,000 60,000 60,000
189 168 168 163 189 189 180 180 165 165 165 172 172 189 178 180 172 172 165 169 165 165 165
TCK179 2520140 2520140
2520670 2520670 2520670
2520140
250103 250102 250141 250179 250067 250194 250194 TCK141 TCK179 2520670 2521940 2521940
Yes Yes Yes Yes

Make Model/ Year Tracer (Cont.) 1997-00 2001 Zephyr 1978-83 Light Trucks Villager 1993 1994-98 Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
A-25
Page
MERCURY (Cont.)
2.0L 4-Cyl. (SOHC, VIN P) 2.0L 4-Cyl. (SOHC, VIN P) 2.3L 4-Cyl. 3.0L V6 (SOHC) 3.0L V6 (SOHC) 250283 250283 250014 250104 250249 2520140 TCK104 Yes Yes Inspect at 120,000, Replace if needed 120,000 60,000 1 105,000 105,000 184 184 189 198 198
MERKUR
XR4Ti 1985-89 2.3L 4-Cyl. 250014 2520140 60,000 1 189
MITSUBISHI
Passenger Cars Cordia & Tredia 1983-84 1.8L 4-Cyl. Balance Shaft Camshaft 1985-86 1.8L 4-Cyl. Balance Shaft Camshaft 1987-88 1.8L 4-Cyl. Balance Shaft Camshaft 1984 2.0L 4-Cyl. Balance Shaft Camshaft 1985-86 2.0L 4-Cyl. Balance Shaft Camshaft 1987-88 2.0L 4-Cyl. Balance Shaft Camshaft Diamante 1992-93 3.0L V6 (DOHC) 1994-96 3.0L V6 (DOHC) 1992-93 3.0L V6 (SOHC, 12-Valve) 1994-96 3.0L V6 (SOHC, 12-Valve) 1997-01 Eclipse 1990-94 1995-97 1998-99 3.5L V6 (SOHC) 1.8L 4-Cyl. Balance Shaft Camshaft 2.0L 4-Cyl. (Non-Turbo) DOHC, VIN Y 2.0L 4-Cyl. (Non-Turbo) DOHC, VIN Y
250090 250089 250159 250089 250159 250158 250090 250089 250159 250089 250159 250158 250195 250195 250139 250139 250287 250159 250158 250246 250246 2521580 2521580 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 2521580 2521580
60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 3 60,000 60,000 Federal 100,000 Calif. 60,000 3 60,000 2 60,000 2 60,000 Federal 3 100,000 Calif. 3 60,000 3
411 411 411 411 411 411 411 411 411 411 411 411 142 142 430 430 430 442 128 128 133 133 133
2521390 2521390
Yes
A-26
Make Model/ Year

MITSUBISHI (Cont.)
Eclipse (Cont.) 1990-94 2.0L 4-Cyl. (DOHC) Balance Shaft Camshaft 1995-97 2.0L 4-Cyl. (DOHC) Turbo Balance Shaft Camshaft 1998-99 2.0L 4-Cyl. (DOHC) Turbo Balance Shaft Camshaft 1996 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 2000-01 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 2000-01 3.0L V6 (SOHC, 24-Valve) Expo & Expo LRV 1992-93 1.8L 4-Cyl. (VINs C & D) 1994 1.8L 4-Cyl. (VINs C & D) 1992 1993-95 Galant 1989-92 1993 1989-92 1993 2.4L 4-Cyl. Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft 2.0L 4-Cyl. Balance Shaft Camshaft 2.0L 4-Cyl. Balance Shaft Camshaft 2.0L 4-Cyl. (DOHC) Balance Shaft Camshaft 2.0L 4-Cyl. (DOHC) Balance Shaft Camshaft 1997-98
250168 250167 250168 250167 250168 250167 250168 250230
2521670 2521670 2521670 2521670 2521670 2521670
60,000 2 60,000 2 60,000 Federal 2, 3 100,000 Calif. 2, 3 60,000 Federal 2, 3 100,000 Calif. 2, 3 60,000 2, 3 100,000 2, 3 60,000 2, 3 100,000 2, 3 60,000 Federal 2 100,000 Calif.2 60,000 Federal 2 100,000 Calif.2 60,000 2 , 3 60,000 2 , 3 60,000 2 , 3 60,000 2 , 3 60,000 3 60,000 60,000 Federal 100,000 California 3 60,000 2 60,000 2 60,000 2 60,000 2
414 414 414 414 414 414 414 414 414 414 425 425 425 425 425 425 425 425 435 131 131 131 136 136 136 136 411 411 411 411 414 414 414 414
250168 250230 250168 250232 250259 250201 250201 250159 250204 250168 250230 250159 250155 250168 250232 250168 250167 250168 250232 TCK155 TCK155 TCK232 TCK232 2521670 2521670 TCK232 TCK232
Yes Yes Yes Yes Yes
Yes Yes Yes
60,000 2 60,000 2 60,000 2 60,000 2 Yes Yes Yes Yes 60,000 2 60,000 2 60,000 2 60,000 2

Make Model/ Year Galant (Cont.) 1994 Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
A-27
Page
MITSUBISHI (Cont.)
2.4L 4-Cyl. (DOHC) Balance Shaft Camshaft Up To May, 1994 From June, 1994 1995-96 2.4L 4-Cyl. (DOHC) Balance Shaft Camshaft 1985-87 1994-96 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 1997-98 1999-01 1988 1999-01 Mirage 1985-86 1987-90 1991-93 1994-96 1997-01 1997-01 1985-88 1989-92 1993 1994-96 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 3.0L V6 (SOHC, 12-Valve) 3.0L V6 (SOHC, 24-Valve) 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.5L 4-Cyl. 1.6L 4-Cyl. (SOHC) 1.6L 4-Cyl. (DOHC) 1.8L 4-Cyl. (VINs C & D) 1.8L 4-Cyl. (VINs C & D) 250168 250256 250230 250168 250230 250159 250124 250168 250230 2521240 2521240 Yes Yes TCK256 Yes Yes Yes Yes Yes 60,000 Federal 100,000 Calif. 60,000 Federal 100,000 Calif. 60,000 Federal 100,000 Calif. 60,000 Federal 100,000 Calif. 60,000 Federal 100,000 Calif. 60,000 2 60,000 2 60,000 Federal 2 100,000 Calif.2 60,000 Federal 2 100,000 Calif.2 60,000 2 , 3 60,000 2 , 3 60,000 2 , 3 60,000 2 , 3 60,000 60,000 3 60,000 60,000 60,000 60,000 Federal 60,000 Calif. 3 100,000 3 60,000 3 60,000 60,000 60,000 60,000 Federal 100,000 Calif. 3 100,000 3 60,000 3 60,000 60,000 Yes 60,000 419 419 419 419 419 419 419 419 419 419 422 422 425 425 425 425 425 425 425 425 430 435 406 406 406 406 406 406 406 409 125 131 131 131 131 131 406 406 430
250168 250230 250168 250232 250139 250259 250073 250128 250191 250191 250289 250289 250093 250165 250201 250201 250288 250288 250073 250128 250139 2521280 2521390
2521390
Yes Yes
2521280 2521910 2521910
Yes Yes Yes Yes
1997-00 1.8L 4-Cyl. 1997-00 1.8L 4-Cyl. Precis 1987-89 1.5L 4-Cyl. 1990-93 1.5L 4-Cyl. Sigma 1989-90 3.0L V6 (SOHC, 12-Valve) Tredia (See Cordia)
Yes Yes
A-28
Make Model/ Year 3000GT 1991-93 1992-98 1997-98 Light Trucks Montero 1989-93 1994 1995-96 1994-96

MITSUBISHI (Cont.)
3.0L V6 (DOHC) 3.0L V6 (DOHC) 3.0L V6 (SOHC, 12-Valve) 3.0L V6 (SOHC, 12-Valve) 3.0L V6 (SOHC, 12-Valve) 3.0L V6 (SOHC, 24-Valve) 3.5L V6 (DOHC) 3.5L V6 (SOHC) 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 2.4L 4-Cyl. (SOHC, VIN G) Balance Shaft Camshaft 3.0L V6 (SOHC, 24-Valve) 3.5L V6 (SOHC) 2.0L 4-Cyl. Balance Shaft Camshaft 2.0L 4-Cyl. Balance Shaft Camshaft 2.3L 4-Cyl. Diesel Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft 2.4L 4-Cyl. Balance Shaft Camshaft 3.0L V6 (SOHC, 12-Valve) 3.0L V6 (SOHC, 12-Valve) 2.4L 4-Cyl. (SOHC) Balance Shaft Camshaft 250195 250195 250139 250139 250139 250259 250253 250287 250168 250230 250168 250232 250259 250287 250090 250089 250159 250158 250092 250091 250159 250124 250168 250229 250139 250139 2521240 2521240 2521581 2521581 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 60,000 60,000 3 60,000 3 60,000 60,000 Federal 100,000 Calif. 60,000 Federal 100,000 Calif. 60,000 Federal 100,000 Calif. 60,000 3 60,000 2 , 3 60,000 2 , 3 60,000 2 , 3 60,000 2 , 3 60,000 3 60,000 3 60,000 2 60,000 2 60,000 2 60,000 2 50,000 2 50,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 Federal 100,000 Calif. 60,000 2 60,000 2 142 142 430 430 430 430 435 435 439 439 442 425 425 425 425 435 442 411 411 411 411 138 138 140 140 140 140 430 430 430 422 422
2521390 2521390 2521390
1997-00 Montero Sport 1997-98 1999 1997-01 1997-01 Pickup 1983-86 1987-89 1983-86 1990-92 1993-96 1990-93 1994 Van 1987-90
Yes Yes
2521390 2521390
Yes Yes
250159 250124
2521240 2521240
NISSAN
Passenger Cars Maxima 1985 3.0L V6 (SOHC) 1996-91 3.0L V6 (SOHC)
250104 250104
TCK104 TCK104
Yes Yes
60,000
454 454

A-29
Page
Maxima (Cont.) 1992-94 3.0L V6 (SOHC) Round Tooth Sprocket 250249 Yes Yes Square Tooth Sprocket 250104 TCK104 Pulsar & Pulsar NX 1983-84 1.5L 4-Cyl. 250077 TCK077 Yes 1987 1.6L 4-Cyl. (DOHC) 250137 Yes Yes 1983-88 1.6L 4-Cyl. (SOHC) 250077 TCK077 1988-89 1.8L 4-Cyl. (DOHC) 250137 Yes Sentra Yes 1982-83 1.5L 4-Cyl. 250077 TCK077 1983-88 1.6L 4-Cyl. (SOHC) 250077 TCK077 Yes 1983-87 1.7L 4-Cyl. Diesel Camshaft 250096 Yes Injection Pump 250097 Yes Stanza 1982-85 2.0L 4-Cyl. 250078 Yes 1986-89 2.0L 4-Cyl. 250078 Yes Stanza Wagon 1982-89 *2.0L 4-Cyl. 250078 200SX 1984-85 1.8L 4-Cyl. (Turbo) T100 1986-87 1.8L 4-Cyl. (Turbo) T100 1984-85 2.0L 4-Cyl. 250078 Yes 1986-88 2.0L 4-Cyl. 250078 Yes Yes 1987-88 3.0L V6 (SOHC) 250104 TCK104 300ZX 1984-85 3.0L V6 (SOHC) 250104 TCK104 Yes 1986-89 3.0L V6 (SOHC) 250104 TCK104 Yes 1990-93 3.0L V6 (DOHC) 250180 Yes 1994-96 3.0L V6 (DOHC) 250251 Yes 310 Yes 1982 1.5L 4-Cyl. 250077 TCK077 Light Trucks Frontier 1999-01 3.3L V6 (SOHC) 250249 Pathfinder Yes 1986-92 3.0L V6 (SOHC) 250104 TCK104 1993-94 3.0L V6 (SOHC) Round Tooth Sprocket 250249 Yes Yes Square Tooth Sprocket 250104 TCK104 1995-96 3.0L V6 (SOHC) 250249 Yes 1999-00 3.3L V6 (SOHC) 250249 Yes Pickup Yes 1986-92 3.0L V6 (SOHC) 250104 TCK104 1993-94 3.0L V6 (SOHC) Round Tooth Sprocket 250249 Yes Yes Square Tooth Sprocket 250104 TCK104 1995-96 3.0L V6 (SOHC) 250249 Yes Quest 1993-94 3.0L V6 (SOHC) Round Tooth Sprocket 250249 Yes Yes Square Tooth Sprocket 250104 TCK104 1995-98 3.0L V6 (SOHC) 250249 Yes 1999-01 3.3L V6 (SOHC) 250249 * - 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 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.
NISSAN (Cont.)
60,000 60,000 60,000 1 60,000 60,000 1 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 60,000 1 60,000 60,000 1 60,000 60,000 60,000 1 60,000 60,000 60,000 60,000 1 105,000 60,000 60,000 60,000 60,000 105,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 105,000 manufacturers
454 454 446 448 446 448 446 446 450 450 451 451 451 451 451 451 451 454 454 454 452 452 446 456 454 454 454 454 456 454 454 454 454 454 454 454 456
A-30
Make Model/ Year Xterra 2000-01

NISSAN (Cont.)
3.3L V6 (SOHC) 250249 105,000 456
OLDSMOBILE
Cutlass Supreme 1991-95 3.4L V6 1996 3.4L V6 Firenza 1982-86 1.8L 4-Cyl. 1987-88 2.0L 4-Cyl.
250192 250273 250081 250081
Yes Yes
Yes Yes
60,000 60,000 60,000 1 60,000 1
238 238 228 229
PEUGEOT
405 1989-91 1991-89 505 1986-91 1.9L 4-Cyl. (DOHC) 1.9L 4-Cyl. (SOHC) 2.2L 4-Cyl. (Exc. Turbo) T188 250189 250140 60,000 1 60,000 1 60,000 1 460 460 462
Passenger Cars Acclaim 1985-89 2.5L 4-Cyl. 1989-93 3.0L V6 (SOHC) 1994-95 3.0L V6 (SOHC) Arrow 1978-80 1.6L 4-Cyl. w/o Bal. Shaft 1977-80 1.6L 4-Cyl. Balance Shaft Camshaft Breeze 1996-00 2.0L 4-Cyl. (SOHC, VIN C) 1996-99 2000 Caravelle 1983-88 1986-87 1988 Champ 1979-82 1979-82 1979-80 2.4L 4-Cyl. (DOHC, VIN X) 2.4L 4-Cyl. (DOHC, VIN X) 2.2L 4-Cyl. 2.5L 4-Cyl. 2.5L 4-Cyl. 1.4L 4-Cyl. 1.6L 4-Cyl. w/o Bal. Shaft 1.6L 4-Cyl. Balance Shaft Camshaft
PLYMOUTH
250153 250139 250139 250064 250062 250013 250245 250265 250265 250071 250114 250132 250073 250064 250062 250013 250073 250073 250128 250191 250064 250064 250093 250062 250013
2521530 2521390 2521390
Yes Yes
60,000 1 60,000 60,000 3 60,000 60,000 2 60,000 2
101 110 110 87 85 85 93 93 106 106 106 101 101 101 83 87 85 85 83 114 114 114 87 87 87 85 85
Yes
Yes Yes Yes
100,000 Federal 105,000 Calif. 105,000 100,000 Federal 105,000 Calif. 60,000 1 60,000 1 60,000 1
2520710
Yes
60,000 60,000 60,000 2 60,000 2
Colt 1979-84 1.4L 4-Cyl. 1985-86 1.5L 4-Cyl. 1987-90 1.5L 4-Cyl. 1991-94 1.5L 4-Cyl. 1978-79 (RWD) 1.6L 4-Cyl. w/o Bal. Shaft 1979-82 (FWD)1.6L 4-Cyl. w/o Bal. Shaft 1983-89 1.6L 4-Cyl. w/o Bal. Shaft 1977-80 1.6L 4-Cyl. Balance Shaft Camshaft
2521280 2521910
Yes Yes Yes
60,000 60,000 60,000 60,000 60,000 60,000 60,000 60,000 2 60,000 2

A-31
Page
PLYMOUTH (Cont.)
Colt (Cont.) 1989-90 1.6L 4-Cyl. (DOHC) 1989-90 1.8L 4-Cyl. (VIN T) 1992-94 1.8L 4-Cyl. (VINs C & D) Colt Vista (Includes Canadian) 1992-94 1.8L 4-Cyl. (VINs C & D) 1984-86 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 1987-91 2.0L 4-Cyl. (SOHC) Balance Shaft Camshaft 1992 2.4L 4-Cyl. Balance Shaft Camshaft 1993 2.4L 4-Cyl. Balance Shaft Camshaft 1994 2.4L 4-Cyl. Balance Shaft Camshaft Colt 100 (Canadian) 1989-90 1.6L 4-Cyl. (DOHC) Colt 200 (Canadian) 1989-90 1.6L 4-Cyl. (DOHC) Horizon 1978-83 1.7L 4-Cyl. 1981-88 2.2L 4-Cyl. 1989-90 2.2L 4-Cyl. Laser 1990-94 1.8L 4-Cyl. Balance Shaft Camshaft 1990-94 2.0L 4-Cyl. (DOHC) Balance Shaft Camshaft Neon 1995-99 2.0L 4-Cyl. (DOHC, VIN Y) 1995-00 2.0L 4-Cyl. (SOHC, VIN C) Reliant 1981-88 2.2L 4-Cyl. 1989 2.2L 4-Cyl. 1986-87 2.5L 4-Cyl. 1988 2.5L 4-Cyl. 1989 2.5L 4-Cyl. Sapporo 1978-80 1.6L 4-Cyl. w/o Bal. Shaft 1977-80 1.6L 4-Cyl. Balance Shaft Camshaft Sundance 1987-88 2.2L 4-Cyl. 1989-94 2.2L 4-Cyl. 1988 2.5L 4-Cyl. 250165 250093 250201 250201 250090 250089 250159 250158 250159 250204 250159 250230 250168 250230 250165 250165 250017 250071 250153 250159 250158 250168 250167 250246 250245 250071 250153 250114 250132 250153 250064 250062 250013 250071 250153 250132 2520710 2521530 2520710 2520710 2521530 2520170 2520710 2521530 2521580 2521580 2521670 2521670 Yes Yes Yes Yes Yes Yes Yes Yes 2521581 2521581 Yes Yes Yes 60,000 60,000 60,000 60,000 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 2 60,000 60,000 60,000 1 60,000 1 60,000 1 60,000 2 60,000 2 60,000 2 60,000 2 105,000 105,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 2 60,000 2 60,000 1 60,000 1 60,000 1 125 91 131 131 121 121 121 121 136 136 136 136 136 136 125 125 89 101 101 128 128 116 116 133 93 101 101 101 101 101 87 85 85 101 101 101
A-32
Make Model/ Year

PLYMOUTH (Cont.)
Sundance (Cont.) 1989-94 2.5L 4-Cyl. 1992-93 3.0L V6 (SOHC) 1994 3.0L V6 (SOHC) TC3 1981-82 1.7L 4-Cyl. 1981-82 2.2L 4-Cyl. Turismo 1983 1.7L 4-Cyl. 1983-87 2.2L 4-Cyl. Light Trucks (See DODGE/PLYMOUTH Light Trucks) Passenger Cars Acadian (Canadian) 1976 1.4L 4-Cyl. 1977 1.4L 4-Cyl. 1976 1.6L 4-Cyl. 1977-78 1.6L 4-Cyl. 1979-87 1.6L 4-Cyl. 1981-85 1.8L 4-Cyl. Diesel Firefly (Canadian) 1985-88 1.0L 3-Cyl. 1989-91 1.0L 3-Cyl. 1994-95 1.0L 3-Cyl. 1996-97 1.0L 3-Cyl. 1998-00 1.0L 3-Cyl. 1995-97 1.3L 4-Cyl. 1998-00 1.3L 4-Cyl. Grand Am 1987-88 2.0L 4-Cyl. 1989 2.0L 4-Cyl. (Turbo) Grand Prix 1991-95 3.4L V6 1996 3.4L V6 J2000 1982 1.8L 4-Cyl. LeMans 1988-89 1.6L 4-Cyl. 1990 1.6L 4-Cyl. With Tensioner Without Tensioner 1991-93 1.6L 4-Cyl. 1989 2.0L 4-Cyl. First Design Second Design 1990 2.0L 4-Cyl. Sunbird 1985-86 1.8L 4-Cyl. 1987-88 2.0L 4-Cyl. 1989-94 2.0L 4-Cyl. Sunburst (Canadian) 1985-88 1.5L 4-Cyl.
250153 250139 250139 250017 250071 250017 250071
2521530 2521390 2521390 2520170 2520710 2520170 2520710
60,000 1 60,000 60,000 3 60,000 1 60,000 1 60,000 1 60,000 1
101 110 110 89 101 89 101
PONTIAC
250037 250039 250037 250039 250061 250076 250095 250166 250243 250194 250194 250272 250194 250081 250163 250192 250273 250081
Yes
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 60,000 60,000 100,000 60,000 100,000 Yes Yes 60,000 1 60,000 1 60,000 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000
221 221 221 221 221 226 211 211 211 211 211 213 213 229 229 238 238 228 223 223 223 223 229 229 229 228 229 229 219
2521940 2521940 2521940 2521630 Yes Yes
Yes Yes Yes Yes
250203 250148 250203 250081 250163 250163 250081 250081 250163 250162 2521630 2521630
Yes Yes Yes
2521630 Yes
Yes

A-33
Page
PONTIAC (Cont.)
T1000 1981-82 1.6L 4-Cyl. 1000 1983-87 1.6L 4-Cyl. 2000 1983 1.8L 4-Cyl. 2000 Sunbird 1984 1.8L 4-Cyl. Light Trucks Sunrunner (Canadian) 1989-95 1.6L 4-Cyl. (8-Valve) California Except California 1994-98 1.6L 4-Cyl. (16-Valve) California Except California 250061 250061 250081 250081 Yes Yes 60,000 1 60,000 1 60,000 1 60,000 1 221 221 228 228
250212 250164 250212 250164
60,000 1 60,000 1 60,000 60,000
215 215 215 215
PORSCHE
924 1977-82 1987-88 2.0L 4-Cyl. 2.5L 4-Cyl. Balance Shaft Camshaft 4.5L V8 4.5L V8 5.0L V8 5.4L V8 250017 250293 250107 250196 250196 250196 250196 250293 250107 250293 250107 250293 250152 250293 250152 250293 250152 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 45,000 45,000 45,000 60,000 60,000 60,000 60,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 45,000 463 464 464 467 467 467 467 464 464 464 464 464 464 464 464 464 464
928 1978-82 1983-84 1985-91 1992-95 944 1983-89
2.5L 4-Cyl. Balance Shaft Camshaft 1989 2.7L 4-Cyl. Balance Shaft Camshaft 1989-91 3.0L 4-Cyl. Balance Shaft Camshaft 944S & 944 Turbo 1987-88 2.5L 4-Cyl. Balance Shaft Camshaft 968 1992-95 3.0L 4-Cyl. Balance Shaft Camshaft
RENAULT
Alliance & Encore 1985-87 1.7L 4-Cyl. Fuego & Sportwagon 1984-86 2.2L 4-Cyl.
250119 250140
Yes
60,000 1 60,000 1
470 472
A-34
Make Model/ Year

SAAB
900 1994-97 9000 1995-97
2.5L V6 3.0L V6
250285 250285
Yes Yes
60,000 60,000
474 474
SATURN
L Series 2000-01 825 1987-88 827 1989-91 Coupe 1985-89 3.0L V6 (DOHC) 250285 Yes Yes 100,000 235
STERLING
2.5L V6 2.7L V6 250129 250129 Yes Yes 60,000 1 60,000 1 475 475
SUBARU
1.8L 4-Cyl. Right Hand Belt Left Hand Belt Impreza & Outback Sport 1993 1.8L 4-Cyl. 1994 1.8L 4-Cyl. 1995-97 1.8L 4-Cyl. 1995-98 2.2L 4-Cyl. 250300 250299 250172 250254 250254 250254 250304 250277 250277 T135 250172 250254 250254 250304 250277 250277 250307 250300 250299 250300 250299 250300 250299 TCK300 TCK299 TCK300 TCK299 TCK300 TCK299 TCK172 Yes Yes TCK300 TCK299 TCK172 52,000 2 52,000 2 60,000 60,000 60,000 Federal 105,000 Calif. 60,000 Federal 105,000 Calif. 105,000 60,000 105,000 60,000 60,000 60,000 60,000 Federal 105,000 Calif. 105,000 60,000 105,000 105,000 52,000 2 52,000 2 52,000 2 52,000 2 52,000 2 52,000 2 478 478 480 480 480 480 480 480 482 484 484 477 480 480 480 480 482 484 484 482 478 478 478 478 478 478
1999-01 2.2L 4-Cyl. (SOHC) 1996-97 2.5L 4-Cyl. (DOHC) 1998-99 2.5L 4-Cyl. (DOHC) Justy 1987-95 1.2L 3-Cyl. Legacy & Outback 1993 2.2L 4-Cyl. 1994 2.2L 4-Cyl. 1995-98 2.2L 4-Cyl. 1999-01 1996-97 1998-99 2000-01 Loyale 1990-94 RX 1985-89 2.2L 4-Cyl. (SOHC) 2.5L 4-Cyl. (DOHC) 2.5L 4-Cyl. (DOHC) 2.5L 4-Cyl. (SOHC) 1.8L 4-Cyl. Right Hand Belt Left Hand Belt
Yes Yes
1.8L 4-Cyl. Right Hand Belt Left Hand Belt Sedan & Station Wagon 1985-89 1.8L 4-Cyl. Right Hand Belt Left Hand Belt

Make Model/ Year SVX 1992-94 1995-97 XT 1985-91 XT6 1988-91 Light Trucks Forester 1998 1999-01 Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
A-35
Page
SUBARU (Cont.)
3.3L 6-Cyl. 3.3L 6-Cyl. 1.8L 4-Cyl. Right Hand Belt Left Hand Belt 2.7L 6-Cyl. Right Hand Belt Left Hand Belt 2.5L 4-Cyl. (DOHC) 2.5L 4-Cyl. (SOHC) T209 T209 60,000 60,000 Federal 105,000 Calif. TCK300 TCK299 52,000 2 52,000 2 60,000 2 60,000 2 Yes 105,000 105,000 491 491 491 478 478 487 487 484 482
250300 250299 250150 250151 250277 250304
SUZUKI
Passenger Cars Esteem 1995-00 1.6L 4-Cyl. Esteem (Canadian) 2001 1.6L 4-Cyl. Swift 1989-92 1.3L 4-Cyl. (DOHC) 1993-94 1.3L 4-Cyl. (DOHC) 1989-92 1.3L 4-Cyl. (SOHC) 1993 1.3L 4-Cyl. (SOHC) 1994 1.3L 4-Cyl. (SOHC) 1995-97 1.3L 4-Cyl. (SOHC) 1998-01 1.3L 4-Cyl. (SOHC) Light Trucks Samurai 1985-92 1.3L 4-Cyl. (SOHC) 1993 1.3L 4-Cyl. (SOHC) 1994 1.3L 4-Cyl. (SOHC) VIN R4100375 & Earlier From VIN R4100376 1995 1.3L 4-Cyl. Sidekick 1989 1.3L 4-Cyl. (SOHC) 1989-91 1.6L 4-Cyl. 1992 1.6L 4-Cyl. Convertible Hardtop 1993-95 1.6L 4-Cyl. Convertible Hardtop 1996-98 1.6L 4-Cyl. Vitara 1999-01 1.6L 4-Cyl. X-90 1996-98 1.6L 4-Cyl.
250212 250212 T171 T171 250095 250095 250243 250272 250194 250095 250095 250095 250243 250243 250095 250164 250164 250212 250164 250212 250212 250212 250212 Yes Yes
60,000 60,000 60,000 1 60,000 60,000 1 60,000 60,000 60,000 60,000 60,000 1 60,000 60,000 60,000 60,000 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 60,000 60,000 60,000
497 497 492 492 494 494 494 494 494 494 494 494 494 494 494 497 497 497 497 497 497 497 497
2521941
A-36
Make Model/ Year

Passenger Cars Avalon 1995-97 3.0L V6 1998-01 3.0L V6 Camry 1984-85 1.8L 4-Cyl. Diesel 1983-85 2.0L 4-Cyl. 1986 2.0L 4-Cyl. 1987-91 2.0L 4-Cyl. 1992-97 2.2L 4-Cyl. 1998-01 2.2L 4-Cyl. 1988-91 2.5L V6 1992-93 3.0L V6 1995-97 3.0L V6 1998-01 3.0L V6 Camry Solara 1999-01 2.2L 4-Cyl. 1998-01 3.0L V6 Celica, Celica GT & ST 1990-92 1.6L 4-Cyl. (DOHC, 4A-F) 1993 1.6L 4-Cyl. (DOHC, 4A-F) 1994-97 1.8L 4-Cyl. (7A-FE) 1986 2.0L 4-Cyl. 1987-89 2.0L 4-Cyl. 1990-93 2.0L 4-Cyl. 1990-97 2.2L 4-Cyl. 1998-01 2.2L 4-Cyl. Celica GTS 1986-88 2.0L 4-Cyl. 1990-93 2.2L 4-Cyl. Celica Supra 1982-83 2.8L 6-Cyl. 1984-86 2.8L 6-Cyl. Corolla 1983-85 1.6L 4-Cyl. (SOHC) 1986-88 1.6L 4-Cyl. (SOHC) 1988-92 1.6L 4-Cyl. (DOHC, 4A-F) 1993-97 1.6L 4-Cyl. (DOHC, 4A-F) 1984-85 1.8L 4-Cyl. Diesel 1993-97 1.8L 4-Cyl. (7A-FE) Corolla FX & FX-16 1986-88 1.6L 4-Cyl. 1985 1.6L 4-Cyl. (4A-GE) 1986-88 1.6L 4-Cyl. (4A-GE) Corolla GTS 1989-91 1.6L 4-Cyl. (4A-GE/GELC) Corolla SR5 1985 1.6L 4-Cyl. 1986-88 1.6L 4-Cyl. Corolla Tercel 1980-82 1.5L 4-Cyl. Cressida 1983 2.8L 6-Cyl. 1984-88 2.8L 6-Cyl.
TOYOTA
250257 250257 250098 250087 250087 250199 250199 250199 250157 250200 250257 250257 250199 250257 250036 250239 250235 250087 250199 250125 250199 250199 250125 250199 250074 250101 250070 250070 250036 250236 250098 250235 250070 250112 250112 250176 250070 250070 250070 250074 250101 2520700 2520700 2520700 2520700 2520700 TCK036 TCK236 TCK087 TCK087 TCK199 TCK199 TCK199
Yes
60,000, Severe 90,000 60,000 60,000 1 60,000, Severe 60,000, Severe 60,000, Severe 90,000 60,000, Severe 60,000, Severe 60,000, Severe 90,000 90,000 90,000 60,000, Severe 60,000, Severe 60,000, Severe 60,000, Severe 60,000, Severe 60,000, Severe 60,000, Severe 90,000 60,000, Severe 60,000, Severe 60,000, Severe 60,000, Severe 60,000 1 60,000, Severe 60,000, Severe 60,000, Severe 60,000 60,000, Severe 60,000, Severe 60,000 1 60,000, Severe 60,000, Severe 60,000 1 60,000, Severe 60,000 1 60,000, Severe 60,000, Severe
543 547 516 518 518 518 525 525 543 543 543 547 525 547 512 512 512 518 518 518 525 525 518 525 533 533 509 509 512 512 516 512 509 506 506 506 509 509 499 533 533
TCK199 TCK036 TCK087 TCK199 TCK199 TCK199 TCK199 Yes Yes Yes Yes Yes Yes Yes
2520700

A-37
Page
Cressida (Cont.) 1989-91 3.0L 6-Cyl. 1992 3.0L 6-Cyl. MR2 1985 1.6L 4-Cyl. (4A-GE) 1986-88 1.6L 4-Cyl. (4A-GE) 1989 1.6L 4-Cyl. (4A-GE) 1991-95 2.0L 4-Cyl. 1991-95 2.2L 4-Cyl. Paseo 1992-97 1.5L 4-Cyl. (5E-FE) 1998 1.5L 4-Cyl. (5E-FE) 1999 1.5L 4-Cyl. (5E-FE) Supra 1986-90 3.0L 6-Cyl. (7M-GE) 1991-92 3.0L 6-Cyl. (7M-GE) 1993-97 3.0L 6-Cyl. (2JZ) 1998 3.0L 6-Cyl. (2JZ) Tercel 1983-86 1.5L 4-Cyl. (3A-C)) 1987 1.5L 4-Cyl. (Sedan, 3E) 1988-94 1.5L 4-Cyl. (3E) 1995-97 1.5L 4-Cyl. (5E-FE) 1998 1.5L 4-Cyl. (5E-FE) 1999 1.5L 4-Cyl. (5E-FE) Tercel Wagon 1987-88 1.5L 4-Cyl. (3A-C) Light Trucks Highlander 2001 3.0L V6 Land Cruiser 1998-01 4.7L V8 Pickup 1981 2.2L 4-Cyl. Diesel 1982 2.2L 4-Cyl. Diesel Up To May 31 From June 1 1983 2.2L 4-Cyl. Diesel 1984-87 2.4L 4-Cyl. Diesel 1988-92 3.0L V6 (3V-ZE) 1993-95 3.0L V6 (3V-ZE) RAV4 1996-97 2.0L 4-Cyl. 1998 2.0L 4-Cyl. 1999-00 2.0L 4-Cyl. Sienna 1998-01 3.0L V6 Tacoma 1995-97 3.4L V6 1999-01 3.4L V6 Tundra 2000-01 3.4L V6 2000-01 4.7L V8
TOYOTA (Cont.)
250126 250238 250112 250112 250176 250125 250199 250208 250208 250208 250126 250238 250215 250215 250070 250136 250233 250208 250208 250208 250070 250257 250298 250079 250079 250084 250084 250084 250154 250240 250199 250199 250199 250257 250271 250271 250271 250298 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 2520700 TCK233 Yes Yes
60,000, Severe 60,000, Severe 60,000 1 60,000, Severe 60,000, Severe 60,000, Severe 60,000, Severe 60,000, Severe 90,000, Severe 90,000 60,000, 60,000, 60,000, 90,000, Severe Severe Severe Severe
535 535 506 506 506 518 525 504 504 504 535 535 537 539 499 501 501 504 504 504 499 547 366 529 529 529 529 531 552 552 523 523 523 547 555 555 555 366
TCK199
Yes Yes
60,000 1 60,000, Severe 60,000, Severe 60,000, Severe 90,000, Severe 90,000 60,000, Severe 90,000 90,000 100,000 100,000 100,000 100,000 100,000 60,000, Severe 60,000, Severe 60,000, Severe 90,000, Severe 90,000 90,000 60,000, Severe 90,000 90,000 90,000
2520700
Yes Yes Yes Yes Yes
A-38
Make Model/ Year T100 1995-97 1998 4Runner 1988-92 1993-95 1996-97 1999-01

TOYOTA (Cont.)
3.4L V6 3.4L V6 3.0L V6 (3V-ZE) 3.0L V6 (3V-ZE) 3.4L V6 3.4L V6 250271 250271 250154 250240 250271 250271 Yes Yes Yes Yes Yes Yes 60,000, Severe 90,000 60,000, Severe 60,000, Severe 60,000, Severe 90,000 555 555 552 552 555 555
VOLKSWAGEN
Passenger Cars Beetle (New Beetle) 1999-01 1.8L 4-Cyl. (APH & AWV) 1998-00 2.0L 4-Cyl. (AEG) 2001 2.0L 4-Cyl. (AEG) 1998-01 1.9L 4-Cyl. Diesel (ALH) Cabrio 1995-01 1999 Cabriolet 1985-89 1985-93 Corrado 1990-92 Dasher 1974-75 1979-80 1976-80 1981 Fox 1987-93 Golf 1985-87 1985-89 1985-92 1993-96 1999-01 2.0L 4-Cyl. (ABA) 2.0L 4-Cyl. (AEG) 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (SOHC) 1.8L 4-Cyl. (SOHC) 1.5L 4-Cyl. 1.5L 4-Cyl. Diesel 1.6L 4-Cyl. 1.6L 4-Cyl. Diesel 1.8L 4-Cyl. (SOHC) 1.6L 4-Cyl. Diesel 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (SOHC) 1.9L 4-Cyl. Diesel AAZ, AHU & 1Z Engines 1.9L 4-Cyl. Diesel (ALH)
250306 250296 250296 250301 250262 250296 250292 250017 250017 250017 250043 250017 250043 250017 250043 250292 250017 250242 250301 250262 250296 250296 250043 250017 250262 250292 250017 250292 250262 250296 2520170 2520170 2520170 2520170 2520170 2520170
Yes Yes Yes
105,000 60,000 1 105,000 60,000 (Man. Trans.) 40,000 (Auto. Trans.) 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1
561 583 583 578 578 581 583 571 569 569 558 559 558 559 569 559 571 569 573 578 578 581 583 583 559 569 581 571 569 571 581 583
Yes
Yes Yes
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1
2520170
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
60,000 1 60,000 1 60,000 1 60,000 60,000 (Man. Trans.) 40,000 (Auto. Trans.) 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1
1993-99 2.0L 4-Cyl. (ABA) 1999 2.0L 4-Cyl. (AEG) 2000 2.0L 4-Cyl. (AEG) Golf (Canadian) 1988-92 1.6L 4-Cyl. Diesel 1993-95 1.8L 4-Cyl. (SOHC) 1995 2.0L 4-Cyl. (ABA) GTI 1985-89 1.8L 4-Cyl. (DOHC) 1985-92 1.8L 4-Cyl. (SOHC) 1990-92 2.0L 4-Cyl. (DOHC) 1996-99 2.0L 4-Cyl. (ABA) 1999 2.0L 4-Cyl. (AEG)
2520170
Yes

Make Model/ Year GTI (Canadian) 1993-95 Jetta 1980 1981-86 1989-92 1981-84 1985-89 1984-92 1993-98 1999-01 Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
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Page
VOLKSWAGEN (Cont.)
2.0L 4-Cyl. (ABA) 1.6L 4-Cyl. 1.6L 4-Cyl. Diesel 1.6L 4-Cyl. Diesel 1.7L 4-Cyl. 1.8L 4-Cyl. (DOHC) 1.8L 4-Cyl. (SOHC) 1.9L 4-Cyl. Diesel AAZ, AHU & 1Z Engines 1.9L 4-Cyl. Diesel (ALH) 250262 250017 250043 250043 250017 250292 250017 250242 250301 250292 250262 250296 250017 250291 250317 250291 250317 250292 250262 250297 250297 250297 250017 250043 250017 250017 250127 250065 250127 250065 250127 250017 250043 250017 250043 250017 250017 250017 250017 250017 2520170 2520170 2520170 2520170 2520170 2520170 2520170 Yes Yes 2520170 2520170 2520170 Yes 2520170 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 2520170 2520170 2520170 Yes Yes Yes Yes Yes Yes Yes Yes Yes 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 60,000 (Man. Trans.) 40,000 (Auto. Trans.) 60,000 1 60,000 1 60,000 1 60,000 1 90,000 90,000 105,000 105,000 60,000 1 60,000 1 90,000 75,000 105,000 60,000 1 60,000 1 60,000 1 60,000 1 Yes Yes Yes Yes Yes
1 1
581 558 559 559 558 571 569 573 578 578 571 581 583 569 564 564 566 566 571 581 585 585 585 569 559 558 569 79 79 79 79 79 558 559 558 559 558 569 558 558 558
1990-92 2.0L 4-Cyl. (DOHC) 1993-99 2.0L 4-Cyl. (ABA) 1999-00 2.0L 4-Cyl. (AEG) Jetta (Canadian) 1993-95 1.8L 4-Cyl. (SOHC) Passat 1998-99 1.8L 4-Cyl. (AEB & ATW) 152 Tooth Belt 153 Tooth Belt 2000-01 1.8L 4-Cyl. (AUG & AWM) 152 Tooth Belt 153 Tooth Belt 1990-92 2.0L 4-Cyl. (DOHC) 1993-96 2.0L 4-Cyl. (ABA) 1998 2.8L V6 1999 2.8L V6 2000-01 2.8L V6 Passat (Canadian) 1992-94 1.8L 4-Cyl. (SOHC) Quantum 1982-86 1.6L 4-Cyl. Diesel 1982-83 1.7L 4-Cyl. 1985 1.8L 4-Cyl. (SOHC) 1984-85 2.1L 5-Cyl. .70 Belt Width .75 Belt Width 1983-86 2.2L 5-Cyl. .70 Belt Width .75 Belt Width 1987-88 2.2L 5-Cyl. Rabbit 1975-79 1.5L 4-Cyl. 1977-80 1.5L 4-Cyl. Diesel 1980 1.6L 4-Cyl. 1981-84 1.6L 4-Cyl. Diesel 1981-84 1.7L 4-Cyl. 1983-84 1.8L 4-Cyl. (SOHC) Scirocco 1978 1.5L 4-Cyl. 1976-80 1.6L 4-Cyl. 1981-83 1.7L 4-Cyl.
Yes
60,000 60,000
60,000 60,000 1 60,000

1 1
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1
A-40
Make Model/ Year

VOLKSWAGEN (Cont.)
Scirocco (Cont.) 1985-89 1.8L 4-Cyl. (DOHC) 1983-89 1.8L 4-Cyl. (SOHC) Light Trucks Pickup & Rabbit Pickup 1980 1.5L 4-Cyl. Diesel 1980 1.6L 4-Cyl. 1981-83 1.6L 4-Cyl. Diesel 1981-83 1.7L 4-Cyl. Vanagon 1982 1.6L 4-Cyl. Diesel
250292 250017 250043 250017 250043 250017 250043
2520170
Yes
60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1 60,000 1
571 569 559 558 559 558 559
2520170 2520170
Yes Yes Yes
VOLVO
C70, S70 & V70 1998 2.3L 5-Cyl. To Eng. VIN 1266127 From Eng. VIN 1266128 1999-01 2.3L 5-Cyl. To Eng. VIN 1266127 From Eng. VIN 1266128 1998 2.4L 5-Cyl. To Eng. VIN 1266127 From Eng. VIN 1266128 1999-01 2.4L 5-Cyl. To Eng. VIN 1266127 From Eng. VIN 1266128 Coupe 1991 2.3L 4-Cyl. DL & GL 1980-83 2.1L 4-Cyl. 1982-85 2.3L 4-Cyl. 1980-84 2.4L 6-Cyl. Diesel Camshaft Injection Pump GLE (Canadian) 1984 2.1L 4-Cyl. GLT 1981-83 2.1L 4-Cyl. GLT (Canadian) 1983 2.3L 4-Cyl. GT Turbo 1984-85 2.1L 4-Cyl. S40 & V40 2000-01 1.9L 4-Cyl. Turbo Up Eng. VIN 1219110 From Eng. VIN 1219111 S60 2001 2.3L 5-Cyl. To Eng. VIN 1266127 From Eng. VIN 1266128 2001 2.4L 5-Cyl. To Eng. VIN 1266127 From Eng. VIN 1266128
250252 250311 250252 250311 250252 250311 250252 250311 250032 250032 250032 250083 250082 250032 250032 250032 250032 250252 250311 250252 250311 250252 250311 TCK032 TCK032 TCK032 TCK032 TCK032 TCK032 TCK032
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
70,000 70,000 105,000 3 105,000 3 70,000 70,000 105,000 3 105,000 3 50,000 40,000 40,000 75,000 2 75,000 2 40,000 40,000 40,000 40,000
598 598 598 598 598 598 598 598 593 592 592 602 602 592 592 592 592 587 587 598 598 598 598
105,000 105,000 105,000 3 105,000 3 105,000 3 105,000 3

Make Model/ Year S90 & V90 1997-98 240 1986-92 1993 242, 244 & 245 1976-79 740 1986-92 1985-86 Engine Belt Part No. Component Kit Part No. Timing Belt Interference Driven Water Engine* Pump Recommended Replacement Interval (Miles)
A-41
Page
VOLVO (Cont.)
2.9L 6-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. 2.1L 4-Cyl. 2.3L 4-Cyl. 2.4L 6-Cyl. Diesel Camshaft Injection Pump 250270 250032 250234 250032 250032 250083 250082 250174 250173 250174 T198 250174 250173 250174 250173 250032 250083 250082 250032 250083 250082 250032 250217 250252 250252 250217 250252 250252 250252 250217 250269 TCK032 TCK032 TCK032 TCK032 TCK032 TCK032 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 70,000 50,000 50,000 40,000 50,000 75,000 2 75,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 2 50,000 75,000 2 75,000 2 40,000 75,000 2 75,000 2 50,000 50,000 3 70,000 3 70,000 50,000 3 70,000 3 70,000 70,000 70,000 70,000 600 593 593 592 593 602 602 594 594 594 594 594 594 594 594 593 602 602 592 602 602 593 600 600 600 600 600 600 600 600 600
740 (Canadian) 1986-88 2.3L 4-Cyl. (B234, DOHC) Balance Shaft Camshaft 1989 2.3L 4-Cyl. (B234, DOHC) Automatic Tensioner Balance Shaft Camshaft Manual Tensioner Balance Shaft Camshaft 1990 2.3L 4-Cyl. (B234, DOHC) Balance Shaft Camshaft 760 1985-90 2.3L 4-Cyl. 1985 2.4L 6-Cyl. Diesel Camshaft Injection Pump 760 GLE 1984 2.3L 4-Cyl. 1983-84 2.4L 6-Cyl. Diesel Camshaft Injection Pump 780 198-90 2.3L 4-Cyl. 850 1994 2.3L 5-Cyl. Turbo Up To Eng. No. 131034 From Eng. No. 131035 1995-97 2.3L 5-Cyl. Turbo 1993 2.4L 5-Cyl. Turbo Up To Eng. No. 131034 From Eng. No. 131035 1994-97 2.4L 5-Cyl. Turbo 850 (Canadian) 1996 2.3L 5-Cyl. Turbo 1995 2.4L 5-Cyl. Turbo Up To Eng. No. 131034 From Eng. No. 131035
A-42
Make Model/ Year 940 1991-92 1993 1994-95

VOLVO (Cont.)
2.3L 4-Cyl. 2.3L 4-Cyl. 2.3L 4-Cyl. (B230FT) 250032 250234 250234 TCK032 Yes Yes Yes 50,000 50,000 50,000 w/o EGR 100,000 w/ EGR Yes Yes Yes Yes Yes Yes 50,000 2 50,000 2 30,000 3 50,000 50,000 70,000 592 592 593 593 594 594 600 600 600 600
940 (Canadian) 1991-92 2.3L 4-Cyl. (B234, DOHC) Balance Shaft Camshaft 960 1992 2.9L 6-Cyl. 1993 2.9L 6-Cyl. 1994 2.9L 6-Cyl. 1995-97 2.9L 6-Cyl.
250174 T198 250217 250252 250252 250270
YUGO
GV Series 1986-89 1987
1.1L 4-Cyl. 1.3L 4-Cyl.
250018 250018
Yes Yes
60,000 1 60,000 1
604 604
Changeover Listing Automotive Timing Belt Numbers
A-43
Showing Competitive Numbers with Corresponding NAPA Stock Numbers

The NAPA numbers shown in the following listings were determined by comparing the applications and physical characteristics of the product. This is a guide for changing over stocks to NAPA numbers, and does not mean that the competitive number shown will fit all applications recommended for the NAPA number. If a customer asks for a product to replace a product of another brand, do not use this list. Ask for the make, model, year and engine size on which it is to be used, and refer to the alphabetical listing to determine the proper replacement.
Competitive No.
NAPA No.
Competitive No.
NAPA No.
Competitive No.
NAPA No.
Competitive No.
NAPA No.
Competitive No.
NAPA No.
ACDELCO TB013 ............. 250013 TB014 ............. 250014 TB017 ............. 250017 TB018 ............. 250018 TB020 ............. 250020 TB028 ............. 250028 TB032 ............. 250032 TB036 ............. 250036 TB037 ............. 250037 TB039 ............. 250039 TB041 ............. 250041 TB043 ............. 250043 TB061 ............. 250061 TB062 ............. 250062 TB064 ............. 250064 TB065 ............. 250065 TB067 ............. 250067 TB070 ............. 250070 TB071 ............. 250071 TB073 ............. 250073 TB074 ............. 250074 TB075 ............. 250075 TB076 ............. 250076 TB077 ............. 250077 TB078 ............. 250078 TB079 ............. 250079 TB081 ............. 250081 TB082 ............. 250082 TB083 ............. 250083 TB084 ............. 250084 TB087 ............. 250087 TB088 ............. 250088 TB089 ............. 250089 TB090 ............. 250090 TB091 ............. 250091 TB092 ............. 250092 TB093 ............. 250093 TB094 ............. 250094 TB095 ............. 250095 TB096 ............. 250096 TB097 ............. 250097 TB098 ............. 250098 TB099 ............. 250099 TB100 ............. 250100 TB101 ............. 250101 TB102 ............. 250102 TB103 ............. 250103 TB104 ............. 250104 TB106 ............. 250106 TB107 ............. 250107 TB112 ............. 250112 TB113 ............. 250113 TB114 ............. 250114 TB117 ............. 250117 TB118 ............. 250118 TB119 ............. 250119 TB121 ............. 250121 TB122 ............. 250122 TB123 ............. 250123 TB124 ............. 250124 TB125 ............. 250125 TB126 ............. 250126 TB127 ............. 250127 TB128 ............. 250128 TB129 ............. 250129 TB130 ............. 250130 TB131 ............. 250131 TB132 ............. 250132 TB134 ............. 250134 TB135 ............. 250135 TB136 ............. 250136 TB137 ............. 250137 TB138 ............. 250138 TB139 ............. 250139 TB140 ............. 250140 TB141 ............. 250141
ACDELCO - Cont. TB142 ............. 250142 TB143 ............. 250143 TB144 ............. 250144 TB145 ............. 250145 TB146 ............. 250146 TB147 ............. 250147 TB148 ............. 250148 TB149 ............. 250149 TB150 ............. 250150 TB151 ............. 250151 TB153 ............. 250153 TB154 ............. 250154 TB155 ............. 250155 TB157 ............. 250157 TB158 ............. 250158 TB159 ............. 250159 TB160 ............. 250160 TB161 ............. 250161 TB162 ............. 250162 TB163 ............. 250163 TB164 ............. 250164 TB165 ............. 250165 TB166 ............. 250166 TB167 ............. 250167 TB168 ............. 250168 TB169 ............. 250169 TB170 ............. 250170 TB171 ............. 250171 TB172 ............. 250172 TB173 ............. 250173 TB174 ............. 250174 TB176 ............. 250176 TB177 ............. 250177 TB178 ............. 250178 TB179 ............. 250179 TB180 ............. 250180 TB181 ............. 250181 TB182 ............. 250182 TB183 ............. 250183 TB184 ............. 250184 TB185 ............. 250185 TB186 ............. 250186 TB187 ............. 250187 TB190 ............. 250190 TB191 ............. 250191 TB192 ............. 250192 TB193 ............. 250193 TB194 ............. 250194 TB195 ............. 250195 TB199 ............. 250199 TB200 ............. 250200 TB201 ............. 250201 TB203 ............. 250203 TB204 ............. 250204 TB205 ............. 250205 TB206 ............. 250206 TB207 ............. 250207 TB208 ............. 250208 TB209 ............. 250209 TB210 ............. 250210 TB211 ............. 250211 TB212 ............. 250212 TB214 ............. 250214 TB215 ............. 250215 TB216 ............. 250216 TB217 ............. 250217 TB218 ............. 250218 TB219 ............. 250219 TB220 ............. 250220 TB221 ............. 250221 TB223 ............. 250223 TB224 ............. 250224 TB225 ............. 250225 TB226 ............. 250226 TB227 ............. 250227 TB228 ............. 250228
ACDELCO - Cont. TB229 ............. 250229 TB230 ............. 250230 TB232 ............. 250232 TB233 ............. 250233 TB234 ............. 250234 TB235 ............. 250235 TB236 ............. 250236 TB237 ............. 250237 TB239 ............. 250239 TB240 ............. 250240 TB241 ............. 250241 TB242 ............. 250242 TB244 ............. 250244 TB245 ............. 250245 TB246 ............. 250246 TB247 ............. 250247 TB248 ............. 250248 TB249 ............. 250249 TB251 ............. 250251 TB252 ............. 250252 TB253 ............. 250253 TB254 ............. 250254 TB255 ............. 250255 TB256 ............. 250256 TB257 ............. 250257 TB258 ............. 250258 TB259 ............. 250259 TB260 ............. 250260 TB262 ............. 250262 TB263 ............. 250263 TB264 ............. 250264 TB265 ............. 250265 TB266 ............. 250266 TB267 ............. 250267 TB270 ............. 250270 TB271 ............. 250271 TB272 ............. 250272 TB273 ............. 250273 TB276 ............. 250276 TB277 ............. 250277 TB278 ............. 250278 TB279 ............. 250279 TB280 ............. 250280 TB281 ............. 250281 TB282 ............. 250282 TB283 ............. 250283 TB284 ............. 250284 TB285 ............. 250285 TB286 ............. 250286 TB287 ............. 250287 TB288 ............. 250288 TB289 ............. 250289 TB290 ............. 250290 TB291 ............. 250291 TB292 ............. 250292 TB293 ............. 250293 TB294 ............. 250294 TB295 ............. 250295 TB296 ............. 250296 TB297 ............. 250297 TB298 ............. 250298 TB299 ............. 250299 TB300 ............. 250300 TB301 ............. 250301 TB302 ............. 250302 TB303 ............. 250303 TB304 ............. 250304 TB305 ............. 250305 TB306 ............. 250306 TB308 ............. 250308 TB309 ............. 250309 TB310 ............. 250310 TB311 ............. 250311 88925830 ........ 250270
ATLAS 689900 ............ 250067 689901 ............ 250071 689902 ............ 250014 689903 ............ 250061 689904 ............ 250017 689905 ............ 250081 689906 ............ 250070 689907 ............ 250089 689908 ............ 250077 689909 ............ 250094 ATLAS (CANADA) TB1001 ........... 250121 TB1002 ........... 250127 TB1003 ........... 250128 TB1004 ........... 250101 TB1005 ........... 250125 TB1006 ........... 250126 TB1007 ........... 250130 TB1008 ........... 250129 TB1010 ........... 250114 TB1011 ........... 250300 TB1012 ........... 250299 TB1013 ........... 250091 TB1014 ........... 250092 TB1015 ........... 250117 TB1016 ........... 250119 TB1017 ........... 250292 TB1018 ........... 250134 TB1020 ........... 250136 TB1021 ........... 250137 TB1022 ........... 250138 TB1023 ........... 250139 TB1024 ........... 250140 TB1026 ........... 250141 TB1027 ........... 250123 TB1028 ........... 250090 TB1031 ........... 250113 TB1032 ........... 250132 TB1033 ........... 250142 TB1034 ........... 250143 TB1035 ........... 250144 TB1036 ........... 250145 TB1037 ........... 250146 TB1038 ........... 250147 TB1039 ........... 250148 TB1040 ........... 250149 TB1041 ........... 250150 TB1042 ........... 250151 TB1044 ........... 250102 TB1045 ........... 250103 TB1047 ........... 250124 TB1048 ........... 250154 TB1049 ........... 250155 TB1051 ........... 250157 TB1052 ........... 250158 TB1053 ........... 250159 TB1054 ........... 250160 TB1055 ........... 250161 TB1056 ........... 250162 TB1057 ........... 250153 TB1058 ........... 250163 TB1059 ........... 250164 TB1060 ........... 250165 TB1061 ........... 250166 TB1062 ........... 250169 TB1063 ........... 250167 TB1064 ........... 250168 TB6401 ........... 250014 TB6402 ........... 250013 TB6403 ........... 250037 TB6404 ........... 250017 TB6406 ........... 250018 TB6408 ........... 250020 TB6409 ........... 250039 TB6410 ........... 250032 TB6411 ........... 250041
ATLAS (CANADA) - Cont. TB6412 ........... 250062 TB6415 ........... 250028 TB6416 ........... 250064 TB6417 ........... 250065 TB6418 ........... 250061 TB6419 ........... 250073 TB6425 ........... 250070 TB6427 ........... 250071 TB6428 ........... 250067 TB6429 ........... 250076 TB6430 ........... 250075 TB6431 ........... 250078 TB6432 ........... 250077 TB6433 ........... 250043 TB6434 ........... 250074 TB6435 ........... 250081 TB6436 ........... 250088 TB6437 ........... 250087 TB6438 ........... 250093 TB6439 ........... 250094 TB6440 ........... 250104 TB6442 ........... 250100 TB6443 ........... 250084 TB6444 ........... 250099 TB6446 ........... 250082 TB6447 ........... 250083 TB6448 ........... 250095 TB6450 ........... 250176 TB6451 ........... 250089 TB6452 ........... 250118 TB6453 ........... 250079 TB6454 ........... 250122 AUTOZONE (See GOODYEAR) AVON AUTO B0100.............. 250100 B0101.............. 250101 B0102.............. 250102 B0103.............. 250103 B0104.............. 250104 B0114.............. 250114 B0118.............. 250162 B013................ 250013 B014................ 250014 B017................ 250017 B018................ 250018 B020................ 250020 B028................ 250028 B032................ 250032 B036................ 250036 B037................ 250037 B039................ 250039 B041................ 250041 B043................ 250043 B061................ 250061 B062................ 250062 B063................ 250073 B064................ 250064 B065................ 250065 B067................ 250067 B070................ 250070 B071................ 250071 B074................ 250074 B075................ 250075 B076................ 250076 B077................ 250077 B078................ 250078 B079................ 250079 B081................ 250081 B082................ 250082 B083................ 250083 B084................ 250084 B087................ 250087 B088................ 250088
A-44
Competitive No. NAPA No.
Changeover Listing - Timing Belts

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. BECK ARNLEY 026-0018......... 250028 026-0026......... 250020 026-0034......... 250020 026-0042......... 250018 026-0067......... 250036 026-0075......... 250041 026-0083......... 250013 026-0091......... 250014 026-0109......... 250032 026-0117......... 250065 026-0133......... 250062 026-0158......... 250064 026-0175......... 250070 026-0176......... 250017 026-0177......... 250043 026-0178......... 250083 026-0179......... 250073 026-0180......... 250082 026-0182......... 250088 026-0183......... 250078 026-0184......... 250077 026-0185......... 250089 026-0186......... 250090 026-0187......... 250092 026-0188......... 250091 026-0189......... 250084 026-0190......... 250074 026-0191......... 250087 026-0192......... 250079 026-0193......... 250076 026-0194......... 250075 026-0195......... 250107 026-0196......... 250093 026-0197......... 250096 026-0198......... 250106 026-0199......... 250140 026-0202......... 250100 026-0205......... 250097 026-0206......... 250101 026-0207......... 250095 026-0208......... 250161 026-0209......... 250160 026-0212......... 250300 026-0213......... 250299 026-0215......... 250158 026-0216......... 250104 026-0217......... 250112 026-0218......... 250293 026-0219......... 250119 026-0220......... 250138 026-0221......... 250071 026-0222......... 250162 026-0223......... 250113 026-0224......... 250117 026-0225......... 250149 026-0226......... 250141 026-0228......... 250122 026-0229......... 250124 026-0230......... 250128 026-0231......... 250134 026-0232......... 250129 026-0233......... 250139 026-0234......... 250146 026-0235......... 250148 026-0236......... 250292 026-0237......... 250170 026-0238......... 250143 026-0239......... 250131 026-0240......... 250144 026-0242......... 250142 026-0243......... 250135 026-0244......... 250179 026-0245......... 250147 026-0246......... 250126 026-0247......... 250136 026-0248......... 250125 026-0249......... 250164 026-0250......... 250166 026-0251......... 250165 026-0252......... 250130 026-0253......... 250121 026-0255......... 250167 026-0256......... 250043 026-0259......... 250137 026-0260......... 250171 026-0261......... 250177 026-0262......... 250179 026-0263......... 250103 026-0264......... 250102 026-0265......... 250157 026-0266......... 250159 026-0267......... 250151 026-0268......... 250182 BECK ARNLEY - Cont. 026-0269......... 250184 026-0270......... 250181 026-0271......... 250155 026-0272......... 250144 026-0273......... 250178 026-0274......... 250104 026-0275......... 250150 026-0276......... 250187 026-0277......... 250180 026-0278......... 250186 026-0279......... 250176 026-0280......... 250191 026-0281......... 250174 026-0282......... 250183 026-0283......... 250154 026-0284......... 250168 026-0285......... 250173 026-0286......... 250172 026-0294......... 250208 026-0295......... 250211 026-0296......... 250201 026-0297......... 250204 026-0298......... 250218 026-0299......... 250216 026-0300......... 250203 026-0301......... 250212 026-0302......... 250193 026-0303......... 250185 026-0304......... 250221 026-0305......... 250220 026-0306......... 250194 026-0307......... 250224 026-0308......... 250226 026-0309......... 250223 026-0310......... 250227 026-0311......... 250214 026-0312......... 250209 026-0314......... 250229 026-0316......... 250230 026-0317......... 250232 026-0318......... 250217 026-0319......... 250195 026-0320......... 250234 026-0322......... 250235 026-0323......... 250252 026-0324......... 250241 026-0325......... 250236 026-0326......... 250262 026-0327......... 250228 026-0329......... 250252 026-0334......... 250249 BORG WARNER TB013 ............. 250013 TB014 ............. 250014 TB017 ............. 250017 TB018 ............. 250018 TB020 ............. 250020 TB028 ............. 250028 TB029 ............. 250104 TB032 ............. 250032 TB036 ............. 250036 TB037 ............. 250037 TB039 ............. 250039 TB041 ............. 250041 TB043 ............. 250043 TB061 ............. 250061 TB062 ............. 250062 TB063 ............. 250073 TB064 ............. 250064 TB065 ............. 250065 TB067 ............. 250067 TB070 ............. 250070 TB071 ............. 250071 TB073 ............. 250073 TB074 ............. 250074 TB075 ............. 250075 TB076 ............. 250076 TB077 ............. 250077 TB078 ............. 250078 TB079 ............. 250079 TB081 ............. 250081 TB082 ............. 250082 TB083 ............. 250083 TB084 ............. 250084 TB087 ............. 250087 TB088 ............. 250088 TB089 ............. 250089 TB090 ............. 250090 TB091 ............. 250091 TB092 ............. 250092 TB093 ............. 250093 TB094 ............. 250094 TB095 ............. 250095 BORG WARNER - Cont. TB096 ............. 250096 TB098 ............. 250098 TB099 ............. 250099 TB100 ............. 250100 TB101 ............. 250101 TB102 ............. 250102 TB103 ............. 250103 TB104 ............. 250104 TB106 ............. 250106 TB107 ............. 250107 TB112 ............. 250112 TB113 ............. 250113 TB114 ............. 250114 TB115 ............. 250299 TB116 ............. 250300 TB117 ............. 250117 TB118 ............. 250118 TB119 ............. 250119 TB121 ............. 250121 TB122 ............. 250122 TB123 ............. 250123 TB124 ............. 250124 TB125 ............. 250125 TB126 ............. 250126 TB127 ............. 250127 TB128 ............. 250128 TB129 ............. 250129 TB130 ............. 250130 TB131 ............. 250131 TB132 ............. 250132 TB133 ............. 250292 TB134 ............. 250134 TB135 ............. 250135 TB136 ............. 250136 TB137 ............. 250137 TB138 ............. 250138 TB139 ............. 250139 TB140 ............. 250140 TB141 ............. 250141 TB142 ............. 250142 TB143 ............. 250143 TB144 ............. 250144 TB145 ............. 250145 TB146 ............. 250146 TB147 ............. 250147 TB148 ............. 250148 TB153 ............. 250153 TB154 ............. 250154 TB155 ............. 250155 TB157 ............. 250157 TB158 ............. 250158 TB159 ............. 250159 TB160 ............. 250160 TB161 ............. 250161 TB162 ............. 250162 TB163 ............. 250163 TB164 ............. 250164 TB165 ............. 250165 TB166 ............. 250166 TB167 ............. 250167 TB168 ............. 250168 TB169 ............. 250169 TB170 ............. 250170 TB171 ............. 250171 TB172 ............. 250172 TB177 ............. 250177 TB178 ............. 250178 TB179 ............. 250179 TB183 ............. 250183 TB184 ............. 250184 TB185 ............. 250185 TB186 ............. 250186 TB187 ............. 250187 TB191 ............. 250191 TB192 ............. 250192 TB194 ............. 250194 TB195 ............. 250195 TB199 ............. 250199 TB200 ............. 250200 TB201 ............. 250201 TB202 ............. 250248 TB204 ............. 250204 TB206 ............. 250206 TB208 ............. 250208 TB210 ............. 250210 TB214 ............. 250214 TB228 ............. 250228 TB233 ............. 250233 TB235 ............. 250235 TB236 ............. 250236 TB237 ............. 250237 T219................ 250219 BRYCO B013................ 250013 B014................ 250014 B017................ 250017 B028................ 250028 B036................ 250036 B041................ 250041 B043................ 250043 B062................ 250062 B064................ 250064 B067................ 250067 B070................ 250070 B071................ 250071 B073................ 250073 B074................ 250074 B075................ 250075 B076................ 250076 B077................ 250077 B078................ 250078 B079................ 250079 B087................ 250087 B088................ 250088 B089................ 250089 B090................ 250090 B091................ 250091 B092................ 250092 B093................ 250093 B094................ 250094 B095................ 250095 B096................ 250096 B099................ 250099 B100................ 250100 B101................ 250101 B102................ 250102 B103................ 250103 B104................ 250104 B112................ 250112 B113................ 250113 B114................ 250114 B115................ 250299 B116................ 250300 B117................ 250117 B118................ 250118 B121................ 250121 B122................ 250122 B123................ 250123 B124................ 250124 B126................ 250126 B127................ 250127 B128................ 250128 B130................ 250130 B132................ 250132 B133................ 250292 B134................ 250134 B136................ 250136 B137................ 250137 B138................ 250138 B139................ 250139 B141................ 250141 B142................ 250142 B143................ 250143 B144................ 250144 B145................ 250145 B146................ 250146 B147................ 250147 B149................ 250149 B153................ 250153 B154................ 250154 B155................ 250155 B157................ 250157 B158................ 250158 B159................ 250159 B160................ 250160 B161................ 250161 B162................ 250162 B164................ 250164 B165................ 250165 B167................ 250167 B168................ 250168 B169................ 250169 B176................ 250176 B177................ 250177 B179................ 250179 B182................ 250182 B184................ 250184 B185................ 250185 B186................ 250186 B187................ 250187 B191................ 250191 B194................ 250194 B195................ 250195 B199................ 250199 B201................ 250201 B204................ 250204
AVON AUTO - Cont. B089................ 250089 B090................ 250090 B091................ 250091 B092................ 250092 B093................ 250093 B094................ 250094 B095................ 250095 B096................ 250096 B099................ 250099 BALKAMP 9-013............... 250013 9-014............... 250014 9-017............... 250017 9-018............... 250018 9-020............... 250020 9-028............... 250028 9-032............... 250032 9-036............... 250036 9-037............... 250037 9-039............... 250039 9-041............... 250041 9-043............... 250043 9-061............... 250061 9-062............... 250062 9-063............... 250073 9-064............... 250064 9-065............... 250065 9-067............... 250067 9-070............... 250070 9-071............... 250071 9-073............... 250073 9-074............... 250074 9-075............... 250075 9-076............... 250076 9-077............... 250077 9-078............... 250078 9-079............... 250079 9-081............... 250081 9-082............... 250082 9-083............... 250083 9-084............... 250084 9-087............... 250087 9-088............... 250088 9-089............... 250089 9-090............... 250090 9-091............... 250091 9-092............... 250092 9-093............... 250093 9-094............... 250094 9-095............... 250095 9-096............... 250096 9-098............... 250098 9-099............... 250099 9-100............... 250100 9-101............... 250101 BANDO 100ZA19.......... 250061 109ZA19.......... 250088 111ZA19.......... 250121 113ZA19.......... 250065 121ZA19.......... 250017 124ZA25.......... 250071 135ZA25.......... 250043 142ZA25.......... 250074 206AL050........ 250062 315AL075........ 250028 326AHL125 ..... 250075 330AL075........ 250070 345AL075........ 250073 398AL075........ 250077 458AL075........ 250013 89ZA19 ........... 250095 94ZA19 ........... 250036 97ZA25 ........... 250067 99ZA15 ........... 250037 99ZA19 ........... 250039 BAP-GEON 54-70301......... 250062 54-70302......... 250073 54-70303......... 250064 54-70901......... 250041 54-70902......... 250028 54-70904......... 250073 54-71501......... 250070 54-72001......... 250017 54-72100......... 250065 54-76000......... 250020 54-76301......... 250018 54-77801......... 250014 54-77802......... 250067 54-79800......... 250013

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. BRYCO - Cont. B208................ 250208 B210................ 250210 B223................ 250223 B224................ 250224 B227................ 250227 B228................ 250228 B229................ 250229 B230................ 250230 B235................ 250235 B236................ 250236 B237................ 250237 B258................ 250258 T115................ 250299 54700 .............. 250095 54742 .............. 250075 54754 .............. 250112 54755 .............. 250176 54788 .............. 250076 CARQUEST T013................ 250013 T014................ 250014 T096................ 250096 T097................ 250097 T098................ 250098 T099................ 250099 T100................ 250100 T101................ 250101 T102................ 250102 T103................ 250103 T104................ 250104 T106................ 250106 T107................ 250107 T112................ 250112 T113................ 250113 T114................ 250114 T117................ 250117 T118................ 250118 T119................ 250119 T121................ 250121 T122................ 250122 T123................ 250123 T124................ 250124 T125................ 250125 T126................ 250126 T127................ 250127 T128................ 250128 T129................ 250129 T130................ 250130 T131................ 250131 T132................ 250132 T134................ 250134 T135................ 250135 T136................ 250136 T137................ 250137 T138................ 250138 T139................ 250139 T140................ 250140 T141................ 250141 T142................ 250142 T143................ 250143 T144................ 250144 T145................ 250145 T146................ 250146 T147................ 250147 T148................ 250148 T149................ 250149 T150................ 250150 T151................ 250151 T153................ 250153 T154................ 250154 T155................ 250155 T157................ 250157 T158................ 250158 T159................ 250159 T160................ 250160 T161................ 250161 T162................ 250162 T163................ 250163 T164................ 250164 T165................ 250165 T166................ 250166 T167................ 250167 T168................ 250168 T169................ 250169 T170................ 250170 T171................ 250171 T172................ 250172 T173................ 250173 T174................ 250174 T176................ 250176 T177................ 250177 T178................ 250178 T179................ 250179 CARQUEST - Cont. T180................ 250180 T181................ 250181 T182................ 250182 T183................ 250183 T184................ 250184 T185................ 250185 T186................ 250186 T187................ 250187 T190................ 250190 T191................ 250191 T192................ 250192 T193................ 250193 T194................ 250194 T195................ 250195 T199................ 250199 T200................ 250200 T201................ 250201 T203................ 250203 T204................ 250204 T205................ 250205 T206................ 250206 T207................ 250207 T208................ 250208 T209................ 250209 T210................ 250210 T211................ 250211 T212................ 250212 T214................ 250214 T215................ 250215 T216................ 250216 T217................ 250217 T218................ 250218 T219................ 250219 T220................ 250220 T221................ 250221 T223................ 250223 T224................ 250224 T225................ 250225 T226................ 250226 T227................ 250227 T228................ 250228 T229................ 250229 T230................ 250230 T232................ 250232 T233................ 250233 T234................ 250234 T235................ 250235 T236................ 250236 T237................ 250237 T239................ 250239 T240................ 250240 T241................ 250241 T242................ 250242 T244................ 250244 T245................ 250245 T246................ 250246 T247................ 250247 T248................ 250248 T249................ 250249 T251................ 250251 T252................ 250252 T253................ 250253 T254................ 250254 T255................ 250255 T256................ 250256 T257................ 250257 T258................ 250258 T259................ 250259 T260................ 250260 T262................ 250262 T263................ 250263 T264................ 250264 T265................ 250265 T266................ 250266 T267................ 250267 T271................ 250271 T272................ 250272 T273................ 250273 T276................ 250276 T277................ 250277 T278................ 250278 T279................ 250279 T280................ 250280 T281................ 250281 T282................ 250282 T283................ 250283 T284................ 250284 T285................ 250285 T286................ 250286 T287................ 250287 T288................ 250288 T289................ 250289 T290................ 250290 CARQUEST - Cont. T291................ 250291 T292................ 250292 T293................ 250293 T294................ 250294 T295................ 250295 T296................ 250296 T297................ 250297 T298................ 250298 T299................ 250299 T300................ 250300 T301................ 250301 T302................ 250302 T303................ 250303 T304................ 250304 T305................ 250305 T306................ 250306 CHIEF TB401 ............. 250014 TB402 ............. 250013 TB403 ............. 250037 TB404 ............. 250017 TB409 ............. 250039 TB411 ............. 250041 TB415 ............. 250028 CLEVELAND MOTIVE B013................ 250013 B014................ 250014 B037................ 250037 B043................ 250043 B074................ 250074 B075................ 250075 B076................ 250076 B077................ 250077 B078................ 250078 B081................ 250081 CLOYES GEAR B013................ 250013 B014................ 250014 B017................ 250017 B018................ 250018 B020................ 250020 B028................ 250028 B032................ 250032 B036................ 250036 B037................ 250037 B039................ 250039 B041................ 250041 B043................ 250043 B061................ 250061 B062................ 250062 B063................ 250073 B064................ 250064 B065................ 250065 B067................ 250067 B070................ 250070 B071................ 250071 B073................ 250073 B074................ 250074 B075................ 250075 B076................ 250076 B077................ 250077 B078................ 250078 B079................ 250079 B081................ 250081 B082................ 250082 B083................ 250083 B084................ 250084 B087................ 250087 B088................ 250088 B089................ 250089 B090................ 250090 B091................ 250091 B092................ 250092 B093................ 250093 B094................ 250094 B095................ 250095 B096................ 250096 B097................ 250097 B098................ 250098 B099................ 250099 B100................ 250100 B101................ 250101 B102................ 250102 B103................ 250103 B104................ 250104 B106................ 250106 B107................ 250107 B108................ 250293 B112................ 250112 B113................ 250113 B114................ 250114 CLOYES GEAR - Cont. B115................ 250299 B116................ 250300 B117................ 250117 B118................ 250118 B119................ 250119 B121................ 250121 B122................ 250122 B123................ 250123 B124................ 250124 B125................ 250125 B126................ 250126 B127................ 250127 B128................ 250128 B129................ 250129 B130................ 250130 B131................ 250131 B132................ 250132 B133................ 250292 B134................ 250134 B135................ 250135 B136................ 250136 B137................ 250137 B138................ 250138 B139................ 250139 B140................ 250140 B141................ 250141 B142................ 250142 B143................ 250143 B144................ 250144 B145................ 250145 B146................ 250146 B147................ 250147 B148................ 250148 B149................ 250149 B150................ 250150 B151................ 250151 B153................ 250153 B154................ 250154 B155................ 250155 B157................ 250157 B158................ 250158 B159................ 250159 B160................ 250160 B161................ 250161 B162................ 250162 B163................ 250163 B164................ 250164 B165................ 250165 B166................ 250166 B167................ 250167 B168................ 250168 B169................ 250169 B170................ 250170 B171................ 250171 B172................ 250172 B174................ 250174 B176................ 250176 B177................ 250177 B178................ 250178 B179................ 250179 B180................ 250180 B181................ 250181 B182................ 250182 B183................ 250183 B184................ 250184 B185................ 250185 B186................ 250186 B187................ 250187 B190................ 250190 B191................ 250191 B192................ 250192 B193................ 250193 B194................ 250194 B195................ 250195 B199................ 250199 B201................ 250201 B203................ 250203 B204................ 250204 B205................ 250205 B206................ 250206 B208................ 250208 B209................ 250209 B210................ 250210 B211................ 250211 B212................ 250212 B214................ 250214 B216................ 250216 B219................ 250219 C013 ............... 250013 C014 ............... 250014 C017 ............... 250017 C018 ............... 250018 C020 ............... 250020
A-45
NAPA No.
CLOYES GEAR - Cont. C028 ............... 250028 C032 ............... 250032 C037 ............... 250037 C039 ............... 250039 C041 ............... 250041 C043 ............... 250043 C061 ............... 250061 C062 ............... 250062 C063 ............... 250073 C064 ............... 250064 C065 ............... 250065 C067 ............... 250067 C070 ............... 250070 C071 ............... 250071 C074 ............... 250074 C075 ............... 250075 C076 ............... 250076 C077 ............... 250077 C078 ............... 250078 C081 ............... 250081 C087 ............... 250087 C088 ............... 250088 C093 ............... 250093 C094 ............... 250094 C095 ............... 250095 C099 ............... 250099 C104 ............... 250104 C112 ............... 250112 CONTINENTAL 6585901 .......... 250065 6585902 .......... 250017 6585910 .......... 250013 6585911 .......... 250082 6585912 .......... 250083 6585913 .......... 250032 6585914 .......... 250043 6585916 .......... 250018 6585918 .......... 250020 6585924 .......... 250078 6585929 .......... 250064 6585933 .......... 250062 6585934 .......... 250073 6585935 .......... 250077 6585939 .......... 250028 6585943 .......... 250041 6585949 .......... 250070 6589089 .......... 250131 6589092 .......... 250084 6589095 .......... 250107 6589100 .......... 250081 6589103 .......... 250106 6598500 .......... 250062 6598506 .......... 250028 6598512 .......... 250073 6598513 .......... 250041 6598519 .......... 250077 6598521 .......... 250088 6598530 .......... 250087 6598534 .......... 250075 6598550 .......... 250094 6598551 .......... 250293 CONTITECH TB014 ............. 250014 TB017 ............. 250017 TB018 ............. 250018 TB032 ............. 250032 TB036 ............. 250036 TB041 ............. 250041 TB043 ............. 250043 TB061 ............. 250061 TB063 ............. 250073 TB064 ............. 250064 TB065 ............. 250065 TB070 ............. 250070 TB074 ............. 250074 TB075 ............. 250075 TB076 ............. 250076 TB077 ............. 250077 TB078 ............. 250078 TB079 ............. 250079 TB081 ............. 250081 TB082 ............. 250082 TB083 ............. 250083 TB084 ............. 250084 TB087 ............. 250087 TB088 ............. 250088 TB089 ............. 250089 TB090 ............. 250090 TB091 ............. 250091 TB092 ............. 250092 TB093 ............. 250093 TB094 ............. 250094
A-46

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. CONTITECH - Cont. TB211 ............. 250211 TB212 ............. 250212 TB214 ............. 250214 TB215 ............. 250215 TB216 ............. 250216 TB217 ............. 250217 TB218 ............. 250218 TB220 ............. 250220 TB221 ............. 250221 TB224 ............. 250224 TB225 ............. 250225 TB227 ............. 250227 TB228 ............. 250228 TB229 ............. 250229 TB230 ............. 250230 TB232 ............. 250232 TB233 ............. 250233 TB235 ............. 250235 TB236 ............. 250236 TB239 ............. 250239 TB240 ............. 250240 TB241 ............. 250241 TB252 ............. 250252 CY-LENT C013 ............... 250013 C014 ............... 250014 C017 ............... 250017 C018 ............... 250018 C020 ............... 250020 C028 ............... 250028 C032 ............... 250032 C037 ............... 250037 C039 ............... 250039 C041 ............... 250041 C043 ............... 250043 C061 ............... 250061 C062 ............... 250062 C063 ............... 250073 C064 ............... 250064 C065 ............... 250065 C067 ............... 250067 C070 ............... 250070 C071 ............... 250071 C073 ............... 250073 C075 ............... 250075 C076 ............... 250076 C077 ............... 250077 C078 ............... 250078 C081 ............... 250081 DAYCO A206L050........ 250062 A234L075........ 250073 A315L075........ 250028 A356L075........ 250041 A371L059........ 250037 A375L075........ 250061 A450L075........ 250064 A453L075........ 250017 A457L075........ 250013 A484L088........ 250014 A547L075........ 250020 94011 .............. 250092 94075 .............. 250070 94078 .............. 250203 94080 .............. 250203 94098 .............. 250089 94100 .............. 250090 94123 .............. 250117 94133 .............. 250128 94165 .............. 250146 94169 .............. 250148 94185 .............. 250163 94266 .............. 250091 94283 .............. 250124 94284 .............. 250185 94293 .............. 250165 94294 .............. 250179 94340 .............. 250155 94341 .............. 250139 94350 .............. 250167 94351 .............. 250168 94430 .............. 250155 95013 .............. 250013 95014 .............. 250014 95017 .............. 250017 95018 .............. 250018 95020 .............. 250020 95028 .............. 250028 95032 .............. 250032 95036 .............. 250036 95037 .............. 250037 95039 .............. 250039 DAYCO - Cont. 95041 .............. 250041 95043 .............. 250043 95061 .............. 250061 95062 .............. 250062 95063 .............. 250073 95064 .............. 250064 95065 .............. 250065 95067 .............. 250067 95070 .............. 250070 95071 .............. 250071 95073 .............. 250073 95074 .............. 250074 95075 .............. 250075 95076 .............. 250076 95077 .............. 250077 95078 .............. 250078 95079 .............. 250079 95081 .............. 250081 95082 .............. 250082 95083 .............. 250083 95084 .............. 250084 95087 .............. 250087 95088 .............. 250088 95089 .............. 250089 95090 .............. 250090 95091 .............. 250091 95092 .............. 250092 95093 .............. 250093 95094 .............. 250094 95095 .............. 250095 95096 .............. 250096 95097 .............. 250097 95098 .............. 250098 95099 .............. 250099 95100 .............. 250100 95101 .............. 250101 95102 .............. 250102 95103 .............. 250103 95104 .............. 250104 95106 .............. 250106 95107 .............. 250107 95108 .............. 250293 95112 .............. 250112 95113 .............. 250113 95114 .............. 250114 95115 .............. 250299 95116 .............. 250300 95117 .............. 250117 95118 .............. 250118 95119 .............. 250119 95121 .............. 250121 95122 .............. 250122 95123 .............. 250123 95124 .............. 250124 95125 .............. 250125 95126 .............. 250126 95127 .............. 250127 95128 .............. 250128 95129 .............. 250129 95130 .............. 250130 95131 .............. 250131 95132 .............. 250132 95133 .............. 250292 95134 .............. 250134 95135 .............. 250135 95136 .............. 250136 95137 .............. 250137 95138 .............. 250138 95139 .............. 250139 95140 .............. 250140 95141 .............. 250141 95142 .............. 250142 95143 .............. 250143 95144 .............. 250144 95145 .............. 250145 95146 .............. 250146 95147 .............. 250147 95148 .............. 250148 95150 .............. 250150 95151 .............. 250151 95153 .............. 250153 95154 .............. 250154 95155 .............. 250155 95157 .............. 250157 95158 .............. 250158 95159 .............. 250159 95160 .............. 250160 95161 .............. 250161 95162 .............. 250162 95163 .............. 250163 95164 .............. 250164 95165 .............. 250165 95166 .............. 250166 DAYCO - Cont. 95167 .............. 250167 95168 .............. 250168 95169 .............. 250169 95170 .............. 250170 95171 .............. 250171 95172 .............. 250172 95173 .............. 250173 95174 .............. 250174 95176 .............. 250176 95177 .............. 250177 95178 .............. 250178 95179 .............. 250179 95180 .............. 250180 95181 .............. 250181 95182 .............. 250182 95183 .............. 250183 95184 .............. 250184 95185 .............. 250185 95186 .............. 250186 95187 .............. 250187 95190 .............. 250190 95191 .............. 250191 95192 .............. 250192 95193 .............. 250193 95194 .............. 250194 95195 .............. 250195 95199 .............. 250199 95200 .............. 250200 95201 .............. 250201 95202 .............. 250248 95203 .............. 250203 95204 .............. 250204 95205 .............. 250205 95206 .............. 250206 95207 .............. 250207 95208 .............. 250208 95210 .............. 250210 95211 .............. 250211 95212 .............. 250212 95214 .............. 250214 95215 .............. 250215 95216 .............. 250216 95217 .............. 250217 95218 .............. 250218 95219 .............. 250219 95220 .............. 250220 95221 .............. 250221 95223 .............. 250223 95224 .............. 250224 95225 .............. 250225 95226 .............. 250226 95227 .............. 250227 95228 .............. 250228 95229 .............. 250229 95230 .............. 250230 95232 .............. 250232 95233 .............. 250233 95234 .............. 250234 95235 .............. 250235 95236 .............. 250236 95237 .............. 250237 95240 .............. 250240 95241 .............. 250241 95244 .............. 250244 95245 .............. 250245 95246 .............. 250246 95247 .............. 250247 95248 .............. 250248 95249 .............. 250249 95251 .............. 250251 95252 .............. 250252 95253 .............. 250253 95254 .............. 250254 95255 .............. 250255 95257 .............. 250257 95258 .............. 250258 95259 .............. 250259 95262 .............. 250262 95263 .............. 250263 95264 .............. 250264 95265 .............. 250265 95266 .............. 250266 95271 .............. 250271 95272 .............. 250272 95273 .............. 250273 95276 .............. 250276 95277 .............. 250277 95278 .............. 250278 95281 .............. 250281 95283 .............. 250283 95284 .............. 250284 95286 .............. 250286 95287 .............. 250287 DAYCO - Cont. 95288 .............. 250288 95289 .............. 250289 95291 .............. 250291 95292 .............. 250292 95293 .............. 250293 95294 .............. 250294 95295 .............. 250295 95296 .............. 250296 95298 .............. 250298 95299 .............. 250299 95300 .............. 250300 95302 .............. 250302 95303 .............. 250303 95304 .............. 250304 DURKEE-ATWOOD 24-436PD........ 250018 24-457PD........ 250017 24-542PD........ 250020 28-457PD........ 250013 28-487PD........ 250014 88013 .............. 250013 88014 .............. 250014 88017 .............. 250017 88018 .............. 250018 88020 .............. 250020 88028 .............. 250028 88032 .............. 250032 88037 .............. 250037 88039 .............. 250039 88041 .............. 250041 88043 .............. 250043 88046 .............. 250013 88047 .............. 250014 88050 .............. 250018 88052 .............. 250020 88057 .............. 250037 88058 .............. 250039 88060 .............. 250017 88061 .............. 250061 88062 .............. 250062 88063 .............. 250073 88064 .............. 250064 88065 .............. 250065 88067 .............. 250067 88070 .............. 250070 88071 .............. 250071 88074 .............. 250074 88075 .............. 250075 88076 .............. 250076 88077 .............. 250077 88078 .............. 250078 88079 .............. 250079 88081 .............. 250081 88082 .............. 250082 88083 .............. 250083 88084 .............. 250084 88087 .............. 250087 88088 .............. 250088 88089 .............. 250089 88090 .............. 250090 88091 .............. 250091 88092 .............. 250092 88093 .............. 250093 88094 .............. 250094 88095 .............. 250095 88099 .............. 250099 88100 .............. 250100 88101 .............. 250101 88102 .............. 250102 88104 .............. 250104 88106 .............. 250106 88107 .............. 250107 88112 .............. 250112 88113 .............. 250113 88114 .............. 250114 88115 .............. 250299 88116 .............. 250300 88117 .............. 250117 88118 .............. 250118 88121 .............. 250121 88122 .............. 250122 88124 .............. 250124 88125 .............. 250125 88126 .............. 250126 88127 .............. 250127 88130 .............. 250130 88131 .............. 250131 88132 .............. 250132 88133 .............. 250292 88134 .............. 250134 88136 .............. 250136 88138 .............. 250138 88141 .............. 250141
CONTITECH - Cont. TB095 ............. 250095 TB096 ............. 250096 TB097 ............. 250097 TB098 ............. 250098 TB099 ............. 250099 TB100 ............. 250100 TB101 ............. 250101 TB102 ............. 250102 TB103 ............. 250103 TB104 ............. 250104 TB106 ............. 250106 TB107 ............. 250107 TB108 ............. 250293 TB112 ............. 250112 TB113 ............. 250113 TB115 ............. 250299 TB116 ............. 250300 TB117 ............. 250117 TB118 ............. 250118 TB119 ............. 250119 TB121 ............. 250121 TB122 ............. 250122 TB123 ............. 250123 TB124 ............. 250124 TB125 ............. 250125 TB126 ............. 250126 TB127 ............. 250127 TB128 ............. 250128 TB129 ............. 250129 TB130 ............. 250130 TB131 ............. 250131 TB133 ............. 250292 TB134 ............. 250134 TB135 ............. 250135 TB136 ............. 250136 TB137 ............. 250137 TB138 ............. 250138 TB139 ............. 250139 TB140 ............. 250140 TB141 ............. 250141 TB142 ............. 250142 TB143 ............. 250143 TB144 ............. 250144 TB145 ............. 250145 TB146 ............. 250146 TB147 ............. 250147 TB148 ............. 250148 TB150 ............. 250150 TB151 ............. 250151 TB154 ............. 250154 TB155 ............. 250155 TB157 ............. 250157 TB158 ............. 250158 TB159 ............. 250159 TB160 ............. 250160 TB162 ............. 250162 TB163 ............. 250163 TB164 ............. 250164 TB165 ............. 250165 TB166 ............. 250166 TB167 ............. 250167 TB168 ............. 250168 TB169 ............. 250169 TB170 ............. 250170 TB171 ............. 250171 TB172 ............. 250172 TB173 ............. 250173 TB174 ............. 250174 TB176 ............. 250176 TB177 ............. 250177 TB178 ............. 250178 TB179 ............. 250179 TB180 ............. 250180 TB181 ............. 250181 TB182 ............. 250182 TB183 ............. 250183 TB184 ............. 250184 TB185 ............. 250185 TB186 ............. 250186 TB187 ............. 250187 TB190 ............. 250190 TB191 ............. 250191 TB193 ............. 250193 TB195 ............. 250195 TB199 ............. 250199 TB200 ............. 250200 TB201 ............. 250201 TB203 ............. 250203 TB204 ............. 250204 TB205 ............. 250205 TB208 ............. 250208 TB209 ............. 250209 TB210 ............. 250210

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. DURKEE-ATWOOD - Cont. 88143 .............. 250143 88144 .............. 250144 88146 .............. 250146 88153 .............. 250153 88157 .............. 250157 88158 .............. 250158 88159 .............. 250159 88160 .............. 250160 88161 .............. 250161 88162 .............. 250162 88163 .............. 250163 88165 .............. 250165 88170 .............. 250170 DYNAFLEX (See DAYCO) DYNAGEAR B013................ 250013 B014................ 250014 B017................ 250017 B018................ 250018 B020................ 250020 B028................ 250028 B032................ 250032 B037................ 250037 B039................ 250039 B041................ 250041 B043................ 250043 B061................ 250061 B062................ 250062 B063................ 250073 B064................ 250064 B065................ 250065 B067................ 250067 B070................ 250070 B071................ 250071 B074................ 250074 B075................ 250075 B076................ 250076 B077................ 250077 B078................ 250078 B081................ 250081 B087................ 250087 B088................ 250088 B093................ 250093 B094................ 250094 B095................ 250095 B099................ 250099 B104................ 250104 B112................ 250112 TB013 ............. 250013 TB014 ............. 250014 TB017 ............. 250017 TB018 ............. 250018 TB020 ............. 250020 TB028 ............. 250028 TB029 ............. 250104 TB032 ............. 250032 TB036 ............. 250036 TB037 ............. 250037 TB039 ............. 250039 TB041 ............. 250041 TB043 ............. 250043 TB061 ............. 250061 TB062 ............. 250062 TB063 ............. 250073 TB064 ............. 250064 TB065 ............. 250065 TB067 ............. 250067 TB070 ............. 250070 TB071 ............. 250071 TB073 ............. 250073 TB074 ............. 250074 TB075 ............. 250075 TB076 ............. 250076 TB077 ............. 250077 TB078 ............. 250078 TB079 ............. 250079 TB081 ............. 250081 TB082 ............. 250082 TB083 ............. 250083 TB084 ............. 250084 TB087 ............. 250087 TB088 ............. 250088 TB089 ............. 250089 TB090 ............. 250090 TB091 ............. 250091 TB092 ............. 250092 TB093 ............. 250093 TB094 ............. 250094 TB095 ............. 250095 TB096 ............. 250096 TB098 ............. 250098 DYNAGEAR - Cont. TB099 ............. 250099 TB100 ............. 250100 TB101 ............. 250101 TB102 ............. 250102 TB103 ............. 250103 TB104 ............. 250104 TB106 ............. 250106 TB107 ............. 250107 TB108 ............. 250293 TB112 ............. 250112 TB113 ............. 250113 TB114 ............. 250114 TB115 ............. 250299 TB116 ............. 250300 TB117 ............. 250117 TB118 ............. 250118 TB119 ............. 250119 TB121 ............. 250121 TB122 ............. 250122 TB123 ............. 250123 TB124 ............. 250124 TB125 ............. 250125 TB126 ............. 250126 TB127 ............. 250127 TB128 ............. 250128 TB129 ............. 250129 TB130 ............. 250130 TB131 ............. 250131 TB132 ............. 250132 TB133 ............. 250292 TB134 ............. 250134 TB135 ............. 250135 TB136 ............. 250136 TB137 ............. 250137 TB138 ............. 250138 TB139 ............. 250139 TB140 ............. 250140 TB141 ............. 250141 TB142 ............. 250142 TB143 ............. 250143 TB144 ............. 250144 TB145 ............. 250145 TB146 ............. 250146 TB147 ............. 250147 TB148 ............. 250148 TB149 ............. 250149 TB150 ............. 250150 TB151 ............. 250151 TB153 ............. 250153 TB154 ............. 250154 TB155 ............. 250155 TB157 ............. 250157 TB158 ............. 250158 TB159 ............. 250159 TB160 ............. 250160 TB161 ............. 250161 TB162 ............. 250162 TB163 ............. 250163 TB164 ............. 250164 TB165 ............. 250165 TB166 ............. 250166 TB167 ............. 250167 TB168 ............. 250168 TB169 ............. 250169 ELGIN MACH. LB-013 ............ 250013 LB-014 ............ 250014 LB-017 ............ 250017 LB-018 ............ 250018 LB-020 ............ 250020 LB-028 ............ 250028 LB-032 ............ 250032 LB-036 ............ 250036 LB-037 ............ 250037 LB-039 ............ 250039 LB-041 ............ 250041 LB-043 ............ 250043 LB-061 ............ 250061 LB-062 ............ 250062 LB-063 ............ 250073 LB-064 ............ 250064 LB-065 ............ 250065 LB-067 ............ 250067 LB-070 ............ 250070 LB-071 ............ 250071 LB-073 ............ 250073 LB-074 ............ 250074 LB-075 ............ 250075 LB-076 ............ 250076 LB-077 ............ 250077 LB-078 ............ 250078 LB-081 ............ 250081 LB-088 ............ 250088 ELGIN MACH. - Cont. LB-093 ............ 250093 FEDERAL MOGUL LB013.............. 250013 LB014.............. 250014 LB020.............. 250020 LB028.............. 250028 LB032.............. 250032 LB036.............. 250036 LB037.............. 250037 LB039.............. 250039 LB041.............. 250041 LB043.............. 250043 LB061.............. 250061 LB062.............. 250062 LB064.............. 250064 LB065.............. 250065 LB067.............. 250067 LB070.............. 250070 LB071.............. 250071 LB073.............. 250073 LB074.............. 250074 LB075.............. 250075 LB076.............. 250076 LB077.............. 250077 LB078.............. 250078 LB081.............. 250081 LB082.............. 250082 LB083.............. 250083 LB087.............. 250087 LB088.............. 250088 LB089.............. 250089 LB090.............. 250090 LB093.............. 250093 LB094.............. 250094 LB095.............. 250095 LB099.............. 250099 LB101.............. 250101 LB102.............. 250102 LB103.............. 250103 LB104.............. 250104 LB107.............. 250107 LB108.............. 250293 LB112.............. 250112 LB113.............. 250113 LB114.............. 250114 LB115.............. 250299 LB116.............. 250300 LB117.............. 250117 LB118.............. 250162 LB119.............. 250119 LB122.............. 250122 LB124.............. 250124 LB125.............. 250125 LB126.............. 250237 LB128.............. 250128 LB129.............. 250129 LB130.............. 250130 LB131.............. 250131 LB132.............. 250132 LB133.............. 250292 LB134.............. 250134 LB135.............. 250135 LB136.............. 250233 LB138.............. 250199 LB139.............. 250139 LB141.............. 250141 LB142.............. 250142 LB143.............. 250143 LB144.............. 250144 LB145.............. 250145 LB146.............. 250146 LB147.............. 250147 LB148.............. 250148 LB149.............. 250149 LB153.............. 250153 LB154.............. 250154 LB155.............. 250155 LB157.............. 250157 LB158.............. 250158 LB159.............. 250159 LB160.............. 250160 LB161.............. 250161 LB162.............. 250162 LB163.............. 250163 LB164.............. 250164 LB165.............. 250165 LB166.............. 250166 LB167.............. 250167 LB168.............. 250168 LB169.............. 250169 LB170.............. 250170 LB172.............. 250254 LB176.............. 250176 FEDERAL MOGUL - Cont. LB177.............. 250177 LB179.............. 250179 LB180.............. 250180 LB183.............. 250183 LB184.............. 250184 LB185.............. 250185 LB186.............. 250186 LB187.............. 250187 LB193.............. 250193 LB194.............. 250194 LB202.............. 250248 LB210.............. 250210 FIRESTONE 51309510 ........ 250017 51309618 ........ 250061 51309677 ........ 250067 51309693 ........ 250071 51309766 ........ 250081 FRESHSTART (See GOODYEAR) GATES (CANADA) T013................ 250013 T014................ 250014 T017................ 250017 T018................ 250018 T020................ 250020 T028................ 250028 T032................ 250032 T036................ 250036 T037................ 250037 T039................ 250039 T041................ 250041 T043................ 250043 T061................ 250061 T062................ 250062 T063................ 250073 T064................ 250064 T065................ 250065 T067................ 250067 T070................ 250070 T071................ 250071 T073................ 250073 T074................ 250074 T075................ 250075 T076................ 250076 T077................ 250077 T078................ 250078 T079................ 250079 T081................ 250081 T082................ 250082 T083................ 250083 T084................ 250084 T087................ 250087 T088................ 250088 T089................ 250089 T090................ 250090 T091................ 250091 T092................ 250092 T093................ 250093 T094................ 250094 T095................ 250095 T096................ 250096 T097................ 250097 T098................ 250098 T099................ 250099 T100................ 250100 T101................ 250101 T102................ 250102 T103................ 250103 T104................ 250104 T106................ 250106 T107................ 250107 T108................ 250293 T112................ 250112 T113................ 250113 T114................ 250114 T115................ 250299 T116................ 250300 T117................ 250117 T118................ 250118 T119................ 250119 T121................ 250121 T122................ 250122 T123................ 250123 T124................ 250124 T125................ 250125 T126................ 250126 T127................ 250127 T128................ 250128 T129................ 250129
A-47
NAPA No.
GATES (CANADA) - Cont. T130................ 250130 T131................ 250131 T132................ 250132 T133................ 250292 T134................ 250134 T135................ 250135 T136................ 250136 T137................ 250137 T138................ 250138 T139................ 250139 T140................ 250140 T141................ 250141 T142................ 250142 T143................ 250143 T144................ 250144 T145................ 250145 T146................ 250146 T147................ 250147 T148................ 250148 T149................ 250149 T150................ 250150 T151................ 250151 T153................ 250153 T154................ 250154 T155................ 250155 T157................ 250157 T158................ 250158 T159................ 250159 T160................ 250160 T161................ 250161 T162................ 250162 T163................ 250163 T164................ 250164 T165................ 250165 T166................ 250166 T167................ 250167 T168................ 250168 T169................ 250169 T170................ 250170 T171................ 250171 T172................ 250172 T173................ 250173 T174................ 250174 T176................ 250176 T177................ 250177 T178................ 250178 T179................ 250179 T180................ 250180 T181................ 250181 T182................ 250182 T183................ 250183 T184................ 250184 T185................ 250185 T186................ 250186 T187................ 250187 T190................ 250190 T191................ 250191 T192................ 250192 T193................ 250193 T194................ 250194 T195................ 250195 T199................ 250199 T200................ 250200 T201................ 250201 T203................ 250203 T204................ 250204 T205................ 250205 T206................ 250206 T207................ 250207 T208................ 250208 T209................ 250209 T210................ 250210 T211................ 250211 T212................ 250212 T214................ 250214 T215................ 250215 T216................ 250216 T217................ 250217 T218................ 250218 T219................ 250219 T220................ 250220 T221................ 250221 T223................ 250223 T224................ 250224 T225................ 250225 T226................ 250226 T227................ 250227 T228................ 250228 T229................ 250229 T230................ 250230 T232................ 250232 T233................ 250233 T234................ 250234
A-48

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. GATES (CANADA) - Cont. 6434 ................ 250074 GATES (U.S.) T013................ 250013 T014................ 250014 T017................ 250017 T018................ 250018 T020................ 250020 T028................ 250028 T032................ 250032 T036................ 250036 T037................ 250037 T039................ 250039 T041................ 250041 T043................ 250043 T061................ 250061 T062................ 250062 T063................ 250073 T064................ 250064 T065................ 250065 T067................ 250067 T070................ 250070 T071................ 250071 T073................ 250073 T074................ 250074 T075................ 250075 T076................ 250076 T077................ 250077 T078................ 250078 T079................ 250079 T081................ 250081 T082................ 250082 T083................ 250083 T084................ 250084 T087................ 250087 T088................ 250088 T089................ 250089 T090................ 250090 T091................ 250091 T092................ 250092 T093................ 250093 T094................ 250094 T095................ 250095 T096................ 250096 T097................ 250097 T098................ 250098 T099................ 250099 T100................ 250100 T101................ 250101 T102................ 250102 T103................ 250103 T104................ 250104 T106................ 250106 T107................ 250107 T108................ 250293 T112................ 250112 T113................ 250113 T114................ 250114 T115................ 250299 T116................ 250300 T117................ 250117 T118................ 250118 T119................ 250119 T121................ 250121 T122................ 250122 T123................ 250123 T124................ 250124 T125................ 250125 T126................ 250126 T127................ 250127 T128................ 250128 T129................ 250129 T130................ 250130 T131................ 250131 T132................ 250132 T133................ 250292 T134................ 250134 T135................ 250135 T136................ 250136 T137................ 250137 T138................ 250138 T139................ 250139 T140................ 250140 T141................ 250141 T142................ 250142 T143................ 250143 T144................ 250144 T145................ 250145 T146................ 250146 T147................ 250147 T148................ 250148 T149................ 250149 T150................ 250150 T151................ 250151 GATES (U.S.) - Cont. T153................ 250153 T154................ 250154 T155................ 250155 T157................ 250157 T158................ 250158 T159................ 250159 T160................ 250160 T161................ 250161 T162................ 250162 T163................ 250163 T164................ 250164 T165................ 250165 T166................ 250166 T167................ 250167 T168................ 250168 T169................ 250169 T170................ 250170 T171................ 250171 T172................ 250172 T173................ 250173 T174................ 250174 T176................ 250176 T177................ 250177 T178................ 250178 T179................ 250179 T180................ 250180 T181................ 250181 T182................ 250182 T183................ 250183 T184................ 250184 T185................ 250185 T186................ 250186 T187................ 250187 T190................ 250190 T191................ 250191 T192................ 250192 T193................ 250193 T194................ 250194 T195................ 250195 T199................ 250199 T200................ 250200 T201................ 250201 T202................ 250248 T203................ 250203 T204................ 250204 T205................ 250205 T206................ 250206 T207................ 250207 T208................ 250208 T209................ 250209 T210................ 250210 T211................ 250211 T212................ 250212 T214................ 250214 T215................ 250215 T216................ 250216 T217................ 250217 T218................ 250218 T219................ 250219 T220................ 250220 T221................ 250221 T223................ 250223 T224................ 250224 T225................ 250225 T226................ 250226 T227................ 250227 T228................ 250228 T229................ 250229 T230................ 250230 T232................ 250232 T233................ 250233 T234................ 250234 T235................ 250235 T236................ 250236 T237................ 250237 T239................ 250239 T240................ 250240 T241................ 250241 T242................ 250242 T244................ 250244 T245................ 250245 T246................ 250246 T247................ 250247 T248................ 250248 T249................ 250249 T251................ 250251 T252................ 250252 T253................ 250253 T254................ 250254 T255................ 250255 T256................ 250256 T257................ 250257 T258................ 250258 GATES (U.S.) - Cont. T259................ 250259 T260................ 250260 T262................ 250262 T263................ 250263 T264................ 250264 T265................ 250265 T266................ 250266 T267................ 250267 T270................ 250270 T271................ 250271 T272................ 250272 T273................ 250273 T274................ 250274 T275................ 250275 T276................ 250276 T277................ 250277 T278................ 250278 T279................ 250279 T280................ 250280 T281................ 250281 T282................ 250282 T283................ 250283 T284................ 250284 T285................ 250285 T286................ 250286 T287................ 250287 T288................ 250288 T289................ 250289 T290................ 250290 T291................ 250291 T292................ 250292 T293................ 250293 T294................ 250294 T295................ 250295 T296................ 250296 T297................ 250297 T298................ 250298 T299................ 250299 T300................ 250300 T301................ 250301 T302................ 250302 T303................ 250303 T304................ 250304 T305................ 250305 T306................ 250306 T308................ 250308 T309................ 250309 T310................ 250310 T311................ 250311 6401 ................ 250014 6402 ................ 250013 6403 ................ 250037 6404 ................ 250017 6406 ................ 250018 6408 ................ 250020 6409 ................ 250039 6410 ................ 250032 6411 ................ 250041 6412 ................ 250062 6415 ................ 250028 6416 ................ 250064 6417 ................ 250065 6418 ................ 250061 6419 ................ 250073 6425 ................ 250070 6427 ................ 250071 6428 ................ 250067 6429 ................ 250076 6430 ................ 250075 6431 ................ 250078 6432 ................ 250077 6433 ................ 250043 6434 ................ 250074 GOODYEAR CD-100............ 250100 CD-101............ 250101 CD-104............ 250104 CD-106............ 250106 CD-112............ 250112 CD-113............ 250113 CD-114............ 250114 CD-115............ 250299 CD-116............ 250300 CD-117............ 250117 CD-118............ 250118 CD-122............ 250122 CD-124............ 250124 CD-125............ 250125 CD-126............ 250126 CD-127............ 250127 CD-128............ 250128 CD-129............ 250129 CD-13.............. 250013 GOODYEAR - Cont. CD-130............ 250130 CD-131............ 250131 CD-132............ 250132 CD-133............ 250292 CD-134............ 250134 CD-136............ 250136 CD-137............ 250137 CD-138............ 250138 CD-139............ 250139 CD-14.............. 250014 CD-140............ 250140 CD-141............ 250141 CD-142............ 250142 CD-143............ 250143 CD-144............ 250144 CD-145............ 250145 CD-146............ 250146 CD-147............ 250147 CD-148............ 250148 CD-149............ 250149 CD-150............ 250150 CD-151............ 250151 CD-153............ 250153 CD-154............ 250154 CD-155............ 250155 CD-157............ 250157 CD-158............ 250158 CD-159............ 250159 CD-160............ 250160 CD-161............ 250161 CD-162............ 250162 CD-163............ 250163 CD-164............ 250164 CD-165............ 250165 CD-166............ 250166 CD-167............ 250167 CD-168............ 250168 CD-169............ 250169 CD-17.............. 250017 CD-170............ 250170 CD-171............ 250171 CD-172............ 250172 CD-173............ 250173 CD-174............ 250174 CD-176............ 250176 CD-177............ 250177 CD-178............ 250178 CD-179............ 250179 CD-18.............. 250018 CD-180............ 250180 CD-181............ 250181 CD-182............ 250182 CD-183............ 250183 CD-184............ 250184 CD-185............ 250185 CD-186............ 250186 CD-187............ 250187 CD-190............ 250190 CD-191............ 250191 CD-192............ 250192 CD-193............ 250193 CD-194............ 250194 CD-195............ 250195 CD-199............ 250199 CD-20.............. 250020 CD-200............ 250200 CD-201............ 250201 CD-202............ 250248 CD-203............ 250203 CD-204............ 250204 CD-205............ 250205 CD-206............ 250206 CD-207............ 250207 CD-208............ 250208 CD-209............ 250209 CD-210............ 250210 CD-211............ 250211 CD-212............ 250212 CD-214............ 250214 CD-215............ 250215 CD-216............ 250216 CD-217............ 250217 CD-218............ 250218 CD-219............ 250219 CD-220............ 250220 CD-221............ 250221 CD-223............ 250223 CD-224............ 250224 CD-225............ 250225 CD-226............ 250226 CD-227............ 250227 CD-228............ 250228 CD-229............ 250229
GATES (CANADA) - Cont. T235................ 250235 T236................ 250236 T237................ 250237 T239................ 250239 T240................ 250240 T241................ 250241 T242................ 250242 T244................ 250244 T245................ 250245 T246................ 250246 T247................ 250247 T248................ 250248 T249................ 250249 T251................ 250251 T252................ 250252 T253................ 250253 T254................ 250254 T255................ 250255 T256................ 250256 T257................ 250257 T258................ 250258 T259................ 250259 T260................ 250260 T262................ 250262 T263................ 250263 T264................ 250264 T265................ 250265 T266................ 250266 T267................ 250267 T270................ 250270 T271................ 250271 T272................ 250272 T273................ 250273 T274................ 250274 T275................ 250275 T276................ 250276 T277................ 250277 T278................ 250278 T279................ 250279 T280................ 250280 T281................ 250281 T282................ 250282 T283................ 250283 T284................ 250284 T285................ 250285 T286................ 250286 T287................ 250287 T288................ 250288 T289................ 250289 T290................ 250290 T291................ 250291 T292................ 250292 T293................ 250293 T294................ 250294 T295................ 250295 T296................ 250296 T297................ 250297 T298................ 250298 T299................ 250299 T300................ 250300 T301................ 250301 T302................ 250302 T303................ 250303 T304................ 250304 T305................ 250305 T306................ 250306 T308................ 250308 T309................ 250309 T310................ 250310 T311................ 250311 6401 ................ 250014 6402 ................ 250013 6403 ................ 250037 6404 ................ 250017 6406 ................ 250018 6408 ................ 250020 6409 ................ 250039 6410 ................ 250032 6411 ................ 250041 6412 ................ 250062 6415 ................ 250028 6416 ................ 250064 6417 ................ 250065 6418 ................ 250061 6419 ................ 250073 6425 ................ 250070 6427 ................ 250071 6428 ................ 250067 6429 ................ 250076 6430 ................ 250075 6431 ................ 250078 6432 ................ 250077 6433 ................ 250043

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. GOODYEAR - Cont. CD-230............ 250230 CD-232............ 250232 CD-233............ 250233 CD-234............ 250234 CD-235............ 250235 CD-236............ 250236 CD-237............ 250237 CD-239............ 250239 CD-240............ 250240 CD-241............ 250241 CD-242............ 250242 CD-244............ 250244 CD-245............ 250245 CD-246............ 250246 CD-247............ 250247 CD-248............ 250248 CD-249............ 250249 CD-251............ 250251 CD-252............ 250252 CD-253............ 250253 CD-254............ 250254 CD-255............ 250255 CD-256............ 250256 CD-257............ 250257 CD-258............ 250258 CD-259............ 250259 CD-260............ 250260 CD-262............ 250262 CD-263............ 250263 CD-264............ 250264 CD-265............ 250265 CD-266............ 250266 CD-267............ 250267 CD-271............ 250271 CD-272............ 250272 CD-273............ 250273 CD-276............ 250276 CD-277............ 250277 CD-278............ 250278 CD-279............ 250279 CD-28.............. 250028 CD-280............ 250280 CD-281............ 250281 CD-282............ 250282 CD-283............ 250283 CD-284............ 250284 CD-285............ 250285 CD-286............ 250286 CD-287............ 250287 CD-288............ 250288 CD-289............ 250289 CD-290............ 250290 CD-291............ 250291 CD-292............ 250292 CD-293............ 250293 CD-294............ 250294 CD-295............ 250295 CD-296............ 250296 CD-297............ 250297 CD-298............ 250298 CD-299............ 250299 CD-300............ 250300 CD-301............ 250301 CD-302............ 250302 CD-303............ 250303 CD-304............ 250304 CD-305............ 250305 CD-306............ 250306 CD-32.............. 250032 CD-36.............. 250036 CD-37.............. 250037 CD-39.............. 250039 CD-41.............. 250041 CD-43.............. 250043 CD-61.............. 250061 CD-62.............. 250062 CD-63.............. 250073 CD-64.............. 250064 CD-65.............. 250065 CD-67.............. 250067 CD-70.............. 250070 CD-71.............. 250071 CD-74.............. 250074 CD-77.............. 250077 CD-78.............. 250078 CD-81.............. 250081 CD-87.............. 250087 CD-88.............. 250088 CD-89.............. 250089 CD-90.............. 250090 CD-91.............. 250091 CD-92.............. 250092 CD-93.............. 250093 GOODYEAR - Cont. CD-94.............. 250094 CD-95.............. 250095 CD-99.............. 250099 40013 .............. 250013 40014 .............. 250014 40017 .............. 250017 40018 .............. 250018 40020 .............. 250020 40028 .............. 250028 40032 .............. 250032 40036 .............. 250036 40037 .............. 250037 40039 .............. 250039 40041 .............. 250041 40043 .............. 250043 40046 .............. 250013 40047 .............. 250014 40050 .............. 250018 40052 .............. 250020 40057 .............. 250037 40058 .............. 250039 40060 .............. 250017 40061 .............. 250061 40062 .............. 250062 40063 .............. 250073 40064 .............. 250064 40065 .............. 250065 40067 .............. 250067 40070 .............. 250070 40071 .............. 250071 40074 .............. 250074 40075 .............. 250075 40076 .............. 250076 40077 .............. 250077 40078 .............. 250078 40079 .............. 250079 40081 .............. 250081 40082 .............. 250082 40083 .............. 250083 40084 .............. 250084 40087 .............. 250087 40088 .............. 250088 40089 .............. 250089 40090 .............. 250090 40091 .............. 250091 40092 .............. 250092 40093 .............. 250093 40094 .............. 250094 40095 .............. 250095 40099 .............. 250099 40100 .............. 250100 40101 .............. 250101 40102 .............. 250102 40103 .............. 250103 40104 .............. 250104 40106 .............. 250106 40107 .............. 250107 40112 .............. 250176 40113 .............. 250113 40114 .............. 250114 40115 .............. 250299 40116 .............. 250300 40117 .............. 250117 40118 .............. 250118 40119 .............. 250119 40121 .............. 250121 40122 .............. 250122 40123 .............. 250123 40124 .............. 250124 40125 .............. 250125 40126 .............. 250126 40127 .............. 250127 40128 .............. 250128 40129 .............. 250129 40130 .............. 250130 40131 .............. 250131 40132 .............. 250132 40133 .............. 250292 40134 .............. 250134 40136 .............. 250136 40137 .............. 250137 40138 .............. 250138 40139 .............. 250139 40140 .............. 250140 40141 .............. 250141 40142 .............. 250142 40143 .............. 250143 40144 .............. 250144 40145 .............. 250145 40146 .............. 250146 40147 .............. 250147 40148 .............. 250148 40153 .............. 250153 GOODYEAR - Cont. 40154 .............. 250154 40155 .............. 250155 40157 .............. 250157 40158 .............. 250158 40159 .............. 250159 40160 .............. 250160 40161 .............. 250161 40162 .............. 250162 40163 .............. 250163 40164 .............. 250164 40165 .............. 250165 40166 .............. 250166 40167 .............. 250167 40168 .............. 250168 40169 .............. 250169 40170 .............. 250170 40172 .............. 250172 40176 .............. 250176 40177 .............. 250177 40178 .............. 250178 40179 .............. 250179 40180 .............. 250180 40183 .............. 250183 40184 .............. 250184 40185 .............. 250185 40186 .............. 250186 40187 .............. 250187 40190 .............. 250190 40191 .............. 250191 40192 .............. 250192 40193 .............. 250193 40194 .............. 250194 40195 .............. 250195 40199 .............. 250199 40200 .............. 250200 40201 .............. 250201 40202 .............. 250248 40203 .............. 250203 40204 .............. 250204 40205 .............. 250205 40208 .............. 250208 40210 .............. 250210 40211 .............. 250211 40212 .............. 250212 40214 .............. 250214 40215 .............. 250215 40216 .............. 250216 40217 .............. 250217 40219 .............. 250219 40220 .............. 250220 40221 .............. 250221 40223 .............. 250223 40224 .............. 250224 40226 .............. 250226 40227 .............. 250227 40228 .............. 250228 40230 .............. 250230 40233 .............. 250233 40234 .............. 250234 40235 .............. 250235 40236 .............. 250236 40237 .............. 250237 40239 .............. 250239 40240 .............. 250240 40241 .............. 250241 40244 .............. 250244 40245 .............. 250245 40246 .............. 250246 40247 .............. 250247 40248 .............. 250248 40249 .............. 250249 40252 .............. 250252 40255 .............. 250255 40257 .............. 250257 40258 .............. 250258 40259 .............. 250259 40262 .............. 250262 40263 .............. 250263 40265 .............. 250265 40266 .............. 250266 40271 .............. 250271 40272 .............. 250272 40273 .............. 250273 40276 .............. 250276 40283 .............. 250283 40292 .............. 250292 40299 .............. 250299 40300 .............. 250300 HOOF PRODUCTS HB013 ............. 250013 HB014 ............. 250014 HB017 ............. 250017 HB018 ............. 250018 HOOF PRODUCTS - Cont. HB020 ............. 250020 HB028 ............. 250028 HB032 ............. 250032 HB036 ............. 250036 HB037 ............. 250037 HB039 ............. 250039 HB041 ............. 250041 HB043 ............. 250043 HB061 ............. 250061 HB062 ............. 250062 HB063 ............. 250073 HB064 ............. 250064 HB065 ............. 250065 HB067 ............. 250067 HB070 ............. 250070 HB071 ............. 250071 HB073 ............. 250073 HB074 ............. 250074 HB075 ............. 250075 HB076 ............. 250076 HB077 ............. 250077 HB078 ............. 250078 HB079 ............. 250079 HB081 ............. 250081 HB082 ............. 250082 HB083 ............. 250083 HB084 ............. 250084 HB087 ............. 250087 HB088 ............. 250088 HB089 ............. 250089 HB090 ............. 250090 HB091 ............. 250091 HB092 ............. 250092 HB093 ............. 250093 HB094 ............. 250094 HB095 ............. 250095 HB096 ............. 250096 HB099 ............. 250099 HB100 ............. 250100 HB102 ............. 250102 HB103 ............. 250103 HB104 ............. 250104 HB114 ............. 250114 HB115 ............. 250299 HB116 ............. 250300 HB118 ............. 250118 HB121 ............. 250121 HB122 ............. 250122 HB127 ............. 250127 HB128 ............. 250128 LAZORLITE L55-4014......... 250013 L55-4022......... 250062 L55-4030......... 250064 L55-4049......... 250028 L55-4057......... 250041 L55-4065......... 250041 L55-4081......... 250073 L55-4103......... 250078 L55-4111......... 250077 L55-4120......... 250074 L55-4138......... 250079 L55-4154......... 250088 L55-4162......... 250089 L55-4170......... 250090 L55-4189......... 250092 L55-4200......... 250070 L55-4219......... 250075 L55-4227......... 250076 L55-4235......... 250117 L55-4243......... 250093 L55-4251......... 250091 L55-4260......... 250095 L55-4286......... 250104 L55-4294......... 250101 L55-4308......... 250084 L55-4316......... 250087 L55-4324......... 250094 L55-4332......... 250099 L55-4405......... 250017 L55-4472......... 250300 L55-4480......... 250299 L55-4499......... 250112 L55-4502......... 250161 L55-4510......... 250118 L55-4529......... 250104 L55-4537......... 250137 L55-4596......... 250149 L55-4600......... 250141 L55-4618......... 250141 L55-4626......... 250117 L55-4634......... 250134 L55-4642......... 250128
A-49
NAPA No.
LAZORLITE - Cont. L55-4650......... 250124 L55-4669......... 250139 L55-4677......... 250103 L55-4685......... 250135 L55-4693......... 250136 L55-4707......... 250126 L55-4715......... 250098 L55-4723......... 250138 L55-4731......... 250130 L55-4740......... 250129 L55-4758......... 250145 L55-4766......... 250122 L55-4774......... 250121 L55-4782......... 250148 L55-4790......... 250138 L55-4812......... 250146 L55-4820......... 250159 L55-4839......... 250168 L55-4847......... 250144 L55-4855......... 250142 L55-4863......... 250143 L55-4880......... 250167 L55-4898......... 250165 L55-4901......... 250164 L55-4910......... 250150 L55-4928......... 250151 L55-4936......... 250166 L55-4944......... 250113 L55-4952......... 250157 L55-4960......... 250154 L55-4979......... 250125 U55-4367 ........ 250018 U55-4383 ........ 250020 U55-4405 ........ 250017 U55-4413 ........ 250065 U55-4421 ........ 250127 U55-4430 ........ 250083 U55-4448 ........ 250032 U55-4456 ........ 250082 U55-4464 ........ 250043 U55-4545 ........ 250082 U55-4553 ........ 250083 U55-4561 ........ 250293 U55-4570 ........ 250107 U55-4588 ........ 250119 U55-4871 ........ 250292 LEMPCO TB013 ............. 250013 TB014 ............. 250014 TB017 ............. 250017 TB018 ............. 250018 TB028 ............. 250028 TB037 ............. 250037 TB039 ............. 250039 TB041 ............. 250041 TB063 ............. 250073 TB064 ............. 250064 TB071 ............. 250071 TB112 ............. 250112 LINK-BELT B013................ 250013 B014................ 250014 B037................ 250037 MBL THREE STARS 100ZA19.......... 250061 106ZA19.......... 250077 109ZA19.......... 250088 113ZA19.......... 250065 116ZA19.......... 250018 120ZA19.......... 250064 121ZA19.......... 250017 122ZA19.......... 250013 123ZA19.......... 250032 124ZA25.......... 250071 129ZA22.......... 250014 134ZA30.......... 250076 134ZB301........ 250076 135ZB25.......... 250043 139ZA25.......... 250087 142ZA25.......... 250074 146ZA19.......... 250020 55ZA13 ........... 250062 84ZA19 ........... 250028 87ZA34 ........... 250075 87ZB34 ........... 250075 88ZA19 ........... 250070 92ZA19 ........... 250073 95ZA19 ........... 250041 97ZA25 ........... 250067 98ZA19 ........... 250078 99ZA15 ........... 250037
A-50

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. MELLING AUTOMOTIVE - Cont. B0164.............. 250164 B0165.............. 250165 B0166.............. 250166 B0167.............. 250167 B0168.............. 250168 B0169.............. 250169 B017................ 250017 B0170.............. 250170 B0171.............. 250171 B0172.............. 250172 B0174.............. 250174 B0176.............. 250176 B0177.............. 250177 B0178.............. 250178 B0179.............. 250179 B018................ 250018 B0180.............. 250180 B0181.............. 250181 B0182.............. 250182 B0183.............. 250183 B0184.............. 250184 B0185.............. 250185 B0186.............. 250186 B0187.............. 250187 B0191.............. 250191 B0192.............. 250192 B0193.............. 250193 B0194.............. 250194 B0195.............. 250195 B0199.............. 250199 B020................ 250020 B0202.............. 250248 B0203.............. 250203 B0204.............. 250204 B0205.............. 250205 B0208.............. 250208 B0210.............. 250210 B0216.............. 250216 B0219.............. 250219 B0223.............. 250223 B0224.............. 250224 B0226.............. 250226 B0228.............. 250228 B0229.............. 250229 B0230.............. 250230 B0232.............. 250232 B0233.............. 250233 B0237.............. 250237 B0239.............. 250239 B028................ 250028 B029................ 250104 B032................ 250032 B036................ 250036 B037................ 250037 B039................ 250039 B041................ 250041 B043................ 250043 B061................ 250061 B062................ 250062 B063................ 250073 B064................ 250064 B065................ 250065 B067................ 250067 B070................ 250070 B071................ 250071 B074................ 250074 B075................ 250075 B076................ 250076 B077................ 250077 B078................ 250078 B079................ 250079 B081................ 250081 B082................ 250082 B083................ 250083 B084................ 250084 B087................ 250087 B088................ 250088 B089................ 250089 B090................ 250090 B091................ 250091 B092................ 250092 B093................ 250093 B094................ 250094 B095................ 250095 B096................ 250096 B097................ 250097 B098................ 250098 B099................ 250099 MICROTEST 9-013............... 250013 9-014............... 250014 9-017............... 250017 MICROTEST - Cont. 9-018............... 250018 9-020............... 250020 9-028............... 250028 9-039............... 250039 9-041............... 250041 9-061............... 250061 9-063............... 250073 9-064............... 250064 9-065............... 250065 9-067............... 250067 9-071............... 250071 MIGHTY CD100............. 250100 CD101............. 250101 CD102............. 250102 CD103............. 250103 CD104............. 250104 CD111............. 250140 CD112............. 250176 CD113............. 250113 CD114............. 250114 CD115............. 250299 CD116............. 250300 CD117............. 250117 CD118............. 250118 CD119............. 250119 CD121............. 250121 CD122............. 250122 CD123............. 250123 CD124............. 250124 CD125............. 250125 CD126............. 250126 CD127............. 250127 CD128............. 250128 CD129............. 250129 CD13............... 250013 CD130............. 250130 CD131............. 250131 CD132............. 250132 CD133............. 250292 CD134............. 250134 CD135............. 250135 CD136............. 250136 CD137............. 250137 CD138............. 250138 CD139............. 250139 CD14............... 250014 CD141............. 250141 CD142............. 250142 CD143............. 250143 CD144............. 250144 CD145............. 250145 CD146............. 250146 CD147............. 250147 CD148............. 250148 CD153............. 250153 CD154............. 250154 CD155............. 250155 CD157............. 250157 CD158............. 250158 CD159............. 250159 CD160............. 250160 CD161............. 250161 CD162............. 250162 CD163............. 250163 CD164............. 250164 CD165............. 250165 CD166............. 250166 CD167............. 250167 CD17............... 250017 CD176............. 250176 CD18............... 250018 CD185............. 250185 CD186............. 250186 CD187............. 250187 CD191............. 250191 CD20............... 250020 CD208............. 250208 CD210............. 250210 CD28............... 250028 CD32............... 250032 CD36............... 250036 CD37............... 250037 CD39............... 250039 CD41............... 250041 CD43............... 250043 CD61............... 250061 CD62............... 250062 CD63............... 250073 CD64............... 250064 CD65............... 250065 CD67............... 250067 CD70............... 250070 MIGHTY - Cont. CD71............... 250071 CD74............... 250074 CD75............... 250075 CD76............... 250076 CD77............... 250077 CD78............... 250078 CD79............... 250079 CD81............... 250081 CD82............... 250082 CD83............... 250083 CD84............... 250084 CD87............... 250087 CD88............... 250088 CD89............... 250089 CD90............... 250090 CD91............... 250091 CD92............... 250092 CD93............... 250093 CD94............... 250094 CD95............... 250095 CD99............... 250099 MITSUBOSHI 106ZA19.......... 250077 111ZA19.......... 250121 116ZA19.......... 250018 120ZA19.......... 250064 122ZA19.......... 250013 123ZA19.......... 250032 127ZA25.......... 250079 129ZA22.......... 250014 134ZB30.......... 250076 139ZA25.......... 250087 146ZA19.......... 250020 55ZA13 ........... 250062 55ZB13 ........... 250090 83ZB19 ........... 250092 84ZA19 ........... 250028 87ZB34 ........... 250075 88ZA19 ........... 250070 89ZA19 ........... 250095 92ZA19 ........... 250073 94ZA19 ........... 250036 95ZA19 ........... 250041 98ZA19 ........... 250078 MOPAR BTC-13............ 250013 BTC-14............ 250014 BTC-37............ 250037 BTC-39............ 250020 B0040013........ 250013 B0040017........ 250017 B0040062........ 250062 B0040063........ 250073 B0040064........ 250064 B0040071........ 250071 MOTORCRAFT CET13............. 250013 CET135........... 250135 CET14............. 250014 CET17............. 250017 CET207........... 250207 CET230........... 250230 CET257........... 250257 CET262........... 250262 CET263........... 250263 CET264........... 250264 CET265........... 250265 CET271........... 250271 CET272........... 250272 CET273........... 250273 CET277........... 250277 CET278........... 250278 CET279........... 250279 CET28............. 250028 CET280........... 250280 CET281........... 250281 CET282........... 250282 CET284........... 250284 CET285........... 250285 CET286........... 250286 CET287........... 250287 CET288........... 250288 CET289........... 250289 CET290........... 250290 CET291........... 250291 CET37............. 250037 CET39............. 250039 CET41............. 250041 CET61............. 250061 CET67............. 250067 CET70............. 250070 MOTORCRAFT - Cont. CET71............. 250071 CET94............. 250094 PAREX TRANS. PARTS 013 .................. 250013 018 .................. 250018 020 .................. 250020 028 .................. 250028 032 .................. 250032 037 .................. 250037 041 .................. 250041 043 .................. 250043 062 .................. 250062 065 .................. 250065 067 .................. 250067 070 .................. 250070 071 .................. 250071 074 .................. 250074 075 .................. 250075 076 .................. 250076 077 .................. 250077 078 .................. 250078 081 .................. 250081 087 .................. 250087 088 .................. 250088 093 .................. 250093 094 .................. 250094 095 .................. 250095 099 .................. 250099 104 .................. 250104 PEP BOYS (See DAYCO) PERFECT CIRCLE 9-100............... 250100 9-101............... 250101 9-102............... 250102 9-103............... 250103 9-104............... 250104 9-13................. 250013 9-14................. 250014 9-17................. 250017 9-18................. 250018 9-20................. 250020 9-28................. 250028 9-32................. 250032 9-36................. 250036 9-37................. 250037 9-39................. 250039 9-41................. 250041 9-43................. 250043 9-61................. 250061 9-62................. 250062 9-63................. 250073 9-64................. 250064 9-65................. 250065 9-67................. 250067 9-70................. 250070 9-71................. 250071 9-74................. 250074 9-75................. 250075 9-76................. 250076 9-77................. 250077 9-78................. 250078 9-79................. 250079 9-81................. 250081 9-84................. 250084 9-87................. 250087 9-88................. 250088 9-89................. 250089 9-90................. 250090 9-91................. 250091 9-92................. 250092 9-93................. 250093 9-94................. 250094 9-96................. 250096 9-98................. 250098 9-99................. 250099 PERFECTION AM B0101.............. 250101 B0102.............. 250102 B0103.............. 250103 B0104.............. 250104 B0114.............. 250114 B0118.............. 250162 B013................ 250013 B014................ 250014 B017................ 250017 B018................ 250018 B020................ 250020 B028................ 250028 B032................ 250032
MBL THREE STARS - Cont. 99ZA19 ........... 250039 MCQUAY-NORRIS TC013 ............. 250013 TC014 ............. 250014 TC017 ............. 250017 TC018 ............. 250018 TC020 ............. 250020 TC028 ............. 250028 TC032 ............. 250032 TC036 ............. 250036 TC037 ............. 250037 TC039 ............. 250039 TC041 ............. 250041 TC043 ............. 250043 TC061 ............. 250061 TC062 ............. 250062 TC063 ............. 250073 TC064 ............. 250064 TC065 ............. 250065 TC067 ............. 250067 TC070 ............. 250070 TC071 ............. 250071 TC074 ............. 250074 TC075 ............. 250075 TC076 ............. 250076 TC077 ............. 250077 TC078 ............. 250078 TC081 ............. 250081 TC087 ............. 250087 TC088 ............. 250088 TC089 ............. 250089 MELLING AUTOMOTIVE B0100.............. 250100 B0101.............. 250101 B0102.............. 250102 B0103.............. 250103 B0104.............. 250104 B0106.............. 250106 B0107.............. 250107 B0108.............. 250293 B0112.............. 250176 B0113.............. 250113 B0114.............. 250114 B0115.............. 250299 B0116.............. 250300 B0117.............. 250117 B0118.............. 250162 B0119.............. 250119 B0121.............. 250121 B0122.............. 250122 B0123.............. 250123 B0124.............. 250124 B0125.............. 250125 B0126.............. 250126 B0127.............. 250127 B0128.............. 250128 B0129.............. 250129 B013................ 250013 B0130.............. 250130 B0131.............. 250131 B0132.............. 250132 B0133.............. 250292 B0134.............. 250134 B0135.............. 250135 B0136.............. 250136 B0137.............. 250137 B0138.............. 250138 B0139.............. 250139 B014................ 250014 B0140.............. 250140 B0141.............. 250141 B0142.............. 250142 B0143.............. 250143 B0144.............. 250144 B0145.............. 250145 B0146.............. 250146 B0147.............. 250147 B0148.............. 250148 B0149.............. 250149 B0150.............. 250150 B0151.............. 250151 B0153.............. 250153 B0154.............. 250154 B0155.............. 250155 B0157.............. 250157 B0158.............. 250158 B0159.............. 250159 B0160.............. 250160 B0161.............. 250161 B0162.............. 250162 B0163.............. 250163

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. PERFECTION AM - Cont. B036................ 250036 B037................ 250037 B039................ 250039 B041................ 250041 B043................ 250043 B061................ 250061 B062................ 250062 B063................ 250073 B064................ 250064 B065................ 250065 B067................ 250067 B070................ 250070 B071................ 250071 B074................ 250074 B075................ 250075 B076................ 250076 B077................ 250077 B078................ 250078 B081................ 250081 B082................ 250082 B083................ 250083 B087................ 250087 B088................ 250088 B089................ 250089 B090................ 250090 B093................ 250093 B094................ 250094 B095................ 250095 B099................ 250099 013 .................. 250013 014 .................. 250014 017 .................. 250017 018 .................. 250020 037 .................. 250037 039 .................. 250039 PROVEN VALU TB-013 ............ 250013 TB-014 ............ 250014 TB-017 ............ 250017 TB-018 ............ 250018 TB-020 ............ 250020 TB-028 ............ 250028 TB-032 ............ 250032 TB-036 ............ 250036 TB-037 ............ 250037 TB-039 ............ 250039 TB-041 ............ 250041 TB-043 ............ 250043 TB-061 ............ 250061 TB-062 ............ 250062 TB-063 ............ 250073 TB-064 ............ 250064 TB-065 ............ 250065 TB-067 ............ 250067 TB-070 ............ 250070 TB-071 ............ 250071 TB-073 ............ 250073 TB-074 ............ 250074 TB-075 ............ 250075 TB-076 ............ 250076 TB-077 ............ 250077 TB-078 ............ 250078 TB-079 ............ 250079 TB-081 ............ 250081 TB-082 ............ 250082 TB-083 ............ 250083 TB-084 ............ 250084 TB-087 ............ 250087 TB-088 ............ 250088 TB-089 ............ 250089 TB-090 ............ 250090 TB-091 ............ 250091 TB-092 ............ 250092 TB-093 ............ 250093 TB-094 ............ 250094 TB-095 ............ 250095 TB-096 ............ 250096 TB-098 ............ 250098 TB-099 ............ 250099 TB-100 ............ 250100 TB-101 ............ 250101 TB-102 ............ 250102 TB-103 ............ 250103 TB-104 ............ 250104 TB-112 ............ 250112 TB-113 ............ 250113 TB-114 ............ 250114 TB-115 ............ 250299 TB-116 ............ 250300 TB-117 ............ 250117 TB-118 ............ 250118 TB-119 ............ 250119 TB-121 ............ 250121 PROVEN VALU - Cont. TB-122 ............ 250122 TB-123 ............ 250123 TB-125 ............ 250125 TB-126 ............ 250126 TB-127 ............ 250127 TB-128 ............ 250128 TB-129 ............ 250129 TB-130 ............ 250130 TB-134 ............ 250134 TB-139 ............ 250139 REPCOPARTS 4013 ................ 250013 4014 ................ 250014 4017 ................ 250017 4018 ................ 250018 4020 ................ 250020 4028 ................ 250028 4029 ................ 250104 4032 ................ 250032 4036 ................ 250036 4037 ................ 250037 4039 ................ 250039 4041 ................ 250041 4043 ................ 250043 4061 ................ 250061 4065 ................ 250065 4070 ................ 250070 4071 ................ 250071 4073 ................ 250073 4074 ................ 250074 4077 ................ 250077 4078 ................ 250078 4079 ................ 250079 4081 ................ 250081 4082 ................ 250082 4083 ................ 250083 4084 ................ 250084 4089 ................ 250089 4091 ................ 250091 4092 ................ 250092 4093 ................ 250093 4094 ................ 250094 4095 ................ 250095 4096 ................ 250096 4097 ................ 250097 4098 ................ 250098 4099 ................ 250099 4100 ................ 250100 4101 ................ 250101 4102 ................ 250102 4103 ................ 250103 4104 ................ 250104 4106 ................ 250106 REPUBLIC R0112 ............. 250176 R0113 ............. 250113 R0114 ............. 250114 R0115 ............. 250299 R0116 ............. 250300 R0117 ............. 250117 R0118 ............. 250162 R0119 ............. 250119 R0122 ............. 250122 R0124 ............. 250124 R0125 ............. 250125 R0126 ............. 250126 R0127 ............. 250127 R0128 ............. 250128 R0129 ............. 250129 R0130 ............. 250130 R0132 ............. 250132 R0133 ............. 250292 R0134 ............. 250134 R0135 ............. 250135 R0136 ............. 250233 R0138 ............. 250138 R0139 ............. 250139 R0141 ............. 250141 R0142 ............. 250142 R0143 ............. 250143 R0144 ............. 250144 R0145 ............. 250145 R0146 ............. 250146 R0147 ............. 250147 R0148 ............. 250148 R0153 ............. 250153 R0154 ............. 250154 R0157 ............. 250157 R0158 ............. 250158 R0159 ............. 250159 R0160 ............. 250160 R0161 ............. 250161 REPUBLIC - Cont. R0162 ............. 250162 R0163 ............. 250163 R0164 ............. 250164 R0166 ............. 250166 R0167 ............. 250167 R0168 ............. 250168 R0169 ............. 250169 R0170 ............. 250170 R0176 ............. 250176 R0177 ............. 250177 R0179 ............. 250179 R0184 ............. 250184 R0185 ............. 250185 R0186 ............. 250186 R0187 ............. 250187 R082 ............... 250082 R083 ............... 250083 REPUBLIC PARTS R-0100 ............ 250100 R-0101 ............ 250101 R-0102 ............ 250102 R-0103 ............ 250103 R-0104 ............ 250104 R-0112 ............ 250112 R-013 .............. 250013 R-014 .............. 250014 R-017 .............. 250017 R-018 .............. 250018 R-020 .............. 250020 R-028 .............. 250028 R-032 .............. 250032 R-036 .............. 250036 R-037 .............. 250037 R-039 .............. 250039 R-041 .............. 250041 R-043 .............. 250043 R-061 .............. 250061 R-062 .............. 250062 R-063 .............. 250073 R-064 .............. 250064 R-065 .............. 250065 R-067 .............. 250067 R-070 .............. 250070 R-071 .............. 250071 R-073 .............. 250073 R-074 .............. 250074 R-075 .............. 250075 R-076 .............. 250075 R-077 .............. 250077 R-078 .............. 250078 R-079 .............. 250079 R-081 .............. 250081 R-084 .............. 250084 R-087 .............. 250087 R-088 .............. 250088 R-089 .............. 250089 R-090 .............. 250090 R-091 .............. 250091 R-092 .............. 250092 R-093 .............. 250093 R-094 .............. 250094 R-095 .............. 250095 R-096 .............. 250096 R-098 .............. 250098 R-099 .............. 250099 ROCKHILL TB-100 ............ 250100 TB-101 ............ 250101 TB-102 ............ 250102 TB-103 ............ 250103 TB-104 ............ 250104 TB-112 ............ 250176 TB-118 ............ 250118 TB-13 .............. 250013 TB-14 .............. 250014 TB-17 .............. 250017 TB-18 .............. 250018 TB-20 .............. 250020 TB-28 .............. 250028 TB-32 .............. 250032 TB-36 .............. 250036 TB-37 .............. 250037 TB-39 .............. 250039 TB-41 .............. 250041 TB-43 .............. 250043 TB-61 .............. 250061 TB-62 .............. 250062 TB-63 .............. 250073 TB-64 .............. 250064 TB-65 .............. 250065 TB-67 .............. 250067 TB-70 .............. 250070 ROCKHILL - Cont. TB-71 .............. 250071 TB-73 .............. 250073 TB-74 .............. 250074 TB-75 .............. 250075 TB-76 .............. 250076 TB-77 .............. 250077 TB-78 .............. 250078 TB-79 .............. 250079 TB-81 .............. 250081 TB-82 .............. 250082 TB-83 .............. 250083 TB-84 .............. 250084 TB-87 .............. 250087 TB-88 .............. 250088 TB-89 .............. 250158 TB-90 .............. 250159 TB-91 .............. 250091 TB-92 .............. 250092 TB-93 .............. 250093 TB-94 .............. 250094 TB-95 .............. 250095 TB-98 .............. 250098 TB-99 .............. 250161 SEALED POWER 222-100........... 250100 222-13............. 250013 222-14............. 250014 222-17............. 250017 222-18............. 250018 222-20............. 250020 222-28............. 250028 222-32............. 250032 222-36............. 250036 222-37............. 250037 222-39............. 250039 222-41............. 250041 222-43............. 250043 222-61............. 250061 222-62............. 250062 222-63............. 250073 222-64............. 250064 222-65............. 250065 222-67............. 250067 222-70............. 250070 222-71............. 250071 222-73............. 250073 222-74............. 250074 222-75............. 250075 222-76............. 250076 222-77............. 250077 222-78............. 250078 222-81............. 250081 222-87............. 250087 222-88............. 250088 222-89............. 250089 222-90............. 250090 222-91............. 250091 222-92............. 250092 222-93............. 250093 222-94............. 250094 222-95............. 250095 222-99............. 250161 222B160.......... 250160 222B161.......... 250161 222B162.......... 250162 222B163.......... 250163 222B164.......... 250164 222B165.......... 250165 222B166.......... 250166 222B167.......... 250167 222B168.......... 250168 222B169.......... 250169 222B170.......... 250170 222B172.......... 250254 222B177.......... 250177 222B179.......... 250179 222B180.......... 250180 222B183.......... 250183 222B184.......... 250184 222B185.......... 250185 222B186.......... 250186 222B187.......... 250187 222B193.......... 250193 222B194.......... 250194 222B202.......... 250248 222B210.......... 250210 222013 ............ 250013 222014 ............ 250014 222017 ............ 250017 222018 ............ 250018 222020 ............ 250020 222028 ............ 250028 222032 ............ 250032
A-51
NAPA No.
SEALED POWER - Cont. 222036 ............ 250036 222037 ............ 250037 222039 ............ 250039 222041 ............ 250041 222043 ............ 250043 222061 ............ 250061 222062 ............ 250062 222063 ............ 250073 222064 ............ 250064 222065 ............ 250065 222067 ............ 250067 222070 ............ 250070 222071 ............ 250071 222074 ............ 250074 222075 ............ 250075 222076 ............ 250076 222077 ............ 250077 222078 ............ 250078 222082 ............ 250082 222083 ............ 250083 222087 ............ 250087 222088 ............ 250088 222089 ............ 250158 222090 ............ 250159 222093 ............ 250093 222094 ............ 250160 222095 ............ 250095 222099 ............ 250161 222101 ............ 250101 222102 ............ 250102 222103 ............ 250103 222104 ............ 250104 222107 ............ 250107 222108 ............ 250293 222112 ............ 250176 222113 ............ 250113 222114 ............ 250114 222115 ............ 250299 222116 ............ 250300 222117 ............ 250117 222118 ............ 250162 222119 ............ 250119 222122 ............ 250122 222124 ............ 250124 222125 ............ 250125 222126 ............ 250237 222128 ............ 250128 222129 ............ 250129 222130 ............ 250130 222131 ............ 250131 222132 ............ 250132 222133 ............ 250292 222134 ............ 250134 222135 ............ 250135 222136 ............ 250233 222138 ............ 250199 222139 ............ 250139 222141 ............ 250141 222142 ............ 250142 222143 ............ 250143 222144 ............ 250144 222145 ............ 250145 222146 ............ 250146 222147 ............ 250147 222148 ............ 250148 222153 ............ 250153 222154 ............ 250154 222155 ............ 250155 222157 ............ 250157 222158 ............ 250158 222159 ............ 250159 SUNOCO TB063 ............. 250073 TB070 ............. 250070 TB077 ............. 250077 TB401 ............. 250014 TB402 ............. 250013 TB403 ............. 250037 TB404 ............. 250017 TB409 ............. 250039 TB411 ............. 250041 TB415 ............. 250028 TB418 ............. 250061 TB428 ............. 250067 T1043.............. 250043 T1064.............. 250064 T1071.............. 250071 T1081.............. 250081 T.R.W. LB074.............. 250074 LB075.............. 250075 LB077.............. 250077
A-52

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. T.R.W. - Cont. LB82................ 250082 LB83................ 250083 LB84................ 250084 LB87................ 250087 LB88................ 250088 LB89................ 250158 LB90................ 250159 LB91................ 250091 LB92................ 250092 LB93................ 250093 LB94................ 250160 LB95................ 250095 LB96................ 250096 LB98................ 250098 LB99................ 250161 TEXACO TB401 ............. 250014 TB402 ............. 250013 TB403 ............. 250037 TB404 ............. 250017 TB409 ............. 250039 TB411 ............. 250041 TB415 ............. 250028 ULTRALAST B013................ 250013 B014................ 250014 B017................ 250017 B028................ 250028 B032................ 250032 B036................ 250036 B037................ 250037 B039................ 250039 B041................ 250041 B043................ 250043 B061................ 250061 B064................ 250064 B067................ 250067 B070................ 250070 B071................ 250071 B073................ 250073 B074................ 250074 B077................ 250077 B078................ 250078 B081................ 250081 B087................ 250087 B088................ 250088 B089................ 250089 B090................ 250090 B094................ 250094 B095................ 250095 B099................ 250099 B101................ 250101 B104................ 250104 B112................ 250112 B113................ 250113 B114................ 250114 B116................ 250300 B117................ 250117 B118................ 250118 B122................ 250122 B124................ 250124 B125................ 250125 B126................ 250126 B128................ 250128 B129................ 250129 B130................ 250130 B132................ 250132 B134................ 250134 B136................ 250136 B138................ 250138 B139................ 250139 B141................ 250141 B142................ 250142 B143................ 250143 B145................ 250145 B146................ 250146 B147................ 250147 B148................ 250148 B153................ 250153 B154................ 250154 B155................ 250155 B157................ 250157 B158................ 250158 B159................ 250159 B160................ 250160 B161................ 250161 B162................ 250162 B163................ 250163 B164................ 250164 B166................ 250166 B167................ 250167 B168................ 250168 ULTRALAST - Cont. B172................ 250172 B177................ 250177 B179................ 250179 B184................ 250184 B185................ 250185 B186................ 250186 B187................ 250187 B191................ 250191 B194................ 250194 B199................ 250199 B233................ 250233 B236................ 250236 B32.................. 250032 TB063 ............. 250073 TB070 ............. 250070 TB077 ............. 250077 TB401 ............. 250014 TB402 ............. 250013 TB403 ............. 250037 TB404 ............. 250017 TB409 ............. 250039 TB411 ............. 250041 TB415 ............. 250028 TB418 ............. 250061 TB428 ............. 250067 T013................ 250013 T014................ 250014 T017................ 250017 T028................ 250028 T032................ 250032 T037................ 250037 T039................ 250039 T041................ 250041 T043................ 250043 T061................ 250061 T063................ 250073 T064................ 250064 T067................ 250067 T070................ 250070 T071................ 250071 T073................ 250073 T077................ 250077 T081................ 250081 T087................ 250087 T089................ 250089 T092................ 250092 T094................ 250094 T099................ 250099 T1043.............. 250043 T1064.............. 250064 T1071.............. 250071 T1081.............. 250081 T115................ 250299 T203................ 250203 T210................ 250210 T228................ 250228 UNIROYAL A206L050........ 250062 A206L050S ..... 250090 A315L075........ 250028 A326L134B ..... 250075 A330L075........ 250070 A345L075........ 250073 A356L075........ 250041 A363L100........ 250067 A367L075........ 250078 A371L060........ 250037 A371L075........ 250039 A375L075........ 250061 A397L075........ 250077 A408L075........ 250088 A416L075R ..... 250081 A423L075........ 250065 A435L075........ 250018 A450L075........ 250064 A450L075S ..... 250093 A453L075........ 250017 A457L075........ 250013 A457L075S ..... 250158 A461L075........ 250032 A465L100........ 250071 A483L087........ 250014 A484L088........ 250014 A502L118B ..... 250076 A506L100B ..... 250043 A521L100........ 250087 A532L100........ 250074 A547L075........ 250020 UNOCAL TB063 ............. 250073 TB070 ............. 250070 TB077 ............. 250077 UNOCAL - Cont. TB401 ............. 250014 TB402 ............. 250013 TB403 ............. 250037 TB404 ............. 250017 TB409 ............. 250039 TB411 ............. 250041 TB415 ............. 250028 TB418 ............. 250061 TB428 ............. 250067 T013................ 250013 T014................ 250014 T017................ 250017 T028................ 250028 T032................ 250032 T037................ 250037 T039................ 250039 T041................ 250041 T043................ 250043 T061................ 250061 T063................ 250073 T064................ 250064 T067................ 250067 T070................ 250070 T071................ 250071 T073................ 250073 T077................ 250077 T081................ 250081 T094................ 250094 T1043.............. 250043 T1064.............. 250064 T1071.............. 250071 T1081.............. 250081 VERA A326L134B ..... 250075 45-00070......... 250062 45-00096......... 250062 45-00724......... 250028 45-00732......... 250036 45-00740......... 250020 45-00773......... 250032 45-00781......... 250018 45-00799......... 250014 45-00807......... 250013 45-00815......... 250043 45-00823......... 250017 45-00849......... 250065 45-00864......... 250070 45-00930......... 250073 45-00948......... 250064 45-00955......... 250041 45-01051......... 250082 45-01069......... 250083 45-01127......... 250076 45-01135......... 250075 45-01150......... 250078 45-01168......... 250077 45-01176......... 250074 45-01200......... 250107 45-01226......... 250158 45-01234......... 250091 45-01267......... 250106 45-01283......... 250088 45-01291......... 250087 45-01325......... 250104 45-01341......... 250099 45-01366......... 250094 45-01382......... 250093 45-01408......... 250062 45-01424......... 250100 45-01440......... 250103 45-01481......... 250090 45-01499......... 250092 45-01580......... 250127 45-01614......... 250293 45-01622......... 250292 45-01630......... 250118 45-01648......... 250095 45-01655......... 250137 45-01663......... 250300 45-01671......... 250299 45-01689......... 250131 45-01697......... 250135 45-01705......... 250136 45-01713......... 250176 45-01721......... 250126 45-01739......... 250101 45-01754......... 250138 45-01762......... 250129 45-01770......... 250071 45-01788......... 250122 45-01796......... 250141 45-01804......... 250134 45-01812......... 250113 VERA - Cont. 45-01820......... 250117 45-01838......... 250124 45-01853......... 250121 45-01861......... 250140 45-01879......... 250147 45-01887......... 250102 45-01895......... 250119 45-01945......... 250187 45-01952......... 250186 45-01960......... 250143 45-01978......... 250145 45-01986......... 250144 45-01994......... 250142 45-02009......... 250124 45-02017......... 250169 45-02025......... 250149 45-02033......... 250146 45-02041......... 250155 45-02066......... 250167 45-02074......... 250168 45-02082......... 250139 45-02090......... 250300 45-02108......... 250299 45-02116......... 250164 45-02124......... 250157 45-02140......... 250199 45-02157......... 250154 45-02199......... 250127 45-02215......... 250128 45-05074......... 250168 WESTERN AUTO 74-2736-2........ 250067 74-2737-0........ 250061 74-2738-8........ 250039 74-2739-6........ 250037 74-2741-2........ 250013 74-2742-0........ 250014 74-2743-8........ 250017 74-2744-6........ 250071 WOLVERINE TB013 ............. 250013 TB014 ............. 250014 TB017 ............. 250017 TB018 ............. 250018 TB020 ............. 250020 TB028 ............. 250028 TB032 ............. 250032 TB036 ............. 250036 TB037 ............. 250037 TB039 ............. 250039 TB041 ............. 250041 TB043 ............. 250043 TB061 ............. 250061 TB062 ............. 250062 TB063 ............. 250073 TB064 ............. 250064 TB067 ............. 250067 TB070 ............. 250070 TB071 ............. 250071 TB073 ............. 250073 TB077 ............. 250077 TB078 ............. 250078 TB081 ............. 250081 TB095 ............. 250095 WORLD PARTS W11-600.......... 250018 W11-601.......... 250020 W11-631.......... 250075 W11-636.......... 250013 W11-639.......... 250013 W11-640.......... 250076 W11-643.......... 250017 W11-645.......... 250020 W11-651.......... 250028 W11-654.......... 250041 W11-655.......... 250014 W11-657.......... 250036 W11-658.......... 250032 W11-659.......... 250043 W11-660.......... 250064 W11-661.......... 250062 W11-665.......... 250070 W11-669.......... 250073 W11-670.......... 250065 W16-801.......... 250079 W16-802.......... 250084 W16-803.......... 250078 W16-804.......... 250087 W16-805.......... 250101 W16-807.......... 250090 W16-808.......... 250158
T.R.W. - Cont. LB078.............. 250078 LB079.............. 250079 LB081.............. 250081 LB082.............. 250082 LB083.............. 250083 LB084.............. 250084 LB087.............. 250087 LB088.............. 250088 LB090.............. 250090 LB091.............. 250091 LB092.............. 250092 LB093.............. 250093 LB094.............. 250094 LB095.............. 250095 LB100.............. 250100 LB101.............. 250101 LB102.............. 250102 LB103.............. 250103 LB104.............. 250104 LB112.............. 250112 LB113.............. 250113 LB114.............. 250114 LB115.............. 250299 LB116.............. 250300 LB117.............. 250117 LB118.............. 250162 LB119.............. 250119 LB121.............. 250121 LB122.............. 250122 LB123.............. 250123 LB124.............. 250124 LB125.............. 250125 LB126.............. 250237 LB128.............. 250128 LB129.............. 250129 LB13................ 250013 LB130.............. 250130 LB132.............. 250132 LB134.............. 250134 LB136.............. 250233 LB137.............. 250137 LB138.............. 250199 LB139.............. 250139 LB14................ 250014 LB141.............. 250141 LB142.............. 250142 LB143.............. 250143 LB144.............. 250144 LB146.............. 250146 LB148.............. 250148 LB149.............. 250149 LB150.............. 250150 LB151.............. 250151 LB153.............. 250153 LB155.............. 250155 LB157.............. 250157 LB158.............. 250158 LB159.............. 250159 LB160.............. 250160 LB161.............. 250161 LB163.............. 250163 LB164.............. 250164 LB165.............. 250165 LB166.............. 250166 LB167.............. 250167 LB168.............. 250168 LB169.............. 250169 LB17................ 250017 LB18................ 250018 LB20................ 250020 LB28................ 250028 LB32................ 250032 LB36................ 250036 LB37................ 250037 LB39................ 250039 LB41................ 250041 LB43................ 250043 LB61................ 250061 LB62................ 250062 LB63................ 250073 LB64................ 250064 LB65................ 250065 LB67................ 250067 LB70................ 250070 LB71................ 250071 LB73................ 250073 LB74................ 250074 LB75................ 250075 LB76................ 250076 LB77................ 250077 LB78................ 250078 LB79................ 250079 LB81................ 250081

Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. NAPA No. Competitive No. WORLD PARTS - Cont. W16-811.......... 250083 W16-812.......... 250082 W16-814.......... 250299 W16-815.......... 250094 W16-816.......... 250300
A-53
NAPA No.
A-54
Manufacturers Part Numbers NAPA Automotive Timing Belts

Showing Factory Part Numbers for Automotive Timing Belts With the Corresponding NAPA Replacement Numbers
NAPA No. 250090 250090 250075 250028 250185 250185 250185 250185 250185 250185 250141 250179 250179 250179 250179 250179 250179 250141 250141 250123 250123 250123 250141 250141 250141 250141 250149 250149 250149 250165 250099 250099 250013 250014 250014 250014 250014 250014 250129 250067 250067 250194 250067 250067 250067 250103 250102 250067 250014 250142 250092 250091 250014 250141 250141 250141 250077 250248 250179 250020 250020 250142 250088 250113 250113 250113 250088 250088 250088 250113 250113 250113 250113 250117 250117 250113 250117 250113 250113 250113 250228 250228 250228 Mfr. Part No. F0BZ 6268 A......... F1ZZ 6268 A......... F17E 6268 AA ...... F2CE 6268 AA...... F2Y112205 ............ F20212205 ............ F20312205 ............ F21012205 ............ F3BZ 6268 A......... F3CZ 6268 A ........ F3DZ 6268 A ........ F3XY 6268 A ........ F32Z 6268 A ......... F32Z 6268 B ......... F37E 6268 AA ...... F4BZ 6268 A......... F4XY 6268 A ........ F42Z 6268 A ......... F47E 6268 AA ...... F47Z 6268 B ......... F5RZ 6268 A ........ F57E 6268 AA ...... F57E 6268 BB ...... F57Z 6268 A ......... F7CZ 6268 AA ...... F8CZ 6268 AA ...... F80112205 ............ F80212205 ............ F9JY 6268 A ......... GTB1208 ............... GTB1237 ............... HM8268BA ............ JE2612205 ............ JE2612205A .......... JE2612205B .......... JE26122050 .......... JF0112205............. JF0112205A .......... JF0112205D .......... J0856351............... KJ0112205 ............ KL0112205 ............ K0AA352700 ......... K0BA352700 ......... MBP0112205B ...... MB6S712205C ...... MD008960 ............. MD008961 ............. MD008968 ............. MD008969 ............. MD009277 ............. MD009352 ............. MD009651 ............. MD009666 ............. MD009667 ............. MD013805 ............. MD015310 ............. MD015311 ............. MD015701 ............. MD030599 ............. MD030600 ............. MD030610 ............. MD040756 ............. MD040797 ............. MD041390 ............. MD041407 ............. MD050119 ............. MD050130 ............. MD050175 ............. MD060461 ............. MD068173 ............. MD095866 ............. MD098491 ............. MD098492 ............. MD098706 ............. MD099706 ............. MD099707 ............. MD099708 ............. MD100103 ............. MD100619 ............. MD100620 ............. MD100632 ............. MD100679 ............. NAPA No. 250185 250210 250210 250194 250134 250134 250134 250134 250185 250179 250248 250104 250228 250214 250210 250185 250249 250228 250210 250210 250258 250276 250276 250276 250283 250294 250077 250077 250179 250129 250142 250013 250183 250183 250183 250183 250146 250146 250146 250140 250267 250214 250248 250248 250185 250179 250013 250062 250013 250062 250064 250013 250062 250064 250064 250093 250093 250159 250089 250073 250073 250073 250062 250062 250158 250159 250092 250091 250092 250091 250124 250093 250089 250124 250073 250073 250091 250090 250090 250064 250013 250062 250139 Mfr. Part No. MD100814 ............. MD102248 ............. MD102249 ............. MD106103 ............. MD110029 ............. MD110041 ............. MD110709 ............. MD111427 ............. MD113561 ............. MD113562 ............. MD113563 ............. MD113564 ............. MD113790 ............. MD115977 ............. MD120487 ............. MD133115 ............. MD133116 ............. MD134377 ............. MD13805 ............... MD140070 ............. MD140227 ............. MD140228 ............. MD140229 ............. MD145713 ............. MD145714 ............. MD145716 ............. MD145813 ............. MD152243 ............. MD152622 ............. MD154243 ............. MD160103 ............. MD161427 ............. MD171748 ............. MD171749 ............. MD176387 ............. MD182195 ............. MD182201 ............. MD182291 ............. MD182292 ............. MD182293 ............. MD182294 ............. MD182295 ............. MD183005 ............. MD183006 ............. MD189522 ............. MD191982 ............. MD193874 ............. MD193875 ............. MD199418 ............. MD307487 ............. MD322641 ............. MD326059 ............. MD336149 ............. MD340625 ............. MO4667611........... OK97212205 ......... RF0312205............ RF03122050.......... RF0312206A ......... RF4312205............ RF7112205............ RF7912205............ R1463635109 ........ T0718752 .............. T0718836 .............. T0729581 .............. XHM460................. ZZM112205 ........... ZZM312205 ........... Z50112205 ............ Z50212205 ............ 0B59712205 .......... 0K24712205 .......... 0K95412205 .......... 0K97212205 .......... 027109119A .......... 027109119C .......... 028109119M.......... 028109119P .......... 034109119............. 03510911............... 035109119............. 038109119............. NAPA No. 250128 250093 250158 250159 250167 250165 250124 250139 250064 250013 250073 250128 250158 250168 250155 250167 250165 250091 250093 250195 250155 250158 250124 250167 250165 250168 250191 250159 250092 250204 250090 250195 250167 250168 250201 250168 250165 250167 250256 250232 250230 250168 250195 250253 250229 250288 250195 250253 250165 250259 250287 250167 250232 250289 250246 250264 250103 250103 250102 250103 250103 250103 250140 250119 250140 250140 250129 250210 250276 250266 250308 250179 250302 250281 250264 250292 250292 250242 250242 250127 250065 250065 250301 Mfr. Part No. 038109119B .......... 038109119D .......... 048109119D .......... 054109119E .......... 054109119H .......... 056109119A .......... 058109119A .......... 06A109119C.......... 06B109119A.......... 06B109119B.......... 068109119............. 068109119A .......... 068109119E .......... 069109119A .......... 069130113A .......... 074109119............. 075RH200 ............. 075109119B .......... 077109119B .......... 077109119C .......... 077109119D .......... 077109119E .......... 078109119A .......... 078109119C .......... 078109119D .......... 081616................... 081632................... 088AG19 ............... 10068553............... 101R24 .................. 10162006............... 102500................... 108R24 .................. 1125360160........... 113R190 ................ 11311272384......... 11311286168......... 11311711082......... 11311713361......... 119RH250 ............. 1257223................. 1257237................. 12612650044......... 1272382................. 1272384................. 12723842............... 1276150G00.......... 1276153B00 .......... 1276153B01 .......... 1276160A00 .......... 1276160B10 .......... 1276160E00 .......... 1276163B00 .......... 1276170C00 .......... 1276171C00 .......... 1276172F00 .......... 1276173000........... 1276173001........... 1276178400........... 1276182000........... 1286168................. 12861684............... 130RG25 ............... 13028AA010.......... 13028AA040.......... 13028AA072.......... 13028AA101.......... 13028AA102.......... 13028AA120.......... 13028AA150.......... 13028AA170.......... 13028AA181.......... 13028D0100 .......... 13028D1700 .......... 13028D4200 .......... 13028D4210 .......... 13028D4211 .......... 13028KA021.......... 13028V4000 .......... 13028V4310 .......... 13028V5100 .......... 13028V5200 .......... 13028V5201 .......... NAPA No. 250301 250301 250262 250225 250225 250017 250291 250296 250306 250306 250043 250043 250043 250083 250082 250170 250082 250083 250207 250297 250207 250207 250218 250297 250218 250018 250140 250070 250163 250099 250192 250078 250094 250075 250065 250106 250106 250131 250131 250083 250083 250082 250129 250106 250106 250106 250194 250171 250171 250164 250166 250241 250095 250194 250212 250272 250028 250028 250070 250095 250106 250106 250084 250300 250150 250277 250172 250172 250209 250254 250300 250304 250100 250078 250137 250137 250137 250135 250017 250093 250104 250104 250104 Mfr. Part No. 13028V5210 .......... 13028V5220 .......... 13028V5221 .......... 130280B700 .......... 130280B785 .......... 1302810M00.......... 1302811M00.......... 1302811M10.......... 1302812C00 .......... 1302812G00.......... 1302816A01 .......... 1302816A10 .......... 1302816E00 .......... 1302816E10 .......... 1302816V00 .......... 1302820R00 .......... 1302845P00 .......... 1302851E00 .......... 1302851E10 .......... 1302861A00 .......... 1302885E00 .......... 13029AA010.......... 13029AA011.......... 13029AA040.......... 13029AA070.......... 13029AA080.......... 13029AA11............ 1320811M00.......... 1326288................. 13405PAAA01 ....... 13405PAAA02 ....... 13405PTO004 ....... 13405PT0004 ........ 13440P5A004........ 1351415010........... 1351487711........... 135148771100....... 1351487711000..... 1356422021........... 135680A010 .......... 1356803010........... 1356803020........... 1356803021........... 1356809040........... 1356809041........... 1356809050........... 1356811030........... 1356811031........... 1356811032........... 1356811033........... 1356811100........... 1356811101........... 1356811111........... 1356815010........... 1356815011........... 1356815020........... 1356815030........... 1356815040........... 1356815041........... 1356815042........... 1356815050........... 1356816010........... 1356816020........... 1356816040........... 1356816041........... 1356816050........... 1356816051........... 1356816060........... 1356816061........... 1356816070........... 1356816071........... 1356819045........... 1356819046........... 1356819055........... 1356819056........... 1356819085........... 1356819086........... 1356819115........... 1356819116........... 1356819125........... 1356819135........... 1356819145........... 1356820010........... NAPA No. 250104 250104 250104 250249 250249 250077 250077 250077 250100 250104 250096 250096 250104 250104 250180 250078 250251 250137 250137 250077 250104 250299 250299 250151 250299 250299 250299 250077 250174 250186 250186 250186 250186 250280 250070 250178 250178 250178 250126 250257 250138 250199 250199 250199 250199 250257 250136 250233 250233 250233 250208 250208 250208 250070 250070 250070 250070 250036 250036 250239 250036 250112 250176 250236 250236 250236 250236 250235 250235 250235 250235 250236 250236 250235 250235 250233 250233 250208 250208 250070 250239 250112 250257
Mfr. Part No. ADO41407............. AD041407.............. A326L134B............ BNP2955 ............... BPY112205 ........... BP0112205............ BP0112205A ......... BP0112205B ......... BP0212205............ BP0212205A ......... B10112205A.......... B59712205 ............ B6S712205A ......... B6S712205B ......... B6S712205C ......... B6S712205C (KIA) B6S712205D ......... B6Y212205............ B63012205 ............ B63012205A.......... B63012205B.......... B63012205C.......... B63012205D.......... B63012205E.......... B63212205 ............ B632122050 .......... B66012205 ............ B66012205B.......... B66012205C.......... C3905942 .............. DBP4131 ............... DBP9289 ............... D1FZ 6268 A ........ D4FZ 6268 A ........ D4ZE 6268 AE...... D42E 6268 AB ...... D8EE 6268 AA...... D9EE 6268 AA...... ECP244 ................. E1EE 6268 DA...... E1FZ 6268 D ........ E2CE 6268 AA...... E2EE 6268 AA...... E3EE 6268 AA...... E3FZ 6268 A......... E43Z 6268 B......... E43Z 6268 C......... E5FZ 6268 A......... E5RE 6268 AA...... E5RE 8286 AA...... E5TZ 6268 A......... E5TZ 6268 B......... E5ZZ 6268 A......... E7GZ 6268 A ........ E7GZ 6268 B ........ E7GZ 6268 C........ E80112205 ............ E9DZ 6268 A ........ E9JY 6268 A......... FC01201202.......... FC01201203.......... FDU1464 ............... FEO1122050 ......... FEY812205............ FEY8122050.......... FEY912205............ FE0112205 ............ FE01122050 .......... FE0212205 ............ FE0312205 ............ FE03122050 .......... FE0412205 ............ FE04122050 .......... FE0612205 ............ FE0812205 ............ FE08122050 .......... FE0912205 ............ FE09122050 .......... FE7912205 ............ FE7915205 ............ FSY112205............ FS0112205A.......... FS0212205 ............
Manufacturers Part Numbers

Mfr. Part No. 1356820020........... 1356829015........... 1356829025........... 1356842010........... 1356842011........... 1356842012........... 1356842020........... 1356842021........... 1356843010........... 1356843020........... 1356843030........... 1356843040........... 1356846020........... 1356849015........... 1356849035........... 1356849036........... 1356849046........... 1356849055........... 1356850010........... 1356850020........... 1356854010........... 1356854020........... 1356854030........... 1356854031........... 1356854038........... 1356854050........... 1356854051........... 1356859015........... 1356859016........... 1356859017........... 1356859025........... 1356859026........... 1356859027........... 1356859045........... 1356859095........... 1356862020........... 1356862030........... 1356862030A ........ 1356862040........... 1356862050........... 1356863010........... 1356863020........... 1356863022........... 1356864010........... 1356864011........... 1356865010........... 1356865010A ........ 1356865020........... 1356869025........... 1356869035........... 1356869045........... 1356869065........... 1356869066........... 1356869075........... 1356869095........... 1356874010........... 1356874011........... 1356874012........... 1356874012B ........ 1356874013........... 1356874020........... 1356874021........... 1356879025........... 1356879045........... 1356879095........... 1356887101........... 1356887101000..... 1356887102........... 1356887102000..... 1356887103........... 1356887103000..... 1356887104........... 1356887104000..... 1356887708........... 1356888360........... 1356888361........... 1356888380........... 1356888381........... 1356888382........... NAPA No. 250257 250257 250257 250126 250237 250126 250126 250237 250074 250074 250101 250101 250215 250237 250215 250215 250074 250101 250190 250298 250079 250079 250079 250079 250079 250084 250084 250079 250079 250079 250084 250084 250084 250190 250298 250157 250200 250200 250157 250271 250087 250087 250087 250098 250098 250154 250154 250240 250200 250157 250087 250098 250098 250240 250271 250138 250138 250199 250199 250199 250138 250199 250199 250125 250199 250181 250181 250181 250181 250182 250182 250182 250182 250178 250125 250125 250125 250125 250125 Mfr. Part No. 139AG25 ............... 14001168............... 14400PAAA01 ....... 14400PAAA02 ....... 14400PC6004........ 14400PC60040...... 14400PC60042...... 14400PD2004........ 14400PD6004........ 14400PE0004........ 14400PE00040...... 14400PE3004........ 14400PE30040...... 14400PG6004 ....... 14400PG60040 ..... 14400PG6014 ....... 14400PG6040 ....... 14400PH7004........ 14400PH70040...... 14400PH7014........ 14400PH70140...... 14400PK1004........ 14400PK10040...... 14400PK2004........ 14400PK20040...... 14400PK3004........ 14400PM3004 ....... 14400PM30040 ..... 14400PM6004 ....... 14400PM70040 ..... 14400PR3004........ 14400PR4A01 ....... 14400PR4A01M1 .. 14400PT0004 ........ 14400PV1004........ 14400PY3A010 ..... 14400PY3004........ 14400P0A004........ 14400P0GA01 ....... 14400P0GA010M1 14400P08004 ........ 14400P13004 ........ 14400P14004 ........ 14400P2E004........ 14400P2FA01........ 14400P28004 ........ 14400P5A004........ 14400P7J004 ........ 14400P72004 ........ 14400P72014 ........ 14400P8AA01 ....... 14400P8AA02 ....... 14400TG6004........ 14400634003......... 14400634004......... 14400634005......... 144006340050....... 144006340051....... 14400634014......... 144006340141....... 14400657004......... 144006570040....... 144006570042....... 14400657014......... 144006570140....... 14400657024......... 144006570240....... 144006570241....... 144006570242....... 1440065704........... 14400673004......... 144006730040....... 144006730041....... 144006730042....... 146R190 ................ 1649170................. 1649171................. 1680616A00 .......... 1680616A10 .......... NAPA No. 250087 250061 250244 250244 250160 250094 250160 250160 250160 250099 250099 250099 250161 250130 250130 250130 250130 250129 250129 250129 250129 250144 250144 250142 250142 250142 250143 250143 250145 250142 250227 250184 250184 250187 250211 250193 250193 250244 250263 250263 250223 250226 250216 250224 250224 250224 250279 250184 250247 250247 250286 250286 250130 250028 250028 250028 250028 250028 250028 250028 250036 250036 250041 250036 250036 250041 250041 250041 250041 250036 250073 250073 250073 250073 250020 250067 250067 250097 250097 Mfr. Part No. 1711082................. 1713361................. 2335632010........... 2335632020........... 2335632030........... 2335633110........... 2335633120........... 2335633130........... 2335633140........... 2335633150........... 2335633160........... 2413232010........... 2431221040........... 2431222010........... 2431223001........... 2431223201........... 2431224000........... 2431224010........... 2431224050........... 2431226000........... 2431232610........... 2431232620........... 2431232820........... 2431233010........... 2431233020........... 2431233030........... 2431233040........... 2431233050........... 2431233060........... 2431233110........... 2431233120........... 2431233130........... 2431233140........... 2431233150........... 2431233160........... 2431235000........... 2431235010........... 2431235040........... 24502982............... 24503363............... 271327................... 271705................... 2717056................. 271720................... 271747................... 2717478................. 271834................... 2718344................. 271856................... 2718567................. 2718765................. 271952................... 2719524................. 272327................... 272329................... 2723294................. 272386................... 3250141................. 3342103................. 3507227................. 3507651................. 3507704................. 3514323................. 3547459................. 35474592............... 360525................... 376388................... 376401................... 40028..................... 414701001............. 414705601............. 4164869................. 4176840................. 4182426................. 4300516................. 4302971................. 4304099................. 4343824................. 4343946................. NAPA No. 250131 250131 250159 250159 250159 250168 250168 250168 250168 250168 250168 250089 250073 250191 250278 250284 250128 250128 250128 250282 250124 250124 250089 250165 250165 250165 250165 250165 250165 250167 250167 250167 250167 250167 250167 250139 250139 250139 250192 250273 250252 250217 250217 250173 250234 250234 250252 250252 250252 250252 250270 250217 250217 250252 250311 250311 250270 250017 250119 250083 250217 250234 250173 250174 250174 250037 250037 250037 250028 250028 250079 250020 250018 250020 250122 250122 250075 250114 250071 Mfr. Part No. 43439469............... 4387534................. 4387549................. 4406634................. 4420507................. 4484494................. 4504163................. 4573944................. 460165................... 4621348................. 4621844................. 46337..................... 463377................... 4633772................. 4663598................. 4667530................. 4667606................. 4667611................. 4667625................. 4770491................. 4792353................. 484981001............. 512430160............. 512536016............. 5125360160........... 5203401................. 52267904............... 52289664............... 524034................... 5240346................. 5862021480........... 5862021620........... 5862059260........... 5862059340........... 5985163................. 636350................... 636359................... 636363................... 636365................... 636368................... 636370................... 636560................... 636562................... 636565................... 70HM 6268 AB ..... 70HM 6268 BA ..... 7533266................. 7533267................. 7700618657........... 7700663550........... 7700717284........... 7700718725........... 7700718726........... 7700718752........... 7700718836........... 7700729581........... 7700853660........... 7701348801........... 8091287220........... 82317934............... 85867058............... 8920639440........... 894109626............. 8941096260........... 8941583270........... 8941606560........... 8941743060........... 894200372A .......... 8942152540........... 8942187820........... 894220372A .......... 8942209220........... 8942220922........... 8942353620........... 8942372420........... 894337708............. 8943377080........... 8943864970........... 8944161450........... NAPA No. 250071 250132 250153 250032 250018 250206 250285 250219 250039 250285 250265 250032 250032 250032 250255 250206 250245 250246 250265 250285 250295 250028 250075 250075 250075 250071 250163 250163 250017 250017 250186 250187 250186 250244 250087 250081 250081 250081 250148 250148 250081 250081 250148 250081 250013 250013 250013 250013 250018 250018 250140 250140 250140 250119 250140 250140 250140 250018 250305 250065 250096 250305 250162 250118 250121 250122 250147 250122 250121 250088 250122 250076 250076 250088 250121 250177 250177 250220 250088 Mfr. Part No. 8944294860........... 8944520940........... 8944795230........... 8970163260........... 8970270620........... 8970417840........... 8970422680........... 8971363210........... 90122429............... 90231883............... 90234902............... 90324698............... 90324699............... 90325576............... 90325578............... 90353179............... 90353211............... 90354783............... 90409900............... 90410014............... 90410768............... 90410771............... 90500360............... 90530599............... 91112009............... 91171175............... 91172367............... 91173157............... 9128500................. 9135031................. 9135450................. 9135733................. 9180954................. 92029834............... 94029834............... 94109626............... 94158327............... 94160656............... 94215254............... 94220922............... 94337708............... 94386497............... 9440383................. 94410221902......... 94410221904......... 94410513703......... 94410515703......... 94410515704......... 94429486............... 94452094............... 94479523............... 94840054............... 94844702............... 94846144............... 94848472............... 94849175............... 94849597............... 94854403............... 94854404............... 94856081............... 94856082............... 95ZA19 .................. 95951646............... 96051646............... 96057945............... 96060050............... 96067809............... 96068423............... 96068591............... 96144976............... 97016326............... 97027062............... 97041784............... 97042268............... 978M 6268 AA ...... 99314718701.........
A-55
NAPA No. 250169 250162 250162 250221 250205 250122 250147 250303 250081 250148 250081 250148 250148 250081 250081 250203 250081 250148 250081 250081 250285 250285 250285 250285 250070 250272 250194 250194 250285 250252 250173 250252 250252 250075 250075 250118 250121 250122 250121 250076 250177 250220 250311 250293 250293 250107 250107 250107 250169 250118 250162 250070 250112 250036 250176 250036 250036 250236 250235 250236 250235 250100 250095 250095 250164 250166 250095 250241 250212 250148 250221 250205 250122 250147 250294 250290
A-56
A-57
Timing Belt Troubleshooting Guide

Synchronous belts have been used on automotive camshaft drives for more than 20 years. Our belts will give OEM equivalent service if the following points are observed. Symptom Probable Cause
1. Excessive shock load. 2. Subminimal diameter. 3.Improper belt handling and storage prior to installation. 4. Debris or foreign object in drive. 5. Extreme sprocket run-out.
Corrective Action
1. Redesign drive for increased capacity. 2. Redesign drive using larger diameters. 3. Follow proper storage and handling procedures. 4. Remove objects and check guard. 5. Replace sprocket.
Tensile Failure
Storage
Belts should be kept in their original packaging until needed. Store in an environment which avoids: Temperature extremes Direct sunlight High humidity Contamination by oil, water, chemicals, etc.
Tooth Shear
1. Excessive shock load. 2. Extreme sprocket run-out. 3. Worn spacer. 4. Backside idler. 5. Misaligned drive. 6. Belt undertensioned.
1. Redesign drive for increased capacity. 2. Replace sprocket. 3. Replace sprocket. 4. Use inside idler. 5. Realign. 6. Adjust tension to recommended value.
Handling
It is important that belts are not crimped during handling since this could seriously damage the tensile members and lead to premature failure.
Tooth Wear
1. Too low or high belt tension. 2. Belt running partly off unflanged sprocket. 3.Misaligned drive. 4. Worn sprocket. 5. Rough sprocket teeth.
1. Adjust tension to recommended value. 2. Correct alignment. 3. Correct alignment. 4. Replace sprocket. 5. Replace sprocket.
Installation Tips
Pulleys should be clean, free from wear or damage and their alignment must be correct. Tensioners and idlers (when applicable) should be free to rotate and move (when appropriate). Bearings should be in good condition. Belts should be fitted in accordance with the engine manufacturers instructions to ensure that belt tension and engine timing is correct. IMPORTANT: Avoid crimping the belt when installing it on pulleys no tools should be used on the belt. Refit cover to prevent drive contamination by foreign matter.
Belt Cracking
1. Subminimal diameter. 2. Backside idler. 3. Extreme low temperature at start-up. 4. Extended exposure to harsh chemicals. 5. Cocked bushing/sprocket assembly.
1. Redesign drive for increased capacity. 2. Use inside idler or increase diameter of backside idler 3. Pre-heat drive environment. 4. Protect drive. 5. Install bushing per instructions.
Land Wear
1. Excessive tension. 2. Rough pulley(s).
1. Adjust tension to recommended value. 2. Replace pulley(s).
Oil Contamination
1. Oil leak.
1. Replace faulty oil seal(s).
Replacement
Follow vehicle manufacturers instructions regarding belt replacement intervals. If the belt is removed, then a new belt should be installed (except where an automatic tensioner is used). If engine is being repaired and belt is near OEM recommended replacement interval, its a good time to replace the belt.
Edge Wear
1. Damage due to handling. 2. Flange damage. 3. Belt too wide. 4. Belt tension too low. 5. Rough flange surface finish. 6. Improper tracking. 7. Belt hitting drive guard or bracketry. 1. High tension. 2. Low tension. 3. Misalignment. 4. Damaged Flange.
1. Follow proper handling instructions. 2. Repair flange or replace sprocket. 3. Use proper width sprocket. 4. Adjust tension to recommended value. 5. Replace or repair flange to eliminate abrasive surface. 6. Correct alignment. 7. Remove obstruction or use inside idler. 1. Adjust tension to recommended value. 2. Adjust tension to recommended value. 3. Realign pulleys. 4. Replace pulleys.
Unusual Noise
A-58
Overhead Valve Engine Identification
The engine illustrations below are all overhead valve type engines. These diagrams are provided for your reference and convenience. This page is also for customers that may not know the engine type they havebut may be able to identify it through these illustrations.
Overhead Valve (OHV) Push Rod Assembly (No Timing Belt Required)
Double Overhead Cam (DOHC)
Single Overhead Cam (SOHC)
Free Running or Interference Engine? A-59 You and Your Customers Need to Know.
Automobile engines can be classified as either Free-Running or Interference, depending on what occurs if piston/valve synchronization is lost. As illustrated below, in the free-running engine with the crankshaft still moving, there is enough clearance between the valve and piston, even if the cam stops with a valve fully open. However, interference engines usually sustain damage if synchronization is lost. As illustrated, disrupted synchronization allows the piston and valve to collide causing damage and very expensive repairs for the vehicle owner. Damage can occur to valves, pistons, or headsand in some cases, completely ruin the engine. Most import (with higher compression engines) and most car and light truck diesel engines are interference. To avoid costly engine repairs, follow the auto manufacturers mileage replacement recommendations or we recommend timing belt replacement at around 60,000 miles.
Free-Running
No Valve/Piston Interference
Interference
Valve/Piston Collision
NOTE: For your convenience, interference engines have been footnoted with a star in the application listings of this publication. This lets you easily identify them}and pass that information on to your customers. Since timing belts are inside the engine they tend to be an out-of-sight, out-of-mind item and are seldom thought of as a part of routine maintenance. Here are some questions to ask customers that will help sell belts and protect the customer from expensive repairs: 1. Did you buy the car new? If yes, theyll know if the belt has ever been replaced. 2. Did you buy the car used? If so, they wont know if the belt has been replaced. This is a flag for the customer to get the belt checked, replaced or at least be aware that he has a timing belt. 3. How many miles are on the vehicle? Generally belts should be replaced at around 60,000 miles or less. Our Timing Belt Replacement Recommendations Booklet is an excellent tool for determining replacement intervals. 4. Have you ever replaced the timing belt? If the answer is yes or no (and the customer knows the mileage) you can determine where the vehicle is in the replacement cycle. Heres a helpful hint for your customers with vehicles within a few thousand miles of the recommended replacement interval. If they are having any engine repair done, have the timing belt checked. If it needs replacement, do it along with the other repairs and save time and money.
A-60
Belt Tensioning
V- Belt Tension Ranges for Manual Tensioners
Always use a belt tension gauge that indicates static tension, such as the KR1 Krikit Tension Gauge, to determine proper tension from the Installation Chart. Tension ranges below are for drives requiring single belts. If multiple belts are needed for a drive, divide tension by number of belts to give per belt tension to be measured. Position belt and set tension to the prescribed Installation Tension. Run belt for five minutes. If belt tension drops below Suggested Tension range, retighten belt to Installation Tension. This will allow the belt to seat-in and run at Suggested Tension after it has operated under normal driving conditions.
Belt Top Width Suggested Tension (lbs.) Ranges 45-65 60-85 85-115 105-145 135-185 155-200 160-220 Installation Tension (lbs.) Used Belts 60.0 75.0 100.0 120.0 150.0 170.0 175.0 Installation Tension (lbs.) New Belts 80.0 100.0 130.0 160.0 200.0 215.0 235.0 Belt Top Width 13/16 7/8 1 1-1/16 1-1/8 1-5/16 Suggested Tension (lbs.) Ranges 175-240 190-255 215-295 225-310 245-330 285-385 Installation Tension (lbs.) Used Belts 190.0 205.0 230.0 240.0 260.0 300.0 Installation Tension (lbs.) New Belts 255.0 270.0 310.0 325.0 345.0 400.0
5/16 3/8
5/8 11/16
NOTE: A belt is considered used once it has been run-in.
V-Ribbed Belt Tension Ranges for Manual Tensioners

Always use a belt tension gauge that indicates static tension, such as the KR2 Krikit Tension Gauge, to determine proper tension from the Installation Chart. Many V-ribbed belts are automatically tensioned by a spring-loaded automatic tensioner, which does not require tension to be set. The tension ranges below are used for applications requiring manual tensioning. For drives with manual take-up on locked-center drives, position the belt and set tension to the prescribed Installation Tension. Run belt for five minutes. If belt tension drops below Suggested Tension range, retighten belt to the Installation Tension. This will allow the belt to seat-in and run at Suggested Tension after it has operated under normal driving conditions.
Number of Ribs 3 4 5 6 7 8 Suggested Tension (lbs.) Ranges 45-60 60-80 75-100 90-125 105-145 120-160 Installation Tension (lbs.) Used Belts 67.5 90.0 112.5 135.0 157.5 180.0 Installation Tension (lbs.) New Belts 90.0 120.0 150.0 187.5 217.5 240.0 Number Of Ribs 9 10 11 12 14 Suggested Tension (lbs.) Ranges 135-180 150-200 165-220 180-240 210-280 Installation Tension (lbs.) Used Belts 202.5 225.0 247.5 270.0 292.5 Installation Tension (lbs.) New Belts 270.0 300.0 333.0 360.0 420.0
NOTE: A belt is considered used once it has been run-in.
ACURA *1.6L 4-Cylinder EL

TIMING BELT APPLICATION
TIMING BELT
Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC EL (Canadian) 1997-00 ................ 1 2.0 Hours ................. 250224 1 - With Air Cond. add .4 hours. With Cruise Control add .3 hours.
MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE

For 1997-00 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
*NOTE: This application is an interference engine. See page A-59 for interference engine cautions.
REMOVAL & INSTALLATION

NOTE: If the radio has a coded theft protection circuit, be sure to get the customers code before disconnecting battery.
Removal: Disconnect battery negative cable. Remove engine lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 3. Remove engine oil dipstick. Remove power steering pump and set aside with hoses attached. Remove timing belt upper cover and A/C drive belt idler pulley bracket. Use jack to support engine. Working from front of engine, remove engine mount bracket nuts. Remove crankshaft pulley. Remove lower cover and dipstick tube. Remove Crankshaft Speed Fluctuation (CKF) sensor from oil pump. Loosen the timing belt tension adjusting bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjusting bolt. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. See Fig. 1. Installation: Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 2. Set camshaft pulley to TDC. TDC marks should align with top surface of cylinder head. See Fig. 3.
Courtesy of American Honda Motor Co. , Inc.
Fig. 1: Exploded View Of Timing Belt Components
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. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. 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 repositioned. To complete installation,reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt ........................ 17 (24) Alternator Adjusting Bolt .................................................. 17 (24) Alternator Mount Bolt ................................................... 33 (45) Camshaft Pulley Center Bolt .......................................... 27 (37) Crankshaft Pulley Bolt 1 Step 1 ....................................................................... 14 (20) Step 2 ...................................... Plus 90 Degrees Clockwise Engine Mount Bracket Nuts ............................................ 54 (74) Power Steering Pump Bracket Bolt ............................ 17 (24) Power Steering Pump Lock Bolt ................................ 17 (24) Timing Belt Tensioner Adjusting Bolt ........................... 33 (45) INCH Lbs. (N.m) CKF Sensor Bolt ....................................................... 106 (12) Engine Lower Splash Shield .......................................... 89 (10) Timing Belt Cover Bolt ................................................ 89 (10) Water Pump Bolt ...................................................... 106 (12) 1 - Lubricate bolt threads and bolt head shoulder.
Fig. 2: Aligning Crankshaft TDC Mark & Oil Pump Mark
Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, and camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulley timing mark are aligned with TDC marks. Loosen and retighten adjusting bolt to tension timing belt. Install lower cover. Install crankshaft pulley. Tighten pulley bolt to specification. See TORQUE SPECIFICATIONS table. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley.
CAUTION: Always adjust timing belt tension with engine cold.
Fig. 3: Aligning Timing Belt Marks
ACURA *1.6L 4-Cylinder EL (Cont.)
Fig. 4: Timing Belt Installation Sequence
Fig. 5: Locating Timing Belt Adjuster Bolt
ACURA *1.6L 4-Cylinder Integra
TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.6L 4-Cyl. Integra 1986-89 ................. 2.8 Hours .................. 250130 1 - With Air Cond. add .2 hours.

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.

TIMING BELT
Removal: Disconnect negative battery cable. Turn crankshaft counterclockwise to bring piston in cylinder No. 1 to TDC of its compression stroke. Remove all drive belts. Remove A/C compressor and power steering pump and position out of way without disconnecting hoses. Remove crankshaft pulley. 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 removed). 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 adjustment bolt. Reverse removal procedure to complete installation. Adjust the drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor/Bracket Bolts .................................. 33 (45) Alternator Belt Adjustment Bolt .................................... 17 (23) Alternator Mount Bolt ................................................... 33 (45) Camshaft Pulley Bolt .................................................. 27 (37) Crankshaft Pulley Bolt .............................................. 83 (112) Power Steering Pump Mounting Bolts .............. 29-33 (38-45) Timing Belt Adjustment Bolt ....................................... 33 (45) Wheel Lug Nuts ....................................................... 80 (110) INCH Lbs. (N.m) Timing Belt Cover Bolts .............................................. 86 (10) Valve Cover Nuts ........................................................ 86 (10)
96D14681
Courtesy of American Honda Motor Co., Inc.
Fig. 1: Exploded View of Timing Belt & Components
96E14682
Fig. 2: Camshaft Timing Marks
ACURA *1.7L 4-Cylinder

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.7L 4-Cyl. Integra 1992-93 ................. 2.8 Hours .................. 250227 1 - With Air Cond. add .2 Hours.
1
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m)

The manufacturer recommends the belt be replaced every 90,000 miles or 72 months.
Camshaft Sprocket Bolts ............................................ 27 (37) Crankshaft Pulley Bolt 1992 ....................................................................... 87 (118) 1993 .................................................................. 1 133 (180) Power Steering Mount Bolt .......................................... 17 (23) Timing Belt Tension Adjuster Bolt ............................... 40 (54) Wheel Lug Nuts ....................................................... 80 (110) INCH Lbs. (N.m) Timing Belt Cover Bolts ............................................ 108 (12) Valve Cover Nuts ......................................................... 84 (10)
1
- Tighten to 147 ft. Lbs. (200 N.m), loosen & retorque to 133 ft. lbs. (180 N.m).

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove left front wheel. Remove left front wheelwell splash shield. Remove drive belts. Remove power steering pump with hoses attached, and set it aside. 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 adjuster 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. Install timing belt onto sprockets. DO NOT bend or twist belt excessively. Adjust timing belt tension. To complete installation, reverse removal procedure. Lubricate threads only of crankshaft pulley bolt, leaving underside of bolt head dry. On 1993 models, tighten crankshaft pulley bolt to 147 ft. Ibs. (200 N.m), loosen, then retighten to 133 ft. Ibs. (180 N.m). Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
ACURA *1.7L 4-Cylinder (Cont.)
Fig. 2: Aligning Timing Marks

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.8L 4-Cyl. (EXC. VTEC) Integra 1990-01 .................. 2.8 Hours ................. 250184 1.8L 4-Cyl. (VTEC) Integra 1994-01 .................. 2.8 Hours ................. 250247 1 - With Air Cond. add .2 hours.
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TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor/Bracket Bolts .................................. 17 (23) Alternator Belt Adjustment Bolt .................................... 17 (23) Alternator Mount Bolt ................................................... 33 (45) Camshaft Sprocket Bolts ............................................ 27 (37) Crankshaft Pulley Bolt 1990-92 ................................................................. 87 (118) 1993-01 ............................................................. 1 133 (180) Engine Mount Bolts .............................................................. 2 Engine Block-To Transaxle Bolt .................................. 47 (64) Power Steering Bolt .................................................... 17 (23) Timing Belt Tension Adjuster Bolt ............................... 40 (54) INCH Lbs. (N.m) Timing Belt Cover Bolts ............................................ 106 (12) Valve Cover Nuts ........................................................ 88 (10) Water Pump Bolt ...................................................... 106 (12) - Tighten crankshaft pulley bolt to 147 ft. Lbs. (200 N.m), loosen then retorque to 133 ft. lbs. (180 N.m). 2 - See Fig. 3.
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For 1990-94 models, manufacturer recommends the belt be replaced every 90,000 miles. For 1995-96 models, the manufacturer recommends the belt be replace every 90,000 miles for normal service and 60,000 miles for severe service. For 1997-01 models, normal replacement interval is at 105,000 miles or 84 months. For 1997-01 models, replace belt at 60,000 miles if vehicle is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees C).
NOTE: Some vehicles may be equipped with radio/cassette or radio/CD players that contain anti-theft protection circuit. When battery is disconnected, radio will go into anti-theft mode. When battery is reconnected, radio will display CODE and will be inoperative until proper code is entered by vehicle owner.

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove left front wheel. Remove left front wheelwell splash shield. Remove all drive belts. Remove power steering pump with hoses attached. Set power steering pump aside. Remove valve cover and upper timing belt cover. See Fig. 1. Turn crankshaft counterclockwise to bring No. 1 piston to TDC of its compression stroke. Position UP mark on sprockets at top. See Fig. 2. Align grooves on sprockets. Remove crankshaft pulley. 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 sprockets. DO NOT bend or twist belt excessively. Adjust timing belt tension. To complete installation, reverse removal procedure. On 1993-96 models, tighten crankshaft pulley bolt to 147 ft. Ibs. (200 N.m), loosen, then retorque to 133 ft. Ibs. (180 N.m). Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 4: Positioning Camshaft
Fig. 3: Engine/Transaxle Mount Location & Tightening Sequence
ACURA *2.2L & 2.3L 4-Cylinder

TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.2L 4-Cyl. 2.2CL 1997 Balance Shaft .......................................... 250186 Camshaft ............. 2.9 Hours .................. 250244 2.3L 4-Cyl. 2.3CL 1998-99 Balance Shaft .......................................... 250186 Camshaft ............. 2.9 Hours .................. 250244 1 - Balance shaft belt included in labor time.
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For the 2.2CL, normal replacement interval is 90,000 miles for normal service or 60,000 miles for severe service. For the 2.3CL, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
Remove crankshaft pulley and lower cover. Ensure crankshaft is still at TDC. Lock timing belt adjuster arm in place by installing a 6x1.0 mm bolt. See Fig. 4. Loosen timing belt adjusting nut about 1 turn and make sure balance shaft belt adjuster moves freely. Push tensioner to remove tension from balance shaft belt adjuster, then retighten nut. Scribe a line 2.9 (74 mm) from the end of a 6x100 mm bolt. See Fig. 5. Remove bolt from side of engine block. To align balance shaft, insert bolt through hole and into balance shaft. Align groove on balance shaft pulley with pointer on oil pump housing. See Fig. 6. Install balance shaft belt. Loosen adjuster nut about 1 turn to tension balance shaft belt. Remove 6x100 mm bolt from balance shaft. Install sealing bolt in side of engine block. Install crankshaft pulley and bolt. Rotate crankshaft about 1 turn counterclockwise, then tighten adjuster nut. Remove 6x1.0 mm bolt from timing belt adjuster arm. Remove crankshaft pulley. Install lower cover. Install rubber seal around adjuster nut. DO NOT loosen adjuster nut. Install crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.

TIMING BELT
Removal: Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a jack, with cushion between oil pan and jack, to support engine. Remove side engine mount. Remove oil dipstick and pipe. Remove valve cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. Loosen timing belt tension adjuster bolt about 1/2 turn. Push tensioner to release belt tension from timing belt and balancer belt. Retighten tension adjuster bolt. Remove balance shaft drive pulley. Remove balance shaft belt and timing belt from pulleys. Installation: Ensure No. 1 piston is at TDC of compression stroke. See Fig. 1. Align camshaft pulley with mating marks on back cover upper surface. Ensure UP mark is at 12 oclock position. See Fig. 2. Install timing belt in sequence shown. See Fig. 3. Loosen and retighten the timing belt adjusting nut about 1 turn. Install balance shaft drive pulley and lower cover. Install crankshaft pulley and center bolt. Rotate crankshaft about 5-6 times counterclockwise. Set No. 1 piston at TDC. Loosen timing belt adjusting nut about 1 turn. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten timing belt adjusting nut. Make sure crankshaft and camshaft pulleys are at TDC.
Fig. 1: Identifying TDC Mark on Crankshaft Drive Pulley
Fig. 2: Aligning Camshaft Sprocket Timing Marks
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ACURA *2.2L & 2.3L 4-Cylinder (Cont.)
Fig. 5: Aligning & Locking Balance Shaft
Fig. 4: Timing Belt Adjuster Nut
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Bracket-to-Engine Bolt ................................. 33 (45) Camshaft Sprocket Bolt ................................................. 27 (37) Crankshaft Pulley Bolt ................................................ 181 (245) Power Steering Pump Mount Bolt ............................... 16 (22) Timing Belt Tension Adjuster Nut ............................... 33 (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

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L 5-Cyl. Vigor 1992-94 ................. 3.1 Hours ................. 250211 2.5TL 1995-98 ................. 3.1 Hours ..................250211
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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: Before disconnecting negative battery cable, obtain radid anti-theft code from vehicle owner.

TIMING BELT
Removal: Disconnect battery negative cable. Remove accessory drive belts. Remove cylinder head cover and upper timing belt covers. See Fig. 1. Rotate crankshaft counterclockwise to bring No. 1 piston to TDC of compression stroke. Remove crankshaft pulley. Remove lower timing belt cover. Loosen timing belt tension adjuster bolt 180 degrees. See Fig. 5. Push tensioner to relieve tension on timing belt. Retighten adjuster bolt. If reusing timing belt, mark direction 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 and crankshaft pulleys are at TDC. If pulleys are not positioned at TDC, remove and reposition timing belt. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for drive belt tension ranges.
Fig. 1: Exploded View of Timing Belt Components
Fig. 2: Aligning Crankshaft Timing Marks
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Fig. 3: Aligning Camshaft Timing Marks
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) 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) Timing Belt Tension Adjuster Bolt ............................... 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolts ............................................ 106 (12) Cylinder Head Cover Nuts ........................................ 106 (12) Water Pump Bolts .................................................... 106 (12)
ACURA *2.5L & 2.7L V6

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L V6 Legend 1986-87 ................ 4.0 Hours ................ 250129 2.7L V6 Legend 1987-90 ................ 4.0 Hours ................ 250129
TORQUE SPECIFICATIONS
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NOTE: After timing belt installation, rotate engine clockwise several times to ensure valves DO NOT contact pistons.

For 1986-89 models, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced every 60,000 miles. For 1990 models, the manufacturer recommends the belt be replaced every 90,000 miles or 72 months.
Application Ft. Lbs. (N.m) A/C Compressor Bolts ............................................... 16 (22) A/C Compressor Bracket Bolts .................................. 33 (45) Alternator Bracket Bolts .............................................. 33 (45) Alternator Mount Bolts ................................................ 16 (22) Camshaft Pulley Bolts ................................................ 23 (31) Crankshaft Pulley Bolt ............................................. 123(170) Engine Mount Bolts .................................................... 40 (54) Power Steering Pump Mount Bolt ............................... 33 (45) Timing Belt Tensioner Bolt ......................................... 33 (45) INCH lbs (N.m) Timing Belt Cover Bolts .............................................. 86 (10) Valve Cover Bolts ...................................................... 106 (12) Water Pump Bolts .................................................... 106 (12)

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 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 upper 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 crankshaft an additional 15 degrees from TDC position. Rotate camshaft pulleys to compression stroke (TDC position) of No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 degrees to TDC position. Push timing belt tensioner to full release position and snug adjuster bolt. Install timing belt over crankshaft pulley, front camshaft pulley, water pump pulley, tensioner and rear camshaft pulley. See Fig. 1. Note position of timing belt pulley guides on both sides of crankshaft. Install pulley guides so guides form a V groove for belt to ride in. Loosen timing belt tensioner bolt.
NOTE: Always adjust timing belt tension with engine cold.
Timing Belt Tension Adjustment: Set No. 1 piston to TDC on compression stroke. Rotate crankshaft clockwise 9 teeth on rear camshaft pulley. Blue mark on crankshaft pulley should match pointer on lower cover. Loosen timing belt tensioner bolt. See Fig. 1. Ensure timing belt is seated properly on pulleys. Tighten adjuster bolt. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A60 for belt tension ranges.
Fig 1: Adjusting Timing Belt
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ACURA *2.5L & 2.7L V6 (Cont.)
93H00122
Courtesy Of American Honda Motor Co., Inc.
ACURA *3.0L, 3.2L & 3.5L V6

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 (J30A1) 3.0CL 1997-99 ................. 4.0 Hours .................. 250286 3.2L V6 (J32A1/A2) 3.2CL 2001 ...................... 4.0 Hours .................. 250286 3.2TL 1999-01 ................. 4.0 Hours ................. 250286 3.5L V6 (J35A3) MDX 2001 ...................... 4.0 Hours ................. 250286
15
*NOTE: These applications are interference engines. See page A-59 for interference engine cautions.

TIMING BELT
Removal: Disconnect negative battery cable. Turn crankshaft pulley so that No. 1 piston is at TDC on compression stroke. White mark on crankshaft pulley should align with pointer on front cover. Remove rubber plugs from front and rear upper timing belt covers. Ensure camshaft sprocket timing marks are aligned with tabs on bottom of access holes. Remove lower engine splash shield. Remove the generator and power steering pump drive belts. Remove dipstick tube from front of engine. Support engine with a jack, and remove engine side mount from front of engine. Remove crankshaft pulley center bolt and pulley. Remove upper and lower timing belt covers. See Figs. 1 and 2. If reusing timing belt, mark direction of belt rotation for installation reference.

Normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
Fig. 1: Exploded View Of Timing Belt Components (1997-99)
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ACURA *3.0L, 3.2L & 3.5L V6 (Cont.)
Fig. 3: Installing Battery Clamp Bolt On Auto-Tensioner
ACURA *3.0L, 3.2L & 3.5L V6 (Cont.)

17
Remove one of the battery clamp bolts from battery tray. Grind threaded end of bolt to a partial point (about 45 degree chamfer). Thread battery bolt into rear cover to hold timing belt adjuster in installed position. Hand tighten ONLY. See Fig. 3. Remove side engine mount bracket from front of engine (above water pump pulley). Loosen timing belt idler pulley bolt 5-6 turns. Remove timing belt. Installation Ensure that engine is at TDC. Align dimple on timing belt drive pulley with pointer on oil pump. See Fig. 4. Align camshaft pulleys with pointers on back covers.
CAUTION: Handle auto-tension carefully so oil does not spill or leak out. Replace any oil that may leak out.
Remove battery clamp bolt from back cover. Remove the timing belt auto-tensioner. For 1997-98 auto-tensioner with removable bolt, hold autotensioner with maintenance bolt pointing up. Remove maintenance bolt. See Fig. 4. Clamp auto-tensioner in soft-jawed vise. DO NOT grip auto-tensioner housing. Insert flat blade screwdriver into maintenance hole. Place stopper on autotensioner 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 autotensioner onto engine with stopper in place.
Application Ft. Lbs. (N.m) Camshaft Sprocket Center Bolt ...................................... 67 (90) Crankshaft Pulley Bolt ............................................ 181 (245) Engine Side Mount-to-Engine Bolts ............................... 33 (44) Engine Side Mount Bracket-to-Mount Through Bolt 3.0CL ............................................................................. 47 (64) Except 3.0CL ................................................................. 40 (54) Idler Pulley Bolt .............................................................. 33 (44) Power Steering Pump Mount Bolt ................................... 17 (24) Power Steering Pump Locknut ....................................... 17 (24) INCH Lbs. (N.m) Auto-Tensioner Mount Bolts ......................................... 106 (12) Auto-Tensioner Maintenance Bolt ..................................... 71 (8) Lower Engine Splash Shield Bolts ............................... 106 (12) Timing Belt Cover Bolts ............................................ 106 (12) Water Pump Bolts .................................................... 106 (12)
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 apply 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 pulley. 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 rubber plugs from upper covers to check camshaft pulley positions. If either camshaft is not at TDC, remove timing belt and readjust position. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belt to correct tension. See page A-60 for belt tension ranges.
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks
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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 *3.2L V6 Legend & 1996-98 3.2 TL

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.2L V6 Legend (C32A1) 1991-95 ................. 5.6 Hours .................. 250193 3.2TL (C32A6) 1996-98 ................. 4.0 Hours ................. 250193
19
NOTE: Some vehicles may be equipped with radio/cassette or radio/CD players that contain anti-theft protection circuit. Obtain radio anti-theft code from vehicle owner before disconnecting negative battery cable.

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

TIMING BELT
Removal (1991-93) Disconnect negative battery cable. Remove injector harness covers. See Fig. 2. Remove engine wiring harness from front of engine. Disconnect breather pipe. Remove vacuum pipe bracket. Remove accessory drive belts. Remove timing belt upper covers. See Fig. 1. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Ensure timing marks are aligned. Remove A/C belt tensioner pulley. Remove crankshaft pulley. Remove engine oil dipstick tube.
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 reused, 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 engine. 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 pressure 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 crankshaft clockwise 15 degrees past No. 1 cylinder TDC. After adjusting left and right camshaft pulleys to TDC, turn crankshaft pulley counterclockwise back to TDC. Install timing belt in this sequence: Crankshaft pulley, tensioner pulley, left camshaft, water pump pulley, right camshaft. To ease installation, advance right camshaft pulley about a half tooth from TDC position. Loosen timing belt tension adjusting bolt, and retight it after tensioning the timing belt. Temporarily install lower timing belt cover and crankshaft pulley. Rotate crankshaft about 5-6 turns clockwise to seat timing belt. Place No. 1 piston at TDC of compression stroke. Rotate crankshaft clockwise 9 teeth on camshaft pulley. Blue mark on crankshaft pulley will should line up with pointer on lower cover. See Fig. 5. Loosen timing belt adjusting bolt 180 degrees. Tighten timing belt adjusting bolt to 31 ft. lbs. (42 N.m). Verify crankshaft and camshaft timing marks are still aligned. If timing marks are not aligned, repeat timing belt installation procedure. To complete installation, reverse removal procedure. Coat crankshaft pulley center bolt threads with oil before installation. Adjust accessory drive belt to proper tension.
NOTE: After installing timing belt, slowly rotate engine clockwise several times to be sure valves do not contact pistons.
Fig. 2: Exploded View Of Intake Manifold (1991-93 Models)
Installation (1994-98) Remove all spark plugs. Ensure No. 1 piston is at TDC of compression stroke. Position crankshaft and camshaft pulleys as shown. See Fig. 4. Adjust camshaft pulley(s) until TDC mark on pulley and pointer on cover plate are aligned. If reusing timing belt, ensure arrow made in removal procedure points in direction of original rotation.
Install timing belt in this sequence: Crankshaft pulley, tension adjuster pulley, left camshaft pulley, water pump pulley, and right camshaft pulley. Loosen and tighten tensioner adjuster bolt to remove slack in belt. Install upper and lower covers and crankshaft pulley. Tighten pulley bolt to specification. Rotate crankshaft clockwise 56 revolutions to seat timing belt. Adjust timing belt tension. Remove upper left camshaft cover. Remove damper from center bracket. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Rotate crankshaft 9 teeth clockwise on camshaft pulley. Align Blue mark on crankshaft pulley with pointer on lower cover. See Fig. 5. Loosen tensioner adjusting bolt 1/ 2 turn , and then tighten bolt to 31 ft. lbs. (42 N.m). Rotate crankshaft clockwise until No. 1 piston is at TDC Of compression stroke. Verify camshaft timing marks are aligned. If timing marks are not aligned, repeat timing belt installation procedure. To complete installation, reverse removal procedure. Coat crankshaft pulley center bolt threads with oil before installation.
ACURA *3.2L V6 Legend & 1996-98 3.2 TL (Cont.)
21
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.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolts ................................................ 23 (31) Center Bracket Bolts ................................................... 40 (54) Crankshaft Pulley Bolt ............................................ 181 (245) Power Steering Mount 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
If timing belt is to be reused, mark direction of rotation before removing. Loosen timing belt adjusting bolt 1/2 turn, push tensioner to remove tension from timing belt, then retighten bolt. Remove timing belt.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.5L V6 (C35A1) 3.5RL 1996-01 Balancer ..................... 1 ......................... 250280 Camshaft ............ 3.6 Hours .................. 250279 1 Balancer belt labor included in camshaft belt labor time.
CAUTION: DO NOT rotate crankshaft pulley or camshaft pulley with timing belt removed. Pistons may hit valves and cause damage. NOTE: Ensure water pump turns freely in clockwise direction and there are no leaks.

For 1996 model year, manufacturer recommends belt be replaced at 90,000 miles for normal service and 60,000 miles on severe service. For 1997-01 model years, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
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 Remove negative battery cable. Turn crankshaft until No. 1 piston is at TDC of compression stroke. Remove engine cover, intake air duct, and air cleaner assembly. Loosen alternator mounting bolt, lock bolt and adjusting rod, then remove alternator belt. Loosen idler pulley center nut and adjuster bolt. Remove A/C belt. Remove Traction Control System (TCS) control valve upper and lower brackets. See Fig. 2. Loosen adjusting bolt, locknut and mounting bolt, then remove power steering pump belt. Disconnect TCS throttle sensor connector, TCS throttle actuator connector and throttle position sensor connector. Remove TCS control valve assembly. Disconnect vehicle speed sensor sub-harness connector, then remove wire harness holder. Remove crankcase breather hose and vacuum hoses from front of right upper cover. Remove ignition control module bracket from right upper cover. Remove idler pulley bracket, dipstick, and dipstick tube. Remove crankshaft pulley. See Fig. 1. Remove upper and lower covers, loosen balancer belt adjusting bolt 1/2 turn and push tensioner to remove tension from balancer belt, then retighten bolt. Remove balancer belt.
Installation Remove spark plugs. Remove balancer belt drive pulley. Noting installed position, remove timing belt guide plate from end of crankshaft. Ensure timing belt drive pulley is set so that No. 1 piston is at TDC. Align TDC mark on timing belt drive pulley with pointer on oil pump. See Fig. 4. Set camshaft pulleys so that No. 1 piston is at TDC. Align TDC marks on camshaft pulleys to pointers on back covers. See Fig. 5. Install timing belt, in sequence, on timing belt drive pulley, adjusting pulley, left camshaft pulley, water pump pulley, and right camshaft pulley. See Fig. 6. Ensure camshaft and crankshaft pulleys remain at TDC. Loosen and retighten timing belt adjusting bolt. Install lower cover and crankshaft pulley. To set timing belt tension, rotate crankshaft pulley about 5 or 6 turns clockwise. Set No. 1 piston at TDC of compression stroke. White mark on crankshaft pulley must be aligned with pointer on lower cover. See Fig. 3. Rotate crankshaft clockwise 10 teeth on camshaft pulley. Blue mark on crankshaft pulley should align with pointer on lower cover. Loosen timing belt adjusting bolt 180 degrees. Tighten adjusting bolt to specification. Remove crankshaft pulley and lower cover. Install timing belt guide plate and balancer belt drive pulley on crankshaft. Ensure guide plate is installed in correction direction. See Fig. 1. Remove 12mm sealing bolt from side of engine block. See Fig. 7. Align maintenance hole and balancer shaft hole. Insert a 6mm bolt into sealing bolt hole. Ensure balancer belt pulley pointer aligns with pointer on balancer gear case. See Fig. 8. Set timing belt drive pulley to TDC. Install balancer belt pulley. Install balancer belt. Loosen and retighten balancer belt adjusting bolt to tension balancer belt. Remove 6 mm bolt. Install sealing bolt in maintenance hole, using new washer. Install crankshaft pulley. Rotate crankshaft pulley about 5 or 6 turns clockwise to position balancer belt on pulleys. Loosen balancer belt adjusting bolt 180 degrees. Tighten balancer belt adjusting bolt to specification. Remove crankshaft pulley. Install upper and lower covers, then install crankshaft pulley. Ensure crankshaft pulley and camshaft pulley are at TDC. Remove inspection plugs in upper camshaft covers to check pulley alignment. To complete installation, reverse removal procedure. Coat threads of crankshaft pulley bolt with oil before installation. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
ACURA *3.5L V6 3.5RL (Cont.)
23
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .................................................. 23 (31) Crankshaft Pulley Bolt ............................................ 181 (245) 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) Timing Belt Tension Adjuster Bolt ............................... 31 (42) Water Pump Bolt (8 x 1.25 mm) ..................................... 16 (22) INCH Lbs. (N.m) Engine Cover Bolts/Nuts ............................................ 89 (10) TCS Upper Bracket Bolts .......................................... 106 (12) Timing Belt Cover Bolts ................................................ 106 (12) Water Pump Bolt (6 x 1.0 mm) .................................. 106 (12)
Fig. 2: Locating TCS Control Valve & Connectors
24
Fig. 3: Aligning Timing Marks (TDC)
Courtesy of American Honda Motor Co., Inc. Courtesy of American Honda Motor Co., Inc.
Fig. 5: Aligning Camshaft Pulleys
Fig. 4: Aligning Timing Belt Drive Pulley
25
Fig. 8: Aligning Balancer Shaft Marks
Fig. 7: Installing Balancer Shaft Lock Bolt
26
ACURA 3.5L V6 DOHC, SLX
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.5L V6 DOHC SLX 1998-99 ................. 2.4 Hours .................. 250303

Normal replacement interval is at 75,000 miles for 1998-99 model years.

TIMING BELT
Fig. 2: Aligning Crankshaft Timing Marks (All Models) NOTE: For correct timing belt installation, lettering on belt must be able to be read as viewed from the front of the vehicle. Also, note arrow on belt which indicates direction of rotation.
Removal: Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove serpentine drive belt. Remove cooling fan and drive pulley. Remove serpentine drive belt idler pulley assembly. Remove serpentine drive belt tensioner assembly. Remove power steering pump with hoses attached, and set aside. Remove crankshaft pulley bolt. Using Puller (J8614-01) or equivalent, remove crankshaft pulley. Remove timing belt covers. Rotate crankshaft to align timing marks. See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be at TDC. If reusing timing belt, mark belt with arrow to indicate original rotation direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove timing belt tensioner, and set aside with push rod facing up. Remove timing belt.
CAUTION: To prevent air from entering timing belt tensioner, tensioner rod must always face up.
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) camshaft sprocket with alignment mark on valve cover. See Fig. 3. Install timing belt on right hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. If reusing old timing belt, align mating marks on belt and camshaft sprocket that were made during removal. Secure belt with spring clip. Align timing mark on left hand (driver side) camshaft sprocket with alignment mark on valve cover. See Fig. 4. Route timing belt around water pump pulley and install on other left hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. Install pinch clip to hold belt on sprocket. Ensure there is no slack in belt between camshaft pulleys. 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.

Courtesy of Isuzu Motor Co.
Holding tensioner upright, SLOWLY compress timing belt tensioner rod until hole in top of rod and holes in housing are aligned. Install a locking pin through the holes. See Fig. 5. Install tensioner on engine with locking pin in place. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove locking pin from timing belt tensioner. Remove clips from camshaft and crankshaft sprockets. Rotate crankshaft 2 turns clockwise. Ensure timing marks are still aligned. Remove crankshaft pulley and install timing belt covers. Ensure rubber sealing bushings are installed on timing belt cover bolts. See Fig. 6.
ACURA 3.5L V6 DOHC, SLX (Cont.)
27
Courtesy of American Honda Motor Co.
Fig. 3: Installing Timing Belt on Right Hand Camshaft Sprocket
Fig. 5: Installing Locking Pin in Timing Belt Tensioner
Fig. 6: Installing Timing Belt Cover Bushings

Install crankshaft pulley. Tighten center bolt to specification. Install cooling fan pulley. Install power steering pump. Install cooling fan. Install serpentine drive belt idler pulley and tensioner assemblies. Install radiator fan shroud. Connect battery. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 72 (98) Cooling Fan Pulley Bolt .............................................. 16 (22) Crankshaft Pulley Bolt ............................................ 123 (167) Power Steering Pump Bolt M8 Bolt ......................................................................... 16 (22) M10 ............................................................................. 34 (46) Timing Belt Cover Bolt ................................................ 14 (19) Timing Belt Idler Arm Pulley Bolt ................................. 38 (52) Timing Belt Tensioner Bolt ......................................... 18 (25) Timing Belt Tensioner Pulley Pivot Bolt ...................... 31 (42) Water Pump Bolt ......................................................... 18 (25)
28
ACURA & HONDA 3.2L V6 SOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.2L V6 SOHC Passport 1994-97 ................ 1 2.8 Hours ................. 250221 SLX 1996-97 ................ 1 2.8 Hours ................. 250221 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.

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

TIMING BELT
Removal: Disconnect negative battery cable. Remove air cleaner assembly. 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 crankshaft pulley. Remove oil cooler hose from timing cover. Remove timing belt cover. Align all timing marks prior to belt removal. See Figs. 1 and 2. Remove belt tensioner pusher and timing belt. Installation: Ensuring all timing marks are aligned. Install belt over one pulley at a time starting at crankshaft sprocket working counterclockwise. Belt should go over tensioner last. Secure belt at each pulley during installation with pinch clips. See Fig. 3.
CAUTION: To ensure correct timing belt installation, ensure direction of rotation arrows are pointing in proper direction. If timing belt is being reused, install belt in original direction of rotation.
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 specification. Remove pin from timing belt tensioner pusher. Remove pinch clips from timing belt, (if used). Install crankshaft pulley, tightening center bolt finger tight. Rotate crankshaft 2 turns clockwise. Ensure timing belt tensioner pusher rod protrudes proper amount. See Fig. 4. If timing belt tensioner pusher rod protrusion is not within specification, remove pusher, loosen tensioner pulley bolt and readjust. Reset timing belt tensioner pusher rod and repeat timing belt tensioning procedure. Remove crankshaft pulley and install timing belt cover. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS. Ad-
Fig. 3: Installing Pinch Clip On Timing Belt
ACURA & HONDA 3.2L V6 SOHC (Cont.)
29
Fig. 4: Adjusting Timing Belt Tensioner Pusher
just drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .................................................. 41 (56) Camshaft Sprocket Bolt .............................................. 41 (56) Crankshaft Pulley Bolt ............................................ 123 (167) Fan Pulley Bolt ............................................................ 16 (22) Front Plate Bolt ........................................................... 14 (19) Idler Arm Retaining Bolt .............................................. 33 (44) Power Steering Pump Bolt .......................................... 34 (46) Timing Belt Cover Bolt ................................................ 13 (18) Timing Belt Tensioner Pulley Bolt ............................... 32 (43) Timing Belt Tensioner Pusher Bolt ............................. 14 (19) Upper Intake Manifold Bolt .......................................... 18 (24) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt ........................................ 87 (10) Cooling Fan Assembly Nut ........................................... 69 (8)
Fig. 5: Exploded View Of Cylinder Head Components
30
ALFA ROMEO 3.0L V6
Turn crankshaft in normal direction of rotation 2-3 revolutions to seat timing belt. Keep timing belt under tension and push hydraulic tension pulley against timing belt. Tighten 2 tensioner retaining nuts. Slightly lift belt tensioner arm, then release tensioner arm, by removing tool holding arm in position. Position No. 1 cylinder at TDC compression stroke. Ensure crankshaft and camshaft timing marks are aligned. If timing marks are not aligned, timing belt must be removed and repositioned. Install spark plugs. Install timing belt covers. On models with heat exchanger, connect oil cooler tubes. On all models, connect coolant hose to thermostat unit, and return hose to water pump. Plug in coolant switch and sensor electrical connectors. Install left side valve cover and gasket. Connect spark plug wires for cylinders No. 4, No. 5, and No. 6. Install right side valve cover and gasket. Install intake ducts and gaskets. Connect spark plug wires for cylinders No. 1, No. 2, and No. 3. Install air intake box. Connect ground strap to air intake box. Connect fuel pressure regulator and power brake unit vacuum hoses. Connect fuel vapor and cruise control hoses. On S models, connect engine throttle sensor electrical connector. Connect accelerator cable. On models with automatic transmission, connect kickdown cable. Install throttle body cover. Connect throttle body switch electrical connector. Connect oil vapor separator hoses. Connect constant idle speed actuator electrical connector. Install crankshaft position sensor and electrical connector. Install hydraulic drive belt tensioner. Install power steering pump, A/C compressor, and water pump drive belts. Install front right inner fenders. Install right front wheel and tire assembly, then lower vehicle. Connect negative cable. Adjujst accessory drive belt tension. See page A-60 for belt tension ranges.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 164 1991-93 .............. 4.8 Hours ................. 250120


TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right front inner fenders. Disconnect throttle opening switch electrical connector. Remove throttle body cover. Remove water pump, air conditioning, and power steering drive belts. Remove hydraulic belt tensioner. Disconnect crankshaft position sensor connector, and remove sensor. Disconnect constant idle speed actuator electrical connector. Disconnect oil vapor separator hoses. Disconnect accelerator cable. On model equipped with automatic transmission, disconnect kickdown cable. On S models, disconnect engine throttle sensor electrical connector. On all models, disconnect fuel vapor and cruise control hoses. Disconnect fuel pressure regulator and power brake unit vacuum hoses. Disconnect ground strap from air intake box. Remove air intake box attaching screws and clamps, and remove air intake box. Disconnect spark plug wires for cylinders No. 1, No. 2, and No. 3. Remove intake ducts and gaskets. Remove right valve cover and gasket. Disconnect spark plug wires for No. 4, No. 5, and No. 6. Remove left side valve cover and gasket. Partially drain cooling system. Disconnect coolant hose from thermostat unit. Disconnect return hose from water pump. Disconnect coolant temperature switch and sensor electrical connectors. If equipped, disconnect oil cooling tubes from heat exchanger. Remove timing belt covers. Remove spark plugs Rotate crankshaft so No. 1 cylinder is at TDC of compression stroke. Flywheel and transmission housing timing marks should align. See Fig. 1. Camshaft sprocket timing marks should align with bearing cap marks. See Fig. 2. Lift belt tensioner arm from timing belt. Insert Holding Tool (1.820.053.00) or equivalent into hole on arm to lock in position. Loosen hydraulic belt tensioner retaining nuts. Push tensioner downward to limit of travel, and tighten upper 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 hydraulic tensioner upper retaining nut.
Fig. 1: Identifying Flywheel Timing Marks
ALFA ROMEO 3.0L V6 (Cont.)
31
Fig. 3: Installing Timing Belt
Fig. 2: Identifying Camshaft Timing Marks
32
AMERICAN MOTORS 2.0L 4-Cylinder

Labor Time 1 Component Kit No. Belt Part No.
TIMING BELT APPLICATION Application 2.0L 4-Cyl. Concord & Gremlin 1977-78 .......... 1.5 Hrs. ...... 2520170 ........ 250017 Concord & Spirit 1979 ............... 1.5 Hrs ....... 2520170 ....... 250017 1 - With Air Cond. add .2 hours
NOTE: A timing belt component kit is available for this application. See page I for information on component kits.


TIMING BELT
Removal: Disconnect negative battery cable. Rotate engine until timing mark (notch) on crankshaft is pointing to zero. Camshaft sprocket timing mark should now be adjacent to pointer on cylinder head cover. See Fig. 1.
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. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
CAUTION: Excessive tension may cause pulley to fail.
Fig. 2: Timing Belt & Components
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Belt Tensioning Idler Screw ....................... 29 (39) Camshaft Sprocket Screw .......................................... 58 (78) Crankshaft Sprocket Screw .................................... 181 (123) Water Pump Screw (Large) ....................................... 16 (21) INCH Lbs. (N.m) Camshaft Rear Bearing Cap Screw ........................... 84 (10) Water Pump Screw (Small) ....................................... 84 (10)
AUDI 1.6L 4-Cylinder Diesel

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. 4000 Diesel 1982-83 .............. 2.3 Hours ................ 250043
33

Although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 33 (45) Crankshaft Pulley/Damper Standard ............................................................... 108 (150) Turbo .................................................................... 145 (200) Injection Pump Sprocket ............................................. 33 (45) Intermediate Shaft Pulley ............................................ 33 (45) Timing Belt Tensioner ................................................ 33 (45)

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 compression 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 prevent camshaft from moving. See Fig. 1. Insert pin tool (2064) through small cutout in injection pump sprocket to lock sprocket in place. Injection pump sprocket must not be allowed to move. Check that timing marks on injection pump sprocket, pump body and mounting plate are aligned. Check that TDC mark on flywheel is aligned with reference mark on bell housing. Loosen timing belt tensioner to relieve tension on timing belt. Remove crankshaft pulley. Do not allow crankshaft to turn. Remove timing belt. Installation: Check that TDC mark on flywheel is still aligned with reference 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 midway between camshaft and injection pump sprockets. Tension 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 injection pump sprocket. Using Tension Gauge (210), recheck timing belt tension. 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 page A-60 for belt tension ranges.
Fig. 1: Camshaft Locking Tool Installation
Fig. 2: Timing Belt Tension Tool Installation
34
AUDI 1.6L & 1.7L 4-Cylinder

Labor Time Component Kit No. Belt Part No.
TIMING BELT APPLICATION Application 1.6L 4-Cyl. Fox 1973-79 .......... 1.1 Hrs. ...... 2520170 ....... 250017 1.7L 4-Cyl. 4000 1980-83 .......... 1.1 Hrs. ...... 2520170 ........ 250017

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 removal 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. 1: Adjusting Timing Belt Tension (1.7L)
Fig. 4: Aligning Camshaft Sprocket With Upper Edge Of Gasket (1.7L)
AUDI 1.6L & 1.7L 4-Cylinder (Cont.)

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ..................................................... 58 (80) Crankshaft Drive Belt Sprocket ................................... 58 (80) Crankshaft V Belt Pulley ........................................... 14 (20) Drive Belt Tension Nut ................................................ 33 (45) Intermediate Shaft Sprocket ....................................... 58 (80)
35
36
AUDI *1.8L 4-Cylinder 1984-87

TIMING BELT APPLICATION Application 1.8L 4-Cyl. 4000S 1984-87 ........ 1.1 Hrs. ...... 2520170 ....... 250017 Labor Time Component Kit Belt Part No.
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 8-Valve ...................................................................... 58 (80) 16-Valve .................................................................... 48 (65) Crankshaft Pulley Nut ................................................. 14 (20) Crankshaft Sprocket Bolt ........................................ 148 (200) Intermediate Shaft Sprocket Bolt 8-Valve ...................................................................... 58 (80) 16-Valve .................................................................... 48 (65) Timing Belt Tensioner Nut .......................................... 33 (45)
MANFACTURERS SUGGESTED SCHEDULED MAINTENANCE

Although the manufacturer does not recommend a specified scheduled maintenance, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
* NOTE: This application is an interference engine. 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 adjusting bolts. Remove all drive belts. Remove water pump pulley, crankshaft pulley, and vibration damper. Remove upper and lower timing belt outer covers. On 16-valve engine, 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 compression 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 intermediate shaft sprockets. Install crankshaft pulley and tighten all 4 bolts. Align mark on crankshaft pulley with mark on intermediate shaft sprocket at TDC. See Fig. 2. Position camshaft so mark on back of sprocket is in line with upper edge of timing belt rear cover. See Fig. 3. Both lobes for No. 1 cylinder should point upward at 45 degrees from camshaft follower so both valves are closed. Install timing belt on camshaft sprocket. Adjust timing belt tension by turning tensioner adjusting hex clockwise against belt. Make sure shaft timing marks have not moved. Tighten tensioner lock nut and check tension 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 timing marks. To complete installation, reverse removal proce dure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 1: 16-Valve Timing Belt Cover & Timing Belt Assembly
Fig. 2: Aligning Intermediate Shaft & Crankshaft
AUDI *1.8L 4-Cylinder 1984-87 (Cont.)
37
Fig. 3: Setting Camshaft Timing Marks
38
AUDI *1.8L 4-Cylinder Turbo A4 & A4 Quattro
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cylinder Turbo A4 & A4 Quattro 1997-99 ............... 3.5 Hours ................. 250291

The manufacturer suggests the belt be replaced at 90,000 mile intervals.

TIMING BELT
Courtesy of Audi of America, Inc.
Removal Remove complete front bumper assembly. Remove engine undercover. Remove air intake duct from air filter housing. Disconnect all necessary electrical connectors from front of vehicle. Install Lock Carrier Support Tool (3369) through lock carrier 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 assembly. Viscous fan pulley is secured by one Allen-head bolt. Allen-head bolt is removed from rear of pulley, through access hole in accessory mount bracket.
CAUTION: Crankshaft center bolt is torque-to-yield type. Manufacturer recommends replacing bolt if it is loosened or removed.
Remove upper timing belt cover. Rotate crankshaft by hand to Top Dead Center (TDC). See Fig. 1. Remove crankshaft vibration damper pulley. It is NOT necessary to remove crankshaft center bolt. Remove lower timing belt cover. Mark timing belt running direction. Using Torx T45 bit, loosen timing belt tensioner. Push timing belt tensioner down and remove timing belt.
Fig. 2: Identifying Tensioner Pistons
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 timing belt on crankshaft sprocket. Install lower timing belt cover. Install vibration damper pulley and tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure crankshaft vibration damper is correctly aligned to lower timing belt cover. See Fig. 1. Install timing belt on the tensioner and camshaft sprocket. To tension timing belt, use spanner wrench to rotate tensioner pulley clockwise until tensioner piston No. 1 is fully extended, and piston No. 2 lifts about .040 (1 mm). See Fig. 2. Tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 revolutions in normal direction of rotation. Make sure camshaft and crankshaft timing marks are aligned.
Fig. 3: Identifying Tensioner Dimensions
39 AUDI *1.8L 4-Cylinder Turbo A4 & A4 Quattro (Cont.)
Fig. 6: Positioning Lock Carrier Assembly Torx Bolts
Fig. 4: Exploded View Of A4 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. 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 removal procedure. Ensure lock carrier Torx bolts are installed in correct position. See Fig. 6. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 48 (65) Crankshaft Sprocket Center Bolt 1 Step 1 ....................................................................... 66 (90) Step 2 ..................................................... Additional 1/4 Turn Lock Carrier-To-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 2
REPLACE torque-to-yield bolt if loosened or removed. Bolt strength grade is 10.9.
Fig. 5: Positioning Lock Carrier Support Tool (3369)
40
AUDI *1.8L 4-Cylinder Turbo TT
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cylinder Turbo (AMU, ATC & AWP) TT Coupe & Roadster 2000 ...................... 3.5 Hours ................. 250306
NOTE: Engine code is located on machined pad on bellhousing flange, where engine connects to transaxle.

The manufacturer suggests the belt be replaced at 120,000 mile intervals.

TIMING BELT
Removal Disconnect charge air cooler duct at bottom of right-hand crossmember (if equipped). See Fig. 2. Remove center and right-hand noise insulation panels from under vehicle. See Fig. 3. Remove serpentine drive belt and tensioner. See Fig. 4. Rotate tensioner clockwise (as viewed from front of engine) to relieve belt tension. Remove cooling system expansion tank and power steering reservoir bolts. Keeping hoses attached, secure expansion 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 supported from below using floor jack. Turn crankshaft sprocket center bolt in normal direction of rotation to align the crankshaft vibration damper at TDC of No. 1 cylinder. Ensure camshaft sprocket timing mark is aligned with mark on rear timing belt cover. See Fig. 5.
NOTE: Crankshaft sprocket center bolt is a torque-to-yield type. If removed, manufacturer recommends replacing the bolt.
Fig. 2: Identifying Air Duct (ATC & AWP Engines)
Remove 4 bolts around center bolt on vibration damper. Remove vibration damper. It is NOT necessary to remove crankshaft center bolt. Do NOT move crankshaft.
NOTE: Engine console and right-hand engine support bolts are torque-to-yield type. Manufacturer recommends replacing the bolts if they are removed.
Remove center and bottom timing belt covers. Remove bolts from engine console and right-hand engine support arm. See Fig. 6. Remove engine console and right-hand engine support arm.
Remove bolts for engine support, but do not remove engine support. See Fig. 7. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Screw a M5 x 55 stud into the timing belt tensioner bracket. See Fig. 8. Install hex nut and washer onto stud. SLOWLY turn hex nut on stud to compress timing belt tensioner. Compress tensioner just enough so that a locking pin or drill bit can be inserted through the tensioner body, locking the tensioner in place. Remove timing belt.
CAUTION: To prevent engine damage, do NOT turn camshaft while the crankshaft is a TDC.
AUDI *1.8L 4-Cylinder Turbo TT (Cont.)
41
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.)
Remove engine Support Bracket (10-222) or floor jack from under vehicle. Install center and upper timing belt covers. Install serpentine belt tensioner and serpentine belt. Install coolant expansion tank and power steering reservoir. Install vacuum line between fuel evaporative canister and throttle body. To install remaining components, reverse removal procedure. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................ 48 (65) Crankshaft Sprocket Center Bolt 1 Step 1 ....................................................................... 66 (90) Step 2 ..................................................... Additional 1/4 Turn Engine Console-To-Body 1 Step 1 ....................................................................... 30 (40) Step 2 ..................................................... Additional 1/4 Turn Engine Support Arm-To-Engine Bracket 1 Step 1 ....................................................................... 44 (60) Step 2 ..................................................... Additional 1/4 Turn Serpentine Belt Tensioner Bolt ....................................... 18 (25) Timing Belt Tensioner Bottom Bolt ................................................................... 11 (15) Top Bolt ........................................................................ 15 (20) Timing Belt Tensioner Pulley Bolt ................................. 20 (27) Vibration Damper-To-Crankshaft Sprocket ..................... 18 (25) Water Pump Bolt ............................................................ 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................... 89 (10) 1 Torque-to-yield type bolt. Manufacturer recommends replacing bolt if it is removed.
Installation Install timing belt onto crankshaft sprocket. Install lower timing belt cover. Install vibration damper pulley, making sure notch in center hole of vibration damper is aligned with projection on crankshaft sprocket. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 5. Install timing belt on water pump, tensioner pulley and camshaft sprocket. Remove locking pin or drill bit from timing belt tensioner. Remove M5 x 55 stud from tensioner bracket. Turn crankshaft 2 complete revolutions in normal direction of rotation. Align camshaft and crankshaft timing marks. Install engine right-hand engine support arm and console using NEW bolts. Adjust engine console and right-hand engine support arm so clearance is about .50 (13 mm). See Fig. 6.
Fig. 8: Compressing Timing Belt Tensioner
AUDI 2.0L 4-Cylinder

TIMING BELT APPLICATION Application 2.0L 4-Cyl. 80 1988-90 ......... 1.8 Hrs. ...... 2520170 ....... 250017 90 1988 ............... 1.8 Hrs. ...... 2520170 ....... 250017 Labor Time Component Kit No. Belt Part No.
43

TIMING BELT
Removal: Disconnect negative battery cable. Use exploded view to locate components. See Fig. 1. Match mark all components for reassembly reference. Place crankshaft at TDC with No. 1 cylinder on compression stroke. Remove alternator belt. Remove A/C and power steering belts (if equipped). Remove upper timing belt cover. Remove water pump and crankshaft pulleys. Remove lower timing belt cover. Remove timing belt. Installation: Align flywheel/flex plate 0 mark with pointer. Remove distributor cap and check position of ignition rotor. Rotate intermediate shaft and position rotor at No. 1 cylinder mark on housing. See Fig. 2. Install timing belt on crankshaft and intermediate shaft gears. With intermediate shaft/ignition rotor positioned, rotate crankshaft and align mark on crankshaft pulley with mark on intermediate shaft sprocket. Position camshaft sprocket mark even with base of valve cover. See Fig. 3. 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 installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 58 (80) Crankshaft Pulley Nut ................................................... 5 (20) Crankshaft Sprocket Bolt ........................................ 133 (180) Timing Belt Tensioner Pulley Nut ............................... 33 (45) Water Pump Pulley ..................................................... 15 (20) INCH Lbs. (N.m) Timing Belt Cover Bolts ................................................ 53 (6)

Fig. 2: Aligning Distributor Rotor
44
AUDI 2.0L 4-Cylinder (Cont.)
Fig. 4: Checking Proper Belt Tension
AUDI *2.0L 5-Cylinder Diesel & Turbo Diesel

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 5-Cyl. Diesel 5000 1979-83 Camshaft ............ 2.6 Hours .................. 250083 Inject. Pump ....... 1.1 Hours .................. 250082 2.0L 5-Cyl. Turbo Diesel 5000 1979-83 Camshaft ............ 2.6 Hours .................. 250083 Inject. Pump ........ 1.1 Hours .................. 250082
45

Using tension tester (VW210), check timing belt tension midway between camshaft and water pump sprockets. Tension is correct when tester reads 12-13. Check that crankshaft and injection pump timing marks are still aligned. Tighten camshaft sprocket bolt and remove camshaft holding tool. Install injection pump sprocket, drive belt and inner pulley half. Tighten injection pump drive sprocket retaining bolt until it is just possible to turn sprocket on camshaft by hand. Adjust fuel injection pump drive belt tension by loosening mounting bolts and reposition mounting plate and support on engine. Using tension tester (VW 210), check belt tension midway between fuel injection pump and drive sprockets. Tighten fuel injection pump drive sprocket bolt and remove pin tool (2064) from injection pump sprocket. Install remaining components in reverse order of removal. Ensure valve timing and injection pump timing are correct. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Front ......................................................................... 33 (45) Rear ....................................................................... 72 (100) Crankshaft Damper/Pulley (Locktite) ...................... 258 (350) Water Pump Bolts ...................................................... 14 (20)

TIMING BELT & INJECTION PUMP BELT
Removal: Disconnect negative battery cable. Remove accessory drive belts. Remove outer half of vacuum pump pulley. Remove power steering pump with hoses connected, and position aside. Remove attaching bolts and remove upper and lower timing belt covers. 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 housing 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 retaining bolt. Remove inner pulley half, pump sprocket and injection pump drive belt. Secure crankshaft from moving with support tool (2084). Loosen crankshaft damper/pulley center bolt. Install camshaft holding tool (2065A) at rear of camshaft. With camshaft locked in place, loosen water pump bolts to relieve tension on timing belt. Remove crankshaft pulley with timing belt sprocket and timing belt. Installation: Ensure crankshaft and injection pump timing marks are aligned. Install crankshaft damper/pulley with sprocket and timing belt. Using tool (2084) to hold crankshaft, install and tighten center bolt. With camshaft still locked in place, loosen camshaft sprocket bolt 1 full turn. Using a brass drift inserted through hole in rear timing belt cover, tap camshaft sprocket loose from camshaft taper. Attach timing belt to camshaft sprocket. To adjust timing belt tension, turn water pump until pump sprocket provides tension against timing belt.
Fig. 1: Camshaft Timing Belt Replacement
46
AUDI *2.0L 5-Cylinder Diesel & Turbo Diesel (Cont.)
Fig. 2: Injection Pump Drive Belt Replacement
AUDI 2.3L 5-Cylinder Coupe Quattro

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L 5-Cyl. Coupe Quattro 1990-91 ................. 1.8 Hours ................. 250197
47


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
Fig. 2: Aligning Timing Marks Fig. 1: Exploded View Of Timing Belt Components
48
AUDI 2.3L 5-Cylinder Coupe Quattro (Cont.)
Installation: Ensure both camshaft lobes on No. 1 cylinder point upward. Mark (notch or dot) on back of camshaft sprocket must be aligned with top of valve cover gasket or rear timing belt cover. Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must be aligned with index point on transmission housing. Install water pump with new sealing O ring. Install timing belt. Turn water pump body counterclockwise to increase belt tension. Tension is correct when belt can be twisted 90 degrees using finger pressure at point midway between camshaft sprocket and water pump sprocket. Recheck valve timing. Complete installation in reverse order of removal. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 59 (80) Timing Belt Idler Pulley Bolt ........................................ 15 (20) Vibration Damper Bolt ............................................ 258 (350) Water Pump Bolt ........................................................ 15 (20) INCH Lbs. (N.m) Valve Cover Nut .......................................................... 84 (10)
Fig. 4: Checking Proper Belt Tension
Fig. 3: Aligning Ignition Rotor
AUDI 2.2L 5-Cylinder Turbo, 1992-95

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 5-Cyl. Turbo S4 1992-94 ................. 1.8 Hours .................. 250225 S6 & S6 Quattro 1995 ....................... 1.8 Hours .................. 250225
49


TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove underpanel. Remove front bumper. Remove upper radiator support with attached parts. Remove bracket for trim panel from right side of vehicle. Remove radiator bolts, radiator air guide and upper air duct from radiator. Attach special radiator support tool (3251) to right bumper mount bracket and swing radiator forward. Remove viscous fan and unclip wiring from fan frame. Relieve tension from accessory drive belt by swinging tensioner in direction shown. See Fig. 2. Insert Pin (3204) into holes. Remove belt. Remove tensioner. Remove upper timing belt guard. NOTE: Turn engine by hand using hex flange on hydraulic pump. Loosen tensioner bolts.
Turn crankshaft to TDC of No. 1 cylinder. See Fig. 3. Camshaft sprocket mark must align with mark on cylinder cover. See Fig. 4. Remove vibration damper. Remove lower timing belt cover. Remove timing belt with vibration damper. Installation: Ensure crankshaft and camshaft are at TDC of cylinder No. 1. TDC marking must be positioned below edge in inspection hole. See Fig. 3. Markings on camshaft sprocket and cylinder head cover must align. See Fig. 4. Place new belt on crankshaft pulley. Install vibration damper and at same time, fit lower timing belt cover. Fit belt onto idler pulley, water pump and camshaft sprocket. Tension belt by turning tensioner toward right with bolts loosened. See Fig. 1. Ensure that belt can just be twisted 90 degrees with thumb and forefinger between camshaft sprocket and water pump. Tighten tensioner. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 59 (80) Timing Belt Idler Pulley Bolt .......................................... 15 (20) Timing Belt Tensioner (1992-95) ................................ 15 (20) Vibration Damper Bolt ............................................ 258 (350) Water Pump Bolt ........................................................ 15 (20) INCH Lbs. (N.m) Radiator Mounting Bolts ............................................. 89 (10) Timing Belt Cover ....................................................... 89 (10) Valve Cover Nuts/Bolts ............................................... 89 (10)
96F14642
Fig. 2: Relieving Tension On Accessory Drive Belt
96H14644
50
AUDI 2.2L 5-Cylinder Turbo, 1992-95 (Cont.)
96G14643
Fig. 3: Locating No. 1 Cylinder TDC Inspection Hole Fig. 4: Aligning Camshaft Sprocket Timing Marking
AUDI 2.3L 5-Cylinder Exc. Coupe Quattro

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L 5-Cyl. 80 1991-92 .................. 1.8 Hours .................. 250170 80/90 Quattro 1988 ....................... 1.8 Hours .................. 250127 1989 Thru Chassis No. 89 J 394 742 ......... 1.8 Hours .................. 250127 From Chassis No. 89 J 394 743 ........ 1.8 Hours .................. 250170 1990-92 ................. 1.8 Hours .................. 250170 90 1988 ....................... 1.8 Hours .................. 250127 1989 Thru Chassis No. 89 J 396 702 ........ 1.8 Hours .................. 250127 From Chassis No. 89 J 396 703 ........ 1.8 Hours .................. 250170 1990-91 .................. 1.8 Hours .................. 250170 100/100 Quattro 1989-91 Thru Chassis No. 063 969 ............... 1.8 Hours .................. 250127 From Chassis No. 063 970 ............... 1.8 Hours .................. 250170 1990-91 .................. 1.8 Hours .................. 250170 5000S 1987-88 .................. 2.2 Hours .................. 250127 5000S Quattro 1988 ....................... 2.2 Hours .................. 250127
51


TIMING BELT
Removal (1986-90): Disconnect negative battery cable. Remove upper radiator cover. Remove drive belts. Remove power steering pump with pressure hoses connected. Set pump aside. Remove valve cover and outer timing belt covers. See Fig. 1. 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. Installation (1986-90): Ensure both camshaft lobes on No. 1 cylinder point upward. Mark (notch or dot) on back of camshaft sprocket must be aligned with top of valve cover gasket or rear timing belt cover. Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must be aligned with index point on transmission housing. Install water pump with new sealing O ring. Install timing belt. Turn water pump body counterclockwise to increase belt tension. Tension is correct when belt can be twisted 90 degrees using finger pressure at point midway between camshaft sprocket and water pump sprocket. Recheck valve timing. Complete installation in reverse order of removal. Adjust drive belts to proper tension. Removal (1991-92): Disconnect negative battery cable. Remove accessory drive belts. Remove upper front and lower front timing belt covers. Rotate crankshaft until timing marks are aligned. See Fig. 2. Mark an arrow on timing belt (if reusing) to indicate direction of rotation. Slightly loosen 3 water pump bolts. Pivot water pump toward center of engine to relieve timing belt tension. Insert Holder (2084) into vibration damper to prevent crankshaft from turning. Using Extension (2079) and breaker bar, remove vibration damper bolt. Remove vibration damper/ crankshaft sprocket. Remove timing belt. Installation (1991-92): Ensure timing marks are aligned. See Fig. 3. With crankshaft sprocket attached to vibration damper, loop timing belt around crankshaft sprocket. Install vibration damper/ crankshaft sprocket with belt onto crankshaft end, ensuring belt is not jammed between crankshaft sprocket and front cover. Slightly loosen 3 water pump bolts. Pivot water pump toward center of engine to allow belt to be looped around camshaft sprocket and idler pulley. Take up all slack in belt between camshaft and water pump, and between water pump and crankshaft. Pivot water pump away from engine until belt is tight. To check belt tension, grasp belt with thumb and forefinger between camshaft and water pump sprocket. Belt tension is correct if belt can be twisted 90 degrees. Tighten water pump bolts to specification. Complete installation in reverse order of removal. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 59 (80) Timing Belt Idler Pulley Bolt ........................................ 15 (20) Vibration Damper Bolt ............................................ 258 (350) Water Pump Bolt ........................................................ 15 (20) INCH Lbs. (N.m) Valve Cover Nut .......................................................... 89 (10) Timing Belt Cover ....................................................... 89 (10)
52
AUDI 2.3L 5-Cylinder Exc. Coupe Quattro (Cont.)
Fig. 1: Exploded View Of Timing Belt, Sprockets & Covers
96E14641
Fig. 2: Aligning Camshaft Sprocket
AUDI *2.7L V6 DOHC, S4 Quattro

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.7L V6 S4 Quattro 2000 ...................... 4.2 Hours .................. 250297
53

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

TIMING BELT
CAUTION: Before removal, mark an arrow indicating direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation.
Courtesy Of Audi Of America, Inc.
Fig. 2: Removing Front Bumper (Up To VIN 8DXA200000; Later Models Similar)
Removal: Disconnect negative battery cable. Remove noise insulator. See Fig. 1.
Fig. 1: Removing Noise Insulation
Fig. 3: Removing Inner End Of Air Inlet Grill
On VIN up to 8DXA200000, remove bumper by removing Torx screws at wheel housing liner, and air inlet grill at bumper by disengaging tabs at top and bottom using a screwdriver. see Fig. 2. Remove inner end of air inlet grill first. See Fig 3. Remove combination bolts. Unclip bumper from bracket and remove toward front. On VIN 8DXA200001 and forward, remove bumper by removing bolt with washer, impact absorber and hex bolts. Remove Torx screws at wheel housing liner, and air inlet grill at bumper by disengaging tabs at top and bottom using a screwdriver. Remove inner end of air inlet grill first. See Fig. 3. Remove bolt and washer assembly. Unclip bumper from bracket and remove toward front. Move lock carrier to service position by removing 3 quick release screws on front of noise insulation panel. See Fig. 4. Unbolt air guide between lock carrier and air cleaner at lock carrier. If installed, remove retaining clamps for wiring harness on left side of radiator frame. Remove bolt and install Support Tool (3369) into left bore. Remove bolts. Remove bolts and pull lock carrier out to stop. To secure lock carrier, install appropriate M6 bolts into rear bored holes of lock carrier and fender bore.
Remove viscous fan using Pin Wrench (3212) to hold fan. See Fig. 5.
NOTE: Viscous fan has left-hand threads. CAUTION: Mark the direction of rotation of the accessory drive belt with chalk or felt pen before removing. A used belt can break if it rotates in the opposite direction when reinstalled.
Loosen accessory drive belt by using a 17 mm wrench to turn to the right until two holes are aligned. Hold in position with Mandrel (3204). Remove accessory drive belt. See Fig. 6. Unscrew bolts and remove center engine cover panel. Remove pressure hoses between charge air coolers and pressure pipes on left and right sides. See Fig. 7. Remove pressure pipes, noting installed position of retaining strips. Remove timing belt tensioner 1. Remove left and right timing belt guards 2 and center guard 3. See Fig. 8. Rotate crankshaft by hand to TDC. Ensure notch A is aligned with notch B. See Fig. 9. Check position of camshafts. Ensure that the larger holes in the securing plates on the camshaft sprockets must face one another on the inside. See Fig. 15. If this is not the case rotate crankshaft one revolution more.
54
Remove sealing plug from left side of cylinder block. The TDC mark in crankshaft must be visible (or be able to be felt) in line with sealing plug hole.
AUDI *2.7L V6 DOHC, S4 Quattro (Cont.)

NOTE: The center bolt does not have to be loosened to remove the vibration damper.
WARNING: DO NOT turn engine while feeling for TDC mark. Injury could result.
Screw Crankshaft Holding Tool (Audi 3242) into sealing plug and tighten. See Fig 10. Remove crankshaft vibration damper. See Fig. 11.
Remove idler wheel for accessory drive belt and timing belt guard behind vibration damper. See Fig. 12. Using a hex key, turn timing belt tensioner clockwise 8 mm in direction of arrow. See Fig. 13. Turn until tensioning lever compresses the oil-damped tensioner element enough to enable Pin (T40011) to be fitted through holes in tensioner housing and plunger. This will secure tensioner plunger in place. Remove timing belt. Installation: Insert Camshaft Locator Bar (3391) into securing plates of the two camshafts. See Fig. 15 . Loosen both camshaft bolts and unscrew approximately 5 turns. Remove Camshaft 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

Position timing belt over camshaft sprockets. See Fig. 16. With large holes in camshaft securing plates facing inboard, install Camshaft Locator Bar (3391) on camshafts. 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 installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS.
55
Fig. 10: Using Crankshaft Holding Tool
Fig. 8: Removing Accessory Drive Belt Tensioner
Fig. 11: Removing Vibration Damper
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bumper Combination Bolts ............................................ 17 (23) Camshaft Sprocket Bolt .............................................. 40 (55) Crankshaft Damper Center Bolt ........................... 1 147 (200) Crankshaft Pulley Bolt ................................................ 15 (20) Idler Wheel Bolt ............................................................ 33 (45) Impact Absorber Hex Bolts ............................................. 33 (45) Lock CarrierTo-Body Support (Hex) Bolts ........................................ 33 (45) INCH Lbs. (N.m) Bracket Combination Bolts ........................................... 14 (1.5) Lock CarrierTo-Fender Torx Bolts ................................................... 89 (10) Timing Belt Tensioner Bolt ......................................... 89 (10) 1Plus 190 degrees. Always use new bolt.
56
Fig. 12: Removing Timing Belt Guard
Fig. 15: Installing Camshaft Locator Bar
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 *2.7L V6 DOHC, A6 Quattro & Allroad

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.7L V6, Twin Turbo (APB) A6 Quattro 2000 ...................... 5.3 Hours .................. 250297 Allroad 2000 ...................... 5.2 Hours .................. 250297
57

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

TIMING BELT
CAUTION: Before removal, mark an arrow indicating direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation.
Fig. 2: Removing Front Bumper
Fig. 1: Removing Noise Insulator
Removal: Disconnect negative battery cable. Remove noise insulator. 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 sockethead 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 Support Tool (3369) into threaded hole. Remove bolts on left and right. See Figs. 3 and 4. Remove bolts and pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender flange. Secure lock carrier using bolts. See Fig. 5.
NOTE: Viscous fan has left-hand threads.
Fig. 3: Moving Lock Carrier To Service Position
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. Remove pressure hoses between charge air coolers and pressure pipes on left and right sides. See Fig. 8. Remove turbocharger pressure pipes. Remove accessory drive belt tensioner 1. Remove left and right timing belt guards 2 and center guard 3. See Fig. 9. Rotate crankshaft by hand to TDC. Ensure notch A is aligned with notch B. See Fig. 10. Check position of camshafts. 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 revolution more.
NOTE: Take note of the position of retaining strips.

Fig. 4: Inserting 3369 Support Tool
Fig. 5: Securing Lock Carrier
Fig. 7: Loosening Accessory Drive Belt
Fig. 6: Removing Viscous Fan

Fig. 8: Removing Pressure Hoses

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.
59
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 timing belt guard behind vibration damper. See Fig. 13. Using a hex key, turn timing belt tensioner clockwise 8 mm in direction of arrow. See Fig. 14. Turn until tensioning lever compresses the oil-damped tensioner element enough to enable Pin (T40011) to be fitted through the holes in the tensioner body and the plunger. This will secure plunger in position. Remove timing belt. Installation: Insert Camshaft Locator Bar (3391) into securing plates of the two camshafts. See Fig. 16 . Loosen both camshaft bolts and unscrew approximately 5 turns.
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. 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).
Fig. 15: Removing Camshaft Sprockets With Gear Puller
Reinstall both camshaft sprockets with securing plates and tighten hand tight. Position timing belt over camshaft sprockets. See Fig. 17. Install Camshaft Locator Bar (3391) on camshafts. Using hex key, turn timing belt tensioner clockwise 8 mm until pin can be removed from tensioner. See Fig. 14. 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.

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bumper Combination Bolts ............................................ 17 (23) Camshaft Pulley-To-Sprocket Bolt .............................. 40 (55) Crankshaft Damper Center Bolt 1 Step 1 ....................................................................... 147 (200) Step 2 ......................................................... Plus 180 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.
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62
AUDI *2.8L V6 12-Valve

Installation: Position timing belt over camshaft sprockets. See Fig. 2. Install camshaft holder. Position timing belt over all sprockets, then position over tensioner. Lightly tighten tensioner bolt (ensure tensioner can be rotated by hand). Tighten belt by rotating tensioner on bolt. Tighten belt until it can be twisted 90 degrees by hand at midway point between right camshaft sprocket and water pump pulley. Tighten tensioner bolt to specification. See TORQUE SPECIFICATIONS. Tighten camshaft sprocket bolts to specification. Remove Camshaft Holding Tool. Remove Crankshaft Holding Tool. Install Crankshaft Position (CKP) sensor. To install accessory drive belt, install mandrel. Position accessory drive belt over drive sprockets and idler roller, then over tensioner roller. Remove mandrel. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.8L V6 A4 1996-97 ................. 2.5 Hours .................. 250218 A4 Quattro 1996-97 ................. 2.5 Hours .................. 250218 A6 1995-97 ................. 2.5 Hours .................. 250218 A6 Quattro 1995-97 ................. 2.5 Hours .................. 250218 Cabriolet 1994-98 ................. 2.5 Hours .................. 250218 90 & 90 Quattro 1993-95 ................. 2.5 Hours .................. 250218 100 & 100 Quattro 1992-94 ................. 2.5 Hours ................. 250218

For 1997-98 model vehicles, manufacturer recommends belt be replaced at 90,00 miles. For 1996 and earlier model years, the manufacturer does not recommend a specific scheduled maintenance interval. However, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.
*NOTE: This is application is an interference engine. See page A-59 for interference engine cautions.

TIMING BELT
CAUTION: Before removal, mark an arrow indicating direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation. Fig. 1: Aligning Crankshaft Timing Marks
Removal: Disconnect negative battery cable. Remove accessory drive belt guard. Hold accessory drive belt in place with Mandrel (3204). Using a 15-mm wrench at accessory drive belt tensioner, slacken and remove accessory drive belt. Rotate crankshaft by hand until cylinder No. 3 is at TDC. Ensure notch A is aligned with notch B. See Fig. 1. Note locating plate on front end of each camshaft sprocket. If large hole in each plate does not face inward, toward center of engine, rotate crankshaft one revolution. 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 timing 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 *2.8L V6 12-Valve (Cont.)

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Bearing Cap Nut ........................................ 11 (15) Camshaft Sprocket Bolt .............................................. 52 (71) Crankshaft Damper Bolt ......................................... 295 (400) Timing Belt Tensioner Bolt ......................................... 33 (45) INCH Lbs. (N.m) Crankshaft Position Sensor (CKP) ............................. 96 (10) Valve Cover Bolt .................................................. 53-89 (6-10)
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Fig. 4: Using Camshaft Holding Tool
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AUDI *2.8L V6 30-Valve
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.8L V6, 30-Valve (AHA & ATQ Engines) A4 & A4 Quattro 1998-99 ................. 4.2 Hours .................. 250297 A6 & A6 Quattro, Non-Turbo 1998-00 ................. 4.6 Hours .................. 250297 A6 & A6 Quattro, Turbo 1998-00 ................. 5.2 Hours ................. 250297

The manufacturer suggests the belt be replaced at 90,000 mile intervals for 1997-98 models, 75,000 mile intervals for 1999 models, and 105,000 miles on 2000 models.

TIMING BELT
NOTE: Obtain radio anti-theft code before disconnecting battery.
Fig. 2: Exploded View Of A6 Bumper Assembly
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 intake duct from air cleaner housing. On right side of lock carrier, remove bolt and install Lock Carrier Support Tool (3369). See Figs. 3, 4 and 5. Remove lock carrier-to-body bolts. Carefully slide lock carrier forward on support tool. Hold cooling fan pulley with spanner wrench. Unscrew and remove viscous cooling fan clutch from pulley. Viscous cooling fan is LEFT-HAND threaded.

Fig. 1: Exploded View Of A4 Bumper Assembly
Use a 17 mm box wrench to turn serpentine belt tensioner counterclockwise to relieve belt tension and remove serpentine belt. If reusing belt, mark belt rotation direction with arrow for reassembly reference. Unclip timing belt guard on front of both camshafts and remove. Turn crankshaft in normal direction of rotation until TDC marks on crankshaft pulley and timing belt cover are aligned. See Fig. 6. Note securing plate on front end of each camshaft sprocket. If large hole in each plate does not face inward, toward center of engine, rotate crankshaft one revolution. See Fig. 7. Ensure crankshaft timing marks are still aligned. Remove sealing plug from left side of engine block. TDC mark on crankshaft must be visible or be felt through seal-
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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 tension. Tighten camshaft sprocket bolts to specification. See TORQUE SPECIFICATIONS. Remove camshaft locator bar. Remove crankshaft holder. Install sealing plug. To complete installation, reverse removal procedure. When installing crankshaft pulley, ensure notches in pulley are aligned with locating lugs in crankshaft. On A4, A6 and Quattro models, ensure lock carrier-to-body Torx bolts are correctly positioned. See Fig. 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 may result if belts are installed in opposite direction of rotation.
Remove crankshaft vibration damper from crankshaft. It is NOT necessary to remove center bolt. If center bolt is removed, manufacturer recommends using NEW bolt on reassembly. Remove serpentine belt idler pulley. Remove lower timing belt guard (if equipped). Remove timing belt.
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TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 40 (55) Crankshaft Pulley-To-Crankshaft Hex Bolt ..................... 15 (20) Crankshaft Pulley Center Bolt ................................... 1 148 (200) + 180 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) Lock Carrier-To-Body Torx bolts ...................................... 89 (10) Timing Belt Tensioner Bolt/Nut ................................... 89 (10) Water Pump Bolt ........................................................ 89 (10) 1 If removed, manufacturer recommends using NEW bolt.
Fig. 7: Locating Camshaft Sprocket Holes
Fig. 8: Installing Crankshaft Holding Tool
Fig. 11: Timing Belt Routing

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

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.6L V8 (PT Engine) V8 Quattro 1990-91 ................. 4.3 Hours .................. 250207 4.2L V8 (ABH Engine) V8 Quattro 1992-94 ................. 4.3 Hours ................. 250207
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The manufacturer recommends belt be replaced at 60,000 miles on 3.6L engines, and 90,000 miles on 4.2L engines. Replacement interval revision is from Audi technical service bulletin 93-02, September 1, 1993.

TIMING BELT
CAUTION: If serpentine or timing belt is being reused, mark belt with an arrow indicating direction of rotation. Damage may result if belts are installed in opposite direction of rotation.
Removal: Disconnect negative battery cable. Battery is under rear seat. Remove noise insulation panel from under front of vehicle. Remove coolant expansion tank cap. Drain coolant from radiator. Remove alternator cooling air duct. See Fig. 2. Loosen clip and disconnect coolant temperature sensor harness connector. Disconnect outer half of air duct at alternator. Remove screws securing wiring harness at alternator. Using 13 mm box wrench, turn serpentine belt tensioner clockwise to relieve tension. See Figs. 1 and 3. Remove alternator and set aside. Working from under vehicle, remove lower timing belt cover. In engine compartment, remove bolt securing intake air ducts. Remove left and right side intake air ducts. Remove upper part of air cleaner housing and air filter. Remove bolts securing lower part of air cleaner housing. Lift out lower part of air cleaner housing. Remove upper radiator hose. Remove electric cooling fan bolts. See Fig. 4. Remove electric cooling fan. Remove serpentine belt. Remove lower radiator hose from thermostat housing. Move lower radiator hose to right at rear. Remove viscous fan shroud. Remove bolts securing viscous fan to pulley and remove fan. Disconnect fan shrouds for viscous fan and electric fan. Hold viscous cooling fan mount with a spanner wrench. Loosen viscous cooling fan by turning clockwise. Viscous cooling fan is LEFT-HAND threaded. See Fig. 5. Lift out fan and shroud.
Fig. 1: Exploded View Of Serpentine Belt Assembly
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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 Setting 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 secondary wires at ignition coils. Remove both ignition distributor 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 3.6L & 4.2L V8 1990-94 (Cont.)
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Fig. 7: Removing Left Side Timing Belt Cover
Fig. 9: Positioning Serpentine Belt Tension
Fig. 8: Exploded View Of Timing Belt Assembly
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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)
Courtesy of Audi of America, Inc. Courtesy of Audi of America, Inc.
Fig. 15: Positioning Adjusting Tool (3204) Into Stop Plate (3.6L Engine)
Ensure distributor rotor points to mark on distributor housing. If not, turn crankshaft one more revolution. See Fig. 11. Remove both distributors. For 3.6L engine, loosen stop plate at timing belt tensioner. See Fig. 12. On 3.6L and 4.2L engines, loosen center bolt on tensioner pulley with eccentric center (right side of engine block). See Fig. 13. Remove timing belt damper top bolt. Remove timing belt tensioner pulley with eccentric center. Fit Locating Flange (3199) at end of each camshaft. Locating pin on distributor flange should fit in slot in locating
flange. See Fig. 14. Secure locating flange with distributor mounting bolts. Using spanner wrench, hold camshaft sprocket. Loosen camshaft sprocket bolts about 2 turns. DO NOT use Locating Flange (3199) to hold camshaft while loosening sprocket bolt. Using a plastic hammer, LIGHTLY tap edge of camshaft sprockets until camshaft sprockets are loose. Remove camshaft sprocket Woodruff keys.
AUDI 3.6L & 4.2L V8 1990-94 (Cont.)
71
Fig. 16: Rotate Tensioner Lever In Direction Of Arrow
Fig. 17: Setting Timing Belt Damper Length
Position timing belt in position over idler pulleys, water pump pulley and camshaft sprockets. Install tensioner pulley with eccentric center. Leave center nut loose so that eccentric can be turned. Fully tighten 4 crankshaft pulley bolts to specification. See TORQUE SPECIFICATIONS. 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 eccentric until damper length is at specified dimension. See Fig. 17. Tighten tensioner pulley center nut to specification. See TORQUE SPECIFICATIONS table. Holding camshaft sprockets in place, tighten camshaft sprocket center bolts to specification. Remove camshaft Locating Flanges (3199). Turn crankshaft at least 2 turns. Tighten crankshaft pulley center bolt to specification. Ensure timing belt damper length is still correct. Readjust, if necessary. On 3.6L engine, tighten stop plate mounting bolt to specifcation. See TORQUE SPECIFICATIONS table. Remove Adjusting Tool (3204). On 3.6L and 4.2L engines, complete installation reverse removal procedure. When refilling cooling system, manufacturer 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 engine off. Set A/C controls to high. Open radiator expansion tank. Fill with coolant while squeezing upper hoses to allow trapped air to escape. Install expansion tank cap. Start and run engine between 2000-3000 RPM until warm. With A/C still on high, raise engine RPM to 4000-5000 RPM several times. Coolant temperature gauge must read just under 212F (100C). Turn off ignition. After about 5-10 minutes, carefully open expansion tank cap. Top off coolant level to MAX mark. Restart engine and repeat topping off procedure. Adjust drive belts to proper tension. See page A-60 for belt tension information. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Bottom Mount Bolt .......................................... 18 (25) Alternator Top Mounting Bolt ........................................... 33 (45) Camshaft Sprocket Bolt .............................................. 33 (45) Crankshaft Pulley Center Bolt ................................. 1 332 (450) Crankshaft Pulley-To-Sprocket Bolts .............................. 18 (25) Engine Front Support Mount Bolt .................................... 30 (40) Serpentine Belt Idler Pulley Bolt ..................................... 18 (25) Timing Belt Adjustment Damper Bolts ........................... 18 (25) Timing Belt Damper Mount Bolt ..................................... 18 (25) Timing Belt Idler Pulley Bolt ............................................ 18 (25) Timing Belt Tensioner Nut .......................................... 18 (25) INCH Lbs. (N.m) Fan Shroud Bolts ........................................................... 89 (10) Stop Plate Mounting Bolt (3.6L) ..................................... 89 (10) Timing Belt Cover Flanged Nut ...................................... 89 (10) Water Pump Bolts ...................................................... 89 (10) 1 - Installwith thread locking sealant AMV 18800102.
Remove 4 bolts fastening crankshaft pulley to crankshaft sprocket. Remove crankshaft center bolt and remove crankshaft pulley. It is not necessary to remove sprocket from crankshaft. Remove timing belt. Inspection: Inspect tensioner and idler pulley for ease of rotation and rough bearings. Replace as necessary. Installation: Ensure crankshaft is still at TDC position. Place timing belt over crankshaft sprocket. Install crankshaft pulley on crankshaft. Install 4 bolts that hold crankshaft pulley to sprocket. Hand tighten temporarily. Apply locking sealant (AMV 188 0012), or equivalent, to crankshaft center bolt threads. Install crankshaft pulley center bolt and hand tighten temporarily. Loosen camshaft sprocket center bolts by about 1 turn. Camshaft sprocket should still be loose on camshaft. Install Vibration Damper Locking Tool (3211). If there is no hole to accept Vibration Damper Locking Tool, ensure TDC mark on vibration damper is aligned with pointer before and after tightening camshaft sprockets.
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AUDI *3.7L & 4.2L V8 1997-99

Removal: Disconnect negative battery cable. Remove noise insulation panel from under front of vehicle. Remove air intake grille from front of bumper. Drain coolant from radiator. Using box wrench, turn serpentine belt tensioner clockwise to relieve tension. Remove serpentine belt. See Fig. 1. Remove engine top trim cover. Remove coolant hose retaining clamp on right side upper timing belt cover. Remove air intake duct between air cleaner and throttle body. Disconnect fan shrouds for viscous fan and electric fan. Hold viscous cooling fan pulley with a spanner wrench. Remove viscous fan by turning clockwise. Viscous fan is LEFT-HAND threaded. See Fig. 2. Remove right front engine mount. See Fig. 3. Remove coolant hoses at front of engine. Rotate crankshaft to TDC of compression stroke. Ensure TDC mark on crankshaft pulley aligns with mark on timing belt cover. See Fig. 4.
CAUTION: Manufacturer recommends that crankshaft pulley center bolt be REPLACED whenever the bolt is loosened or removed.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.7L V8 (AEW Engine) A8 1997-99 ................. 4.3 Hours .................. 250207 4.2L V8 (ABZ Engine) A8 Quattro 1997-99 ................. 4.3 Hours ................. 250207

For 1997 and 1998 model vehicles, manufacturer recommends belt be replaced at 90,000 miles. For 1999 model year, the manufacturer recommends the belt be replaced at 75,000 miles.
*NOTE: This is an interference engine. See page A-59 for interference engine cautions.

TIMING BELT
CAUTION: If serpentine or timing belt are being reused, mark belt with an arrow indicating direction of rotation. Damage may result if belts are installed in opposite direction of rotation.
Holding crankshaft pulley with Crankshaft Pulley Holder (3197), loosen center bolt about 1 turn. See Fig. 5. Remove camshaft position sensor at housing at rear of left cylinder head. See Fig. 6. If camshaft sensor is NOT positioned behind sensor plate window, rotate crankshaft 1 full revolution. Remove camshaft flange at rear of right side cylinder head.
Fig. 1: Exploded View Of Serpentine Belt Assembly
AUDI *3.7L & 4.2L V8 1997-99 (Cont.)

Disconnect harness connector from switch for intake manifold change-over valve. Remove timing belt guard. Unclip cap at guide pulley for serpentine belt at right side timing belt guard. Remove top of air cleaner housing. Remove right side timing belt guard mounting bolts. Carefully lift right side timing belt guard up and out. Holding camshaft sprocket with Sprocket Holder (3036), loosen camshaft sprocket bolts. See Fig. 7. Remove camshaft position sensor plate and housing. See Fig. 6. Install Camshaft Locking Device (3341) at rear of each cylinder head. If necessary, rotate camshaft to allow locking device to engage. See Fig. 8. Camshafts can be rotated by removing the valve cover and using the hex machined into the front end of the camshaft.
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CAUTION: The Camshaft Locking Devices (3341) are NOT to be used to hold camshafts in place when loosening or tightening the camshaft sprocket bolts.
Fig. 4: Aligning Crankshaft Pulley TDC Marks
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. 6: Camshaft Position Sensor & Housing
Fig. 3: Removing Right Front Engine Mount
Fig. 7: Loosening Camshaft Sprocket Bolts
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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 *3.7L & 4.2L V8 1997-99 (Cont.)
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Remove 4 bolts fastening crankshaft pulley to crankshaft sprocket. Remove crankshaft center bolt and remove crankshaft pulley. It is not necessary to remove sprocket from crankshaft. Remove timing belt. 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 pulley center bolt be REPLACED whenever the bolt is loosened or removed. Lightly oil threads and contact surfaces of NEW center bolt. Using locking compound AMV 00102, or equivalent, install crankshaft pulley center bolt and hand tighten temporarily. Loosen camshaft sprocket center bolts by about 1 turn. Camshaft sprocket should still be loose on camshaft tapers. Position timing belt in position over idler pulleys, water pump pulley and camshaft sprockets. See Fig. 9. Push timing belt over tensioner pulley. Tighten tensioner pulley center nut hand tight. Eccentric insert should still be able to turn. Tighten 4 crankshaft pulley-to-crankshaft sprocket mounting nuts. See TORQUE SPECIFICATIONS. To set basic timing belt tension, turn tensioner pulley eccentric insert clockwise. Use a spanner wrench inserted into the 2 holes in the eccentric insert. Adjust position of timing belt tensioner until damper length is within specified range. See Fig. 11. Tighten timing belt tensioner center nut to specification. See TORQUE SPECIFICATIONS. Holding camshaft sprockets in place, tighten camshaft sprocket center bolts to specification. Remove Camshaft Locking Device (3341) from rear of each camshaft. Install housing behind camshaft position sensor and tighten bolts to specification. Camshaft position sensor plate MUST engage in camshaft with catch. Turn crankshaft at least 2 revolutions in normal direction of rotation. Tighten crankshaft center bolt to specification. Check timing belt damper length. Readjust timing belt tension, if necessary. To complete installation, reverse removal procedure. When refilling cooling system, use Audi coolant additive G12-A8D TL 774D (Red color). Use 50/50 mix of coolant and water. Before filling cooling system, open vent screws at heater core feed and return lines (rear of engine). Remove cap from radiator expansion tank. Add coolant until it flows from vent valves. Close vent valves. Install cap on radiator expansion tank. Disconnect 2-pin electrical connector from coolant pump unit. Coolant pump unit is located in left rear corner of engine compartment, near power brake booster.
Fig. 11: Adjusting Timing Belt Damper Length
Set A/C controls to LO position. Start engine and run at about 2000 RPM for about 3 minutes. Check coolant level in radiator expansion tank. Refill to MAX level, if necessary. Turn off ignition. Reconnect coolant pump 2-pin connector. Set A/C controls to HI position, and blower motor to lowest setting. Start and run engine at 2000-3000 RPM for about 10 minutes. Turn off ignition. Turn ignition on, with engine off. With ignition on, and A/C controls set to HI, coolant pump must NOT make any noise. Noise indicates that air is trapped in system and bleed procedure needs to be repeated. If there are no unusual noises from coolant pump, turn off ignition. Refill radiator expansion tank. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Position Sensor Housing Bolt ................... 15 (20) Camshaft Sprocket Bolt .............................................. 41 (55) Crankshaft Pulley Center Bolt ................................. 1 332 (450) Crankshaft Pulley-To-Sprocket Bolts .............................. 18 (25) Serpentine Belt Idler Pulley Bolt ..................................... 18 (25) Timing Belt Adjustment Damper Bolts ........................... 18 (25) Timing Belt Idler Pulley Bolt ............................................ 18 (25) Timing Belt Tensioner Nut .......................................... 18 (25) INCH Lbs. (N.m) Timing Belt Cover Flanged Nut ...................................... 89 (10) Water Pump Bolts ...................................................... 89 (10) 1 - Use NEW bolt if loosened or removed. Oil threads. Install with thread locking compound AMV 00102, or equivalent.
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AUDI *4.2L V8 2000
TIMING BELT APPLICATION Application Labor Time Belt Part No. 4.2L V8 (AKB, AUX & AYS Engines) A8 Quattro 2000 ...................... 4.3 Hours ................. 250297

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

TIMING BELT
CAUTION: If serpentine or timing belt are being reused, mark belt with an arrow indicating direction of rotation. Damage may result if belts are installed in opposite direction of rotation.
Removal: Remove trim cover at front of engine compartment. Remove air intake duct for air cleaner. Remove engine top trim cover and cylinder head trim covers. Disengage spring clips at timing belt covers. Remove timing belt covers. Remove noise insulation panel from under front of vehicle. Using box wrench, turn serpentine belt tensioner clockwise 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. Viscous fan is LEFT-HAND threaded. See Fig. 1. Rotate crankshaft to TDC of compression stroke. Ensure TDC mark on crankshaft pulley aligns with mark on engine. See Fig. 2. Check position of camshafts. Larger hole in camshaft sprocket securing plates must face inboard and align with each other. See Fig. 3.
Fig. 3: Aligning Camshaft Sprocket Securing Plate Holes
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 necessary to remove center bolt. Remove crankshaft pulley.
AUDI *4.2L V8 2000 (Cont.)
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Fig. 5: Viscous Cooling Fan Mounting Bracket
Fig. 7: Installing Camshaft Bar (T40005)
Fig. 6: Relieving Timing Belt Tension CAUTION: Manufacturer recommends REPLACING crankshaft pulley center bolt if it has been loosened or removed.
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 sprockets 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 hydraulic tensioner piston. Set initial timing belt tension using Tensioning Key (T40009), Socket Attachment (5122) and Torque Wrench (1410). See Fig. 9. Set tension to 35 INCH lbs. (4 N.m). While holding tensioner at this point, tighten center nut to 16 ft. lbs. (22 N.m). Remove 5 mm drill bit. Using 8 mm hex wrench, rotate timing belt tensioning lever counterclockwise until Spring Pin (T40011) can be removed from hydraulic tensioner. Rotate timing belt tensioner lever CLOCKWISE until a 7 mm drill bit can be inserted between the tip of the tensioning lever and the top of the hydraulic tensioner body. Tighten camshaft sprocket bolts to specification. See TORQUE SPECIFICATIONS. Keep Camshaft Bar (T40005) in place to prevent camshafts from moving.
Remove bracket for viscous cooling fan. See Fig. 5. Using 8 mm hex wrench, SLOWLY compress hydraulic timing belt tensioner by turning tensioning lever counterclockwise. 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 eccentric 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 (passenger 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 Crankshaft Clamping Bolt (3242) from side of engine block. Install sealing plug in hole. Turn crankshaft 2 revolutions in normal direction of rotation. Measure distance between tensioning lever and top of hydraulic tensioner body. Dimension should be .197 (5 mm). See Fig. 8. If dimension is not correct, readjust timing belt tension until dimension is .197 (5 mm). Measure clearance between bottom of right hand timing belt guard and top of timing belt. See Fig. 10. If clearance is not correct, turn crankshaft until all rear timing belt cover bolts are exposed. Loosen bolts and adjust clearance to .0393 (1 mm). Tighten rear timing belt cover bolts. Measure clearance between bottom of left hand timing belt guard and top of timing belt. See Fig. 11. If clearance is not correct, turn crankshaft until all rear timing belt cover bolts are exposed. Loosen bolts and adjust clearance to .0393 (1 mm). Tighten rear timing belt cover bolts. Install crankshaft pulley. Tighten all bolts to specification. To complete installation reverse removal procedure. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 41 (55) 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.
Fig. 11: Measuring Timing Belt-To-Guard Clearance (Left-Side Cylinder Head)
AUDI & VOLKSWAGEN 2.1L & 2.2L 5-Cylinder, 1978-91

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.1L 5-Cyl. Quantum 1984-85 .70 Belt T.W. ....... 1.8 Hours .................. 250127 .75 Belt T.W. ....... 1.8 Hours .................. 250065 2.2L 5-Cyl. Coupe 1981-83 ................ 2.2 Hours .................. 250065 1984-85 120 Tooth Belt .... 2.2 Hours .................. 250127 113 Tooth Belt ..... 2.2 Hours .................. 250065 1986-87 .................. 2.2 Hours .................. 250127 Quantum 1983-86 .70 Belt T.W. ....... 1.8 Hours .................. 250127 .75 Belt T.W. ....... 1.8 Hours .................. 250065 1987-88 .................. 1.8 Hours .................. 250127 Quattro 1983 ....................... 1.1 Hours .................. 250065 1984-85 120 Tooth Belt .... 2.2 Hours .................. 250127 113 Tooth Belt ..... 2.2 Hours .................. 250065 200 1989 (Thru Chassis No. 44 K 400 000) ....... 2.5 Hours .................. 250127 (From Chassis No. 44 K 400 001) ....... 2.5 Hours .................. 250170 1990-91 ................ 2.5 Hours .................. 250170 200 Quattro 1989 (Thru Chassis No. 44 K 004 457) ....... 2.5 Hours .................. 250127 (From Chassis No. 44 K 004 458) ....... 2.5 Hours .................. 250170 1990-91 .................. 2.5 Hours .................. 250170 4000 1980-81 .................. 1.8 Hours .................. 250065 4000CS 1986-87 .................. 1.8 Hours .................. 250127 4000CS Quattro 1987 ....................... 1.8 Hours .................. 250127 4000S Quattro 1984-85 120 Tooth Belt .... 1.8 Hours .................. 250127 113 Tooth Belt ..... 1.8 Hours .................. 250065 1986 ....................... 1.8 Hours .................. 250127 5000 1978-83 .................. 1.1 Hours .................. 250065 5000CS Quattro 1987-88 .................. 2.2 Hours .................. 250127 5000S 1984-85 120 Tooth Belt .... 1.8 Hours .................. 250127 113 Tooth Belt ..... 1.8 Hours .................. 250065 1986-87 ................. 1.8 Hours ................. 250127
79


TIMING BELT
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. See Fig. 1. 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. Installation: Ensure both camshaft lobes on No. 1 cylinder point upward. Mark (notch or dot) on back of camshaft sprocket must be aligned with top of valve cover gasket or rear timing belt cover. Crankshaft must be at TDC for No. 1 cylinder. Flywheel TDC mark must be aligned with index point on transmission housing. Install water pump with new sealing O ring. Install timing belt. Turn water pump body counterclockwise to increase belt tension. Tension is correct when belt can be twisted 90 degrees using finger pressure at point midway between camshaft sprocket and water pump sprocket. Recheck valve timing. Reverse installation order of removal. Adjust drive belts.See page A-60 for belt tension ranges. NOTE: Turn engine by hand using hex flange on hydraulic pump. Loosen tensioner bolts. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 59 (80) Timing Belt Idler Pulley Bolt .......................................... 15 (20) Timing Belt Tensioner (1992-95) ................................ 15 (20) Vibration Damper Bolt ............................................ 258 (350) Water Pump Bolt ........................................................ 15 (20) INCH Lbs. (N.m) Radiator Mounting Bolts ............................................. 89 (10) Timing Belt Cover ....................................................... 89 (10) Valve Cover Nuts/Bolts ............................................... 89 (10)
80
AUDI & VOLKSWAGEN 2.1L & 2.2L 5-Cylinder, 1978-91 (Cont.)
96I14520
Fig. 1: Exploded View Of Timing Belt, Sprockets & Covers
96E14641
Fig. 2: Aligning Camshaft Sprocket
92A00398
BMW *2.5L & *2.7L 6-Cylinder

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L 6-Cyl. 325 Series 1987-88 127 Tooth Belt ... 3.2 Hours .................. 250131 128 Tooth Belt ... 3.2 Hours .................. 250106 1989-91 ................. 3.2 Hours .................. 250131 525i 1989-95 ................. 3.2 Hours .................. 250131 2.7L 6-Cyl. 325 Series 1984-88 127 Tooth Belt ... 3.2 Hours .................. 250131 128 Tooth Belt ... 3.2 Hours .................. 250106 528e 1982-88 127 Tooth Belt ... 3.2 Hours .................. 250131 128 Tooth Belt ... 3.2 Hours ................. 250106
NOTE: Use 127 tooth belt with retrofit tensioner pulley. Use 128 tooth belt with with OEM tensioner pulley. DO NOT use 128 tooth belt on new style adjusting pulley.
81
Remove front cover. Loosen timing belt tensioner mounting bolts and press in on tension roller. Tighten upper mounting bolt to hold tensioner in place. Remove timing belt. Installation: Ensure arrow on camshaft sprocket is still aligned with timing mark on cylinder head. Ensure timing mark on crankshaft sprocket is aligned with notch in cover (about one oclock position). See Fig. 1. Install timing belt on sprockets. Loosen tensioner adjusting bolt to allow spring tension on timing belt. Turn crankshaft in direction of normal rotation until timing belt tightens. Tighten tensioner bolt. Clean gasket mating surfaces. Coat oil pan-to-cover gasket with gasket sealer. Install Centering Tool (11 2 211) on crankshaft and on intermediate shaft to align front cover. Using new gasket, install and tighten timing belt cover. When installing crankshaft sprocket, lettering must face forward. Install remaining components in reverse order of removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TIGHTENING SPECIFICATIONS Application Ft. Lb.s. (N.m) Camshaft Sprocket ........................................... 47-50 (65-70) Intermediate Shaft Sprocket ............................. 40-47 (55-64) Vibration Damper Hub .............................. 283-311 (390-430)

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 electrical 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 crankshaft. Remove distributor cap and rotor. Remove cover from distributor housing. Ensure cylinder No. 1 is set to TDC on compression stroke. See Fig. 1. Remove alternator tension bracket and move aside.
Fig. 1: Aligning Timing Sprockets
82
BMW *2.5L & *2.7L 6-Cylinder (Cont.)
Fig. 2: Exploded View Of Camshaft Drive Assembly
CHRYSLER *1.4L 4-Cylinder

TIMING BELT APPLICATION Labor Time Belt Part No. Application 1.4L 4-Cyl. Colt 1979-84 ................. 1.1 Hours .................. 250073 Champ 1979-82 ................. 1.1 Hours .................. 250073 1 - With Air Cond. add .2 hours.
1
83

Slowly turn crankshaft one revolution clockwise and realign crankshaft sprocket timing mark at TDC. Do not push or shake belt while turning or turn crankshaft in counterclockwise direction. Loosen tensioner spring bolt first then slotted adjustment hole bolt. Tighten tensioner bolts by tightening slotted adjustment hole bolt first and tensioner spring bolt last. Check belt tension by pushing tension side of timing belt in horizontally using about 11 lbs. (5 kg) force. Timing belt tooth end should be approximately 1/4 of tensioner mounting bolt head width (across flats) away from bolt head center. See Fig. 3. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ........................................... 47-54 (64-73) Crankshaft Sprocket Bolt .................................. 37-43 (50-58) Timing Chain Tensioner ................................... 15-18 (20-24) INCH Lbs. (N.m) Crankshaft Pulley Bolt .................................... 90-102 (10-11) Oil Pump Cover ................................................ 72-108 (8-10)

TIMING BELT
Removal: Disconnect negative battery cable. On front wheel drive models, remove air cleaner assembly, then disconnect accelerator cable and oxygen sensor lead. On all models, mark position of spark plug wires for installation, then remove wires from spark plugs. On front wheel drive models, support engine using a suitable engine support bar. Remove left engine mount bracket. Remove fan, spacer, water pump pulley and drive belt. Remove rocker arm cover and timing belt cover. Move timing belt tensioner upward toward water pump and secure. Remove timing belt from camshaft sprocket. Mark belt with an arrow indicating direction of rotation for installation reference, and remove timing belt. Installation: Align camshaft and crankshaft sprockets. Mount belt tensioner, spring, spacer and temporarily tighten bolt. Position spring against tensioner first, then against case and tighten bolt. See Fig. 2. Position and secure tensioner toward water pump. Install timing belt on crankshaft and camshaft sprockets. Ensure tension side is tight and timing marks are aligned when pressure is applied to turn camshaft in reverse direction. Align dowel and install crankshaft pulley. Loosen tensioner bolt. Ensure proper mesh of belt and sprocket. With only spring tension applied to belt, tighten tensioner spring bolt first and slotted adjustment hole bolt last.
Fig. 1: Removing/Installing Timing Belt
84
CHRYSLER *1.4L 4-Cylinder (Cont.)
Fig. 3: Checking Timing Belt Tension Fig. 2: Installing Timing Belt Tensioner
CHRYSLER 1.6L 4-Cylinder With Balance Shaft

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC Arrow & Sapporo 1977-80 ................ 1 1.7 Hours .............. 2 250013 1977-80 ................ 1 1.7 Hours .............. 3 250062 Challenger 1978-79 ................ 1 1.7 Hours .............. 2 250013 1978-79 ................ 1 1.7 Hours .............. 3 250062 Champ 1979-80 ................ 1 1.7 Hours ............... 2 250013 1979-80 ................ 1 1.7 Hours ............... 3 250062 Colt 1977-80 ................ 1 1.7 Hours ............... 2 250013 1977-80 ................ 1 1.7 Hours ............... 3 250062 1 - Counterbalance shaft belt included in labor time. With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. 2 Camshaft timing belt. 3 Counterbalance shaft belt.
85

Fig. 1: Counterbalance & Timing Belt Routing

TIMING BELT
Removal: Disconnect negative battery cable. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley, upper and lower timing belt front covers. Loosen timing belt tensioner mounting nut and bolt. Move tensioner away from timing belt and temporarily tighten nut. Remove timing belt. See Fig. 1. Remove plug at bottom of left side of cylinder block. See Fig. 2. Insert a screwdriver to keep left counterbalance (silent) shaft in position. Screwdriver MUST insert at least 2.36 (59.9 mm). If not, turn oil pump sprocket (which drives left counterbalance shaft) one full turn until timing mark is aligned again. Keep screwdriver in place until timing belt is installed. Remove outer crankshaft sprocket and flange. Loosen center 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 eccentric in the center of the pulley is located to the left and above the bolt. See Fig. 4. Ensure pulley flange faces toward front of engine. While keeping tension on counterbalance shaft belt, tighten tensioner pulley bolt. DO NOT allow tensioner pulley to rotate while tightening center bolt. If camshaft timing belt tensioner was removed, install tensioner. Ensure tension spring is seated in correct position on water pump body. See Fig. 5. Secure tensioner away from timing belt.
Fig. 2: Installing Screwdriver To Hold Counterbalance (Silent) Shaft In Place
Fig. 3: Aligning Counterbalance Shaft Timing Marks
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.
Fig. 5: Positioning Camshaft Timing Belt Tensioner Spring
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 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ...................................... 44-57 (60-78) Crankshaft Sprocket Center Bolt ........................ 44-50 (60-68) Oil Pump Sprocket Bolt ....................................... 25-28 (34-39) Timing Belt Tensioner Mounting Bolt ................ 16-21 (22-29) Timing Belt Tensioner Mounting Nut ................ 16-21 (22-29) INCH Lbs. (N.m) Crankshaft Pulley Bolt ...................................... 90-102 (10-11)
Install outer crankshaft sprocket. Install camshaft timing belt first on crankshaft sprocket, then around the oil pump sprocket and camshaft sprocket. Keep slack out of belt during installation. Ensure crankshaft, camshaft and oil sprocket timing marks are still aligned. Remove screwdriver inserted in left side of engine block. Install plug. Temporarily install crankshaft pulley to prevent timing belt movement when crankshaft is turned. Loosen camshaft timing belt tensioner nut and bolt. Lightly push camshaft belt tensioner toward timing belt. Ensure timing belt fully meshes with all teeth on sprockets. Tighten camshaft timing belt tensioner mounting nut first,
CHRYSLER 1.6L 4-Cylinder Without Balance Shaft

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC, Without Balance Shaft Arrow & Sapporo 1978-80 ................ 1 1.6 Hours ............... 250064 Challenger & Colt (RWD) 1978-79 ................ 1 1.6 Hours ................. 250064 Champ 1979-82 ................. 2.8 Hours .................. 250064 Colt (FWD) 1979-82 ................ 1 2.8 Hours ................. 250064 1983-89 ................ 1 2.8 Hours ................. 250093 Vista (Canadian) 1989 ..................... 1 2.8 Hours ................. 250093 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
87

Ensure that all timing marks are still in alignment. See Fig. 1. If tensioner was removed, ensure spring is positioned correctly under water pump body. See Fig. 2. Secure tensioner out of way so that timing belt can be installed. Install timing belt on crankshaft sprocket, on oil pump sprocket and camshaft sprocket, in that order. Keep slack out of belt during installation. Ensure all timing marks are still aligned. Temporarily install crankshaft pulley. Loosen tensioner mounting bolt so that spring-loaded tensioner applies pressure to the timing belt. Lightly push tensioner up by hand to ensure timing belt completely meshes with drive sprockets. Tighten tensioner mounting nut, then tighten mounting bolt. See Fig. 3. Turn crankshaft one turn in normal direction of rotation. Do NOT turn in opposite direction. Loosen the timing belt tensioner mounting bolt and nut. This will take out any slack in belt. Tighten mounting nut to specifed torque. See TORQUE SPECIFICATIONS. Tighten timing belt tensioner bolt. To check timing belt tension, grasp belt between thumb and forefinger near timing belt tensioner. See Fig. 4. Tension is correct when distance between back of belt and edge of rear timing case cover is .47" (12 mm) with finger pressure. Readjust tension, if necessary.

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 crankshaft pulley, upper and lower timing belt front covers. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 1. Loosen belt tensioner mounting nut and bolt. Move tensioner away from belt and temporarily tighten nut. Remove timing belt. See Fig. 1. Installation:
Fig. 2: Installing Timing Belt Tensioner
Fig. 3: Adjusting Timing Belt Tension 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Timing Belt Tensioner Nut/Bolt ......................... 16-21 (22-29) INCH Lbs. (N.m) Crankshaft Pulley Bolt ...................................... 90-102 (10-11)
Fig. 4: Checking Timing Belt Tension
CHRYSLER 1.7L 4-Cylinder

TIMING BELT APPLICATION Labor Component Kit No. Application Time1 1.7L 4-Cyl. Charger 1983 ............... 3.1 Hours ... 2520710 ........ 250017 Horizon 1978-83 .......... 3.1 Hours ... 2520710 ........ 250017 Omni 1978-83 .......... 3.1 Hours ... 2520710 ........ 250017 TC3 1981-82 .......... 3.1 Hours ... 2520710 ........ 250017 Turismo 1983 ............... 3.1 Hours ... 2520710 ........ 250017 024 1981-82 .......... 3.1 Hours ... 2520710 ........ 250017 1 - With Air Cond. add .2 hours. With Air Pump add .2 hours. With Pwr. Strng. add .2 hours Belt Part No.
89
NOTE: Do not turn engine by turning camshaft pulley. This will cause belt to skip teeth.
Turn engine clockwise from TDC 2 complete crankshaft revolutions to TDC. Tighten tensioner lock nut while holding belt tensioner wrench in position. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.

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 sprockets. See Fig. 2. Turn camshaft sprocket until timing mark on sprocket is lined up with camshaft cover sealing surface. See Fig. 3. Install timing belt and Belt Tensioner Tool (L-4502 or equivalent) horizontally on large hex of belt tensioner pulley and loosen tensioner lock nut. See Fig. 4. If necessary, reset belt tensioner tool to have axis within 15 of horizontal.
Fig. 2: Crankshaft & Intermediate Sprocket Timing Marks
90
CHRYSLER 1.7L 4-Cylinder (Cont.)
Fig. 3: Camshaft Timing Mark
TORQUE SPECIFICATIONS Application Ft. Lbs (N.m) Camshaft Sprocket Bolt .............................................. 58 (80) Crankshaft Sprocket Bolt ............................................ 58 (80) Intermediate Shaft Retainer Bolt ................................. 18 (29) Intermediate Shaft Sprocket Bolt ................................. 58 (80) Timing Belt Cover Screw ............................................... 8 (11) Water Pump Bolts ...................................................... 30 (41)
Fig. 4: Tensioning Timing Belt
CHRYSLER 1.8L 4-Cylinder VIN T

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.8L 4-Cyl. Colt & Colt Wagon 1989-90 ................. 2.4 Hours ................. 250093 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
1
91


TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine).
Removal: Disconnect negative battery cable. Remove protective cover below engine. Support engine and remove engine mount from timing belt end of engine. Remove spark plug wires and rocker cover. Remove drive belts and water pump pulley. Remove A/C belt tensioner (if equipped). Remove crankshaft pulley assembly. Remove upper front and lower timing belt covers. Note bolt lengths and locations. Rotate engine clockwise (as viewed from timing belt end of engine) to align timing mark on camshaft sprocket with mark on upper rear cover. See Fig. 1. If reusing belt, mark timing belt position on camshaft sprocket and indicate direction of belt rotation. Loosen timing belt tensioner bolt and nut. Move timing belt tensioner toward water pump to release tension and tighten nut temporarily to maintain tensioner position. See Fig. 2. Remove timing belt.
Inspection: Check belt teeth for cracks, damage or oil contamination. Inspect all sprockets for damage. Check belt tensioner for signs of grease leakage or roughness in tensioner rotation. Replace components if damaged. Installation: Rotate tensioner toward water pump and temporarily tighten retaining nut. See Fig. 2. Ensure camshaft and crankshaft timing marks are aligned. See Fig. 1. Apply pressure on tension side of belt and install timing belt on oil pump sprocket and then on crankshaft sprocket. Apply force on camshaft sprocket, in counterclockwise direction, to apply tension on tension side of belt. Ensure all timing marks are aligned. Loosen belt tensioner bolt, then loosen nut to place tension on timing belt. Rotate camshaft sprocket clockwise until timing mark is offset by 2 teeth to apply tension on belt. Ensure all timing marks are aligned. Tighten tensioner nut, then tighten bolt. Check belt tension by applying slight thumb pressure to timing belt in direction of timing belt lower rear cover. See Fig. 3. Ensure distance between back of timing belt (smooth side) and timing belt lower rear cover is approximately .23" (6 mm). To complete installation, reverse removal procedure. Adjust accessory drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt ...................................... 11-13 (15-18) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Damper Pulley Bolt ........................................... 11-13 (15-18) Engine Support Bracket Bolt ............................. 22-30 (30-41) Front Cover Bolt ................................................ 11-13 (15-18) Tensioner Pulley Bracket Bolt ........................... 17-20 (23-27) Water Pump Bolt 8 X 70 mm ...................................................... 15-19 (20-26) All Others .................................................................. 10 (14) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Valve Cover Bolt .................................................... 48-60 (5-7) Water Pump Pulley Bolt ........................................ 72-84 (8-9)
Fig. 1: Aligning Timing Mark & Arranging Belt
Fig. 2: Positioning Timing Belt Tensioner
92
CHRYSLER 1.8L 4-Cylinder VIN T (Cont)
91G00816
Courtesy of Chrysler Corp.
CHRYSLER *2.0L 4-Cylinder SOHC, VIN C

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. SOHC Breeze 1996-00 ................ 1 2.4 Hours ................. 250245 Cirrus 2000 ..................... 1 2.4 Hours ................. 250245 Neon 1995-00 ................ 1 2.4 Hours ................. 250245 Stratus 1995-00 ................ 1 2.4 Hours ................. 250245 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
Timing Belt Tensioner Bracket Precaution:
93
NOTE: The following revised information regarding the tensioner pulley pivot bolt is from Chrysler technical service bulletin 0906-96; March 29, 1996.
On models with hydraulic timig belt tensioner, do not loosen, tighten, or remove timing belt tensioner pivot bolt. Bolt is installed at factory with special threadlocking compound that is not reusable. If tensioner pivot bolt is disturbed, entire bracket assembly must be replaced. The tensioner pulley center bolt MAY be removed and installed.

On Neon models, the manufacturer recommends the belt be replaced at 105,000 mile intervals. On Breeze, Cirrus and Stratus models, the manufacturer recommends the belt be replaced at 100,000 mile intervals on vehicles with Federal emissions, and 105,000 mile intervals with California emissions.
Oil Pump Body

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 access plug from top of timing belt cover. See Fig. 1. Ensure timing mark on camshaft aligns with mark on rear cover. See Fig. 2. Disconnect negative battery cable. Remove accessory drive 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 Stratus, remove generator (with wiring attached) and bracket, and secure out of way. On Neon, remove power steering pump with hoses attached, and secure out of way. Remove upper and lower engine torque struts (2001-00 Neon). On all models, remove right engine mount bracket from engine. See Fig. 3. Remove front timing belt cover. See Fig. 1. Rotate crankshaft so that timing marks are aligned. See Fig. 2. Loosen timing belt tensioner bolts. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Remove timing belt and tensioner. DO NOT loosen, tighten, or remove tensioner pulley pivot bolt.
CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt. NOTE: When tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Index tensioner in vise the same way it is installed on engine to ensure proper pin orientation when tensioner is installed on engine.
Courtesy of DaimlerChrysler
Fig. 2: Aligning Timing Marks & Adjusting Belt Tension (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 locking 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 before TDC. Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. See Fig. 2. Move crankshaft to 1/2 notch mark before TDC for belt installation. See Fig. 5. Install timing belt by starting at crankshaft, then around water pump sprocket and then camshaft sprocket. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block, but do not final tighten bolts. Using a torque wrench on tensioner pulley, apply 21 ft. lbs. (28 N. m) of torque in clockwise direction. With torque applied to tensioner pulley, move the tensioner up against the tensioner pulley bracket. Final tighten tensioner bolts. See Fig. 1. Pull tensioner plunger locking pin. Pretension is correct when pin can be removed and installed. Rotate crankshaft 2 revolutions. Check alignment of the timing marks. Install front timing belt cover. Install engine mount bracket. Install generator and bracket (Breeze and Stratus) or power steering pump (Neon).
96D14483
Fig. 3: Locating Right Engine Mount Bracket (Typical)
96I14488
Fig. 4: Compressing Hydraulic Timing Belt Tensioner
Courtesy of DaimlerChrysler Courtesy of DaimlerChrysler
Fig. 5: Aligning Crankshaft Sprocket Timing Marks
Fig. 6: Aligning Timing Marks & Adjusting Belt Tension (Mechanical Timing Belt Tensioner)
CHRYSLER *2.0L 4-Cylinder SOHC, VIN C (Cont.)

Install right engine mount. Remove jack from under engine. Install crankshaft damper and tighten bolt to specification. See TORQUE SPECIFICATIONS. Raise vehicle on hoist. Install right inner splash shield. Lower vehicle. Install accessory drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. On Neon models, connect scan tool to Data Link Connector (DLC) under lower left edge of instrument panel. Follow scan tool manufacturers instructions to access the cam/ crank relearn procedure. Perform cam/crank relearn procedure.
95
NOTE: Chrysler recommends replacing worn mechanical tensioners with updated hydraulic tensioner kits. Information is from Chrysler technical service bulletin 09-06-00; March 10, 2000.
Removal (Mechanical Tensioner): Remove No. 1 spark plug. Using dial indicator, set number one cylinder to TDC of compression stroke. Remove access plug from top of timing belt cover. See Fig. 1. Ensure timing mark on camshaft aligns with mark on rear cover. See Fig. 6. Disconnect negative battery cable. Remove accessory drive belts. Raise vehicle and remove right inner splash shield. See Fig. 7. Remove crankshaft damper bolt. Use gear puller to remove crankshaft damper. On Breeze and Stratus, lower vehicle and place a jack under engine to support weight. Remove right engine mount from engine and body. Remove generator (with wiring attached) and bracket, and secure out of way. Remove engine mount bracket from engine. For 2000 Breeze and Stratus, remove accessory drive belt idler pulley from generator bracket. Remove generator bracket-to-engine bolts. Move bracket away from engine for clearance to remove timing belt cover. On 2000 Neon, remove lower torque strut. On all Neon models, lower vehicle and place jack under engine to support weight. Remove power steering pump with hoses attached, and secure out of way. Remove upper torque strut (if equipped). Remove right engine mount-to-engine mount bracket through bolt. Remove engine mount bracket from engine. On all models, remove timing belt cover. Rotate the crankshaft 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 counterclockwise with 8 mm Allen wrench while pushing lightly on the 3 mm Allen wrench, until it slides into the locking hole. If reusing old timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt.
CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the 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.
and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Mechanical Tensioner): Set crankshaft sprocket to TDC by aligning sprocket with arrow on oil pump housing, then back off to 3 notches before TDC. Set camshaft to TDC by aligning mark on sprocket with arrow on rear of timing belt cover. See Fig. 6. Move crankshaft to 1/2 mark before TDC for belt installation. See Fig. 5. Install timing belt by starting at crankshaft, then around water pump sprocket and then camshaft sprocket. See Fig. 6. Move crankshaft sprocket to TDC to take up belt slack. Remove Allen wrench from timing belt tensioner pulley. Rotate crankshaft clockwise 2 revolutions. Check alignment of camshaft and crankshaft timing marks. If timing marks do not align, remove timing belt and realign timing marks. Install front timing belt cover. Install engine mount bracket to engine. Continue installation in reverse of removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust accessory drive belts to proper tension. See page A-60 for belt tension ranges. On 1998-00 Neon models, connect scan tool to Data Link Connector under lower left edge of dash. Follow scan tool manufacturers instructions to access the cam/crank relearn procedure. Perform cam/crank relearn procedure. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 85 (115) Crankshaft Damper Bolt ......................................... 105 (142) Engine Mount Bolt .......................................................... 45 (61) Engine Mount Bracket-to-Engine Bolts ....................... 45 (61) Engine Torque Strut Bolts (2001-00 Neon) .................. 87 (118) Generator Mounting Bolts ............................................... 45 (61) Power Steering Pump Mounting Bolts ............................ 40 (54) Timing Belt Tensioner Bolt Hydraulic Tensioner ................................................... 23 (31) Timing Belt Tensioner Bracket Bolt Mechanical Tensioner ................................................ 23 (31) INCH Lbs. (N.m) Timing Belt Cover Bolts (M6) .................................... 106 (12) Water Pump Mounting Bolts ..................................... 106 (12)
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
Fig. 7: Exploded View Of Splash Shield Components
96
CHRYSLER 2.2L 4-Cylinder DOHC, VIN A
Install a belt tension gauge on the timing belt. Install tension on the belt run between the 2 camshafts. Tension gauge must contact timing belt between the teeth to get an accurate reading. Rotate timing belt tensioner clockwise to obtain a tension of 110 lbs. (445 N.) for a new belt, or 70 lbs. (311 N.) for a used belt. Tighten timing belt tensioner center bolt to specification. See TORQUE SPECIFICATIONS.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 4-Cyl. DOHC, Turbo III Daytona (Includes Canadian) 1992-93 .............. 1 2.6 Hours ................. 250206 Spirit 1991-92 ................ 1 4.1 Hours ................. 250206 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
CAUTION: Do NOT reverse rotate crankshaft or attempt to rotate crankshaft using camshaft or intermediate shaft bolt.


TIMING BELT
Removal: Remove PCV hose. Remove upper timing belt cover. Remove accessory drive belts. Rotate crankshaft so that cylinder No. 1 is at TDC of compression stroke. Raise vehicle on hoist and remove right wheel and inner splash shield. Remove water pump pulley. Remove crankshaft pulley bolts and remove pulley. It is NOT necessary to remove center bolt from the crankshaft. 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 secondary 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 timing belt. Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Check camshaft, crankshaft and intermediate shaft seals for leaks. Replace damaged components. Installation: 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 crankshaft 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.
Rotate crankshaft clockwise 2 revolutions. Check alignment of camshaft and crankshaft timing marks. Recheck timing belt tension. Readjust, if necessary. Tighten rocker arm shafts in sequence. See Fig. 1. See TORQUE SPECIFICATIONS. Install valve covers, spark plugs and ignition wire covers. Install fresh air duct. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 1: Rocker Arm Loosening & Tightening Sequence
CHRYSLER 2.2L 4-Cylinder DOHC, VIN A (Cont.)

97
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 65 (89) Crankshaft Pulley-To-Sprocket Bolt ............................... 27 (31) Crankshaft Sprocket Center Bolt .................................. 85 (115) Intermediate Shaft Bolt ................................................... 65 (88) Right Engine Mount To-Engine Bracket Through Bolt .............................. 100 (136) To-Frame Rail Bolts .................................................... 50 (68) Timing Belt Tensioner Bolt ......................................... 45 (61) Water Pump Pulley Bolt .................................................. 21 (28) Wheel Lug Nut ............................................................. 95 (129) INCH Lbs. (N.m) Rocker Arm Shaft Bolts Step 1 ........................................................................ 106 (12) Step 2 ......................................................................... 210 (24)
98
CHRYSLER 2.2L 4-Cylinder DOHC, VIN R

Remove the spark plugs. Remove the pin punches. Rotate crankshaft to TDC. Place Tension Tool (C-4703) on large hex nut in center of timing belt tensioner pulley. See Fig. 4. Loosen tensioner pulley lock nut. Adjust tensioner tool index, if necessary, to position the axis within 15 degrees of horizontal. See Fig. 4.
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 2.2L 4-Cyl. DOHC, Turbo TC (Maserati) 1990 ............... 2.9 Hrs. ...... 2521530 ....... 250153 NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
CAUTION: Do NOT rotate crankshaft counterclockwise or attempt to rotate the engine using the camshaft or intermediate shaft mounting bolt.

Rotate crankshaft clockwise from TDC 2 full revolutions back to TDC. Tighten the locknut on the timing belt tensioner. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 60 (80) Crankshaft Pulley-To-Sprocket Bolt ............................... 21 (28) Crankshaft Sprocket Center Bolt ................................. 50 (68) Generator Drive Belt Idle Pulley Bolt .............................. 40 (54) Intermediate Shaft Bolt ................................................... 65 (88) Right Engine Mount To-Engine Bracket Through Bolt ................................ 75 (102) To-Frame Rail Bolts .................................................... 21 (28) Timing Belt Tensioner Bolt ......................................... 45 (61) INCH Lbs. (N.m) Water Pump Pulley Bolt ............................................... 106 (12)

TIMING BELT
Removal: Rotate crankshaft so that cylinder No. 1 is at TDC of compression stroke. Raise vehicle on hoist and remove right inner splash shield. Remove accessory drive belts. Remove water pump pulley. Remove crankshaft pulley bolts and remove pulley. It is NOT necessary to remove center bolt from the crankshaft. Lower vehicle. Remove upper and lower timing belt covers. Place floor jack under vehicle to support weight of engine and transaxle assembly. Remove right engine mount (timing 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 direction of rotation. Remove timing belt. Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Check camshaft, crankshaft and intermediate shaft seals for leaks. Replace damaged components. Installation: Turn crankshaft and intermediate shaft until the alignment marks on the sprockets are aligned. See Figs. 2 and 3. The distributor rotor must be facing the No. 1 cylinder in the distributor cap. Position pin punches in intake and exhaust camshaft alignment holes. See Fig. 1. Position both camshafts so that the 2 alignment holes in the exhaust and intake camshaft sprockets are below and adjacent to the centerline of the 2 sprockets. See Fig. 2. The 2 keyways not used must be positioned at the top, outside of the vertical centerline of the camshafts. Turn crankshaft until the alignment mark on the sprocket is in line with the crankshaft and intermediate shaft centerline. Turn the intermediate shaft until the marking on the sprocket (if there is one) is in line with the marking on the crankshaft sprocket. If there is no marking on the intermediate shaft sprocket, set timing hole on vertical line through center of the axis, upper side, 2 degrees clockwise. Position timing belt on the crankshaft sprocket first. Then, install timing belt on intermediate shaft sprocket by turning it slightly, if necessary. Repeat this procedure for the camshaft sprockets.
Fig. 1: Installing Pin Punches In Camshafts
CHRYSLER 2.2L 4-Cylinder DOHC, VIN R (Cont.)
99
Fig. 3: Aligning Camshaft, Crankshaft & Intermediate Shafts
100
CHRYSLER 2.2L 4-Cylinder DOHC, VIN R (Cont.)
CHRYSLER 2.2L & 2.5L 4-Cylinder

TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time1 2.2L 4-Cyl. SOHC Aries & Reliant 1981-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 1989 ............... 2.2 Hrs. ...... 2521530 ........ 250153 Caravan, Town & Country & Voyager 1982-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 Caravelle, New Yorker & 600 1983-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 Charger & Turismo 1983-87 .......... 2.2 Hrs. ...... 2520710 ........ 250071 Dakota 1987-88 .......... 2 1.1 Hrs. .... 2520710 ........ 250071 Daytona 1984-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 1989-93 .......... 2.2 Hrs. ...... 2521530 ........ 250153 E Class 1983-84 .......... 2.2 Hrs. ...... 2520710 ........ 250071 Executive Limo (Canadian) 1986 ............... 2.2 Hrs. ...... 2520710 ........ 250071 Expo (Canadian) 1987-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 1989 ............... 2.2 Hrs. ...... 2521530 ........ 250153 Horizon & Omni 1981-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 1989-90 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Lancer 1985-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 1989 ............... 2.2 Hrs. ...... 2521530 ........ 250153 Laser 1984-86 .......... 2.2 Hrs. ...... 2520710 ........ 250071 LeBaron & LeBaron GTS 1982-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 1989-90 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Mini Ram Van 1984-87 .......... 2.2 Hrs. ...... 2520710 ........ 250071 New Yorker 1983-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 Rampage 1982-84 .......... 2.2 Hrs. ...... 2520710 ........ 250071 Scamp Pickup 1983 ............... 2.2 Hrs. ...... 2520710 ........ 250071 Shadow & Sundance 1987-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 1989-94 .......... 2.2 Hrs. ...... 2521530 ........ 250153 TC3 1981-82 .......... 2.2 Hrs. ...... 2520710 ........ 250071 Turismo 1983-87 .......... 2.2 Hrs. ...... 2520710 ........ 250071 024 1981-82 .......... 2.2 Hrs. ...... 2520710 ........ 250071 TIMING BELT APPLICATION (Cont.)
101
Belt Labor Component Part Kit No. No. Application Time1 2.2 L 4-Cyl. SOHC (Cont.) 400 1982-83 .......... 2.2 Hrs. ...... 2520710 ........ 250071 600 1983-88 .......... 2.2 Hrs. ...... 2520710 ........ 250071 2.5L 4-Cyl. SOHC Acclaim 1989-95 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Aries, Lancer & Reliant 1986-87 .......... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 1989 ............... 2.2 Hrs. ...... 2521530 ........ 250153 Caravan, Town & Country & Voyager 1986-87 .......... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 1989-95 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Caravelle & 600 1986-87 .......... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 Dakota 1989-95 .......... 1.1 Hrs. ...... 2521530 ........ 250153 Daytona 1986-87 .......... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 1989-93 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Dynasty 1988 ............... 2.2 Hrs. ............................. 250132 1989-93 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Lancer 1986-87 .......... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 1989 ............... 2.2 Hrs. ...... 2521530 ........ 250153 Laser 1986 ............... 2.2 Hrs. ............................. 250114 LeBaron & LeBaron GTS 1986-87 .......... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 1989-94 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Mini Ram Van 1987 ............... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 New Yorker 1986-87 .......... 2.2 Hrs. ............................. 250114 1988 ............... 2.2 Hrs. ............................. 250132 Shadow & Sundance 1988 ............... 2.2 Hrs. ............................. 250132 1989-94 .......... 2.2 Hrs. ...... 2521530 ........ 250153 Spirit 1989-1995 ...... 2.2 Hrs. ...... 2521530 ........ 250153 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. 2 - With Air Cond. add .5 hours. With Pwr. Strng. add .2 hours.
102
CHRYSLER 2.2L & 2.5L 4-Cylinder (Cont.)


TIMING BELT
Removal: Disconnect negative battery cable. Remove all accessory drive belts. If necessary, remove alternator, mounting brackets, and A/C compressor (if equipped). DO NOT disconnect refrigerant lines. Remove A/C belt idler pulley. Raise and support vehicle. Remove right inner splash shield. Remove water pump and crankshaft pulleys. Remove upper and lower timing belt covers. See Fig. 1. Support engine using a jack.
CAUTION: If timing belt is to be reused, mark direction of rotation for reassembly reference.
96I14660 Courtsey of Chrysler Corp.
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 timing 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.
Fig. 1: Removing Timing Belt Covers
Rotate crankshaft clockwise 2 complete revolutions to TDC. Tighten tensioner retaining bolt to specification while holding belt tensioner wrench in position. See TORQUE SPECIFICATIONS. Check all timing marks for proper alignment. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bracket-To-Block Bolt ................................................. 70 (95) Damper Weight ............................................... 21-23 (28-30) Intermediate Shaft Sprocket Bolt ................................. 65 (88) Timing Belt Tensioner Bolt ......................................... 40 (54) INCH Lbs. (N.m) Balance Shaft Chain Guide Nut ................................ 106 (12) Balance Shaft Chain Pivot & Tensioner Bolt ............. 106 (12) Balance Shaft Cover Bolt .......................................... 106 (12) Intermediate Shaft Retainer Bolt ............................... 106 (12) Timing Belt Cover Bolt .................................................. 44 (5) Valve Cover Bolt ........................................................ 106 (12) Water Pump Pulley Bolt ............................................ 106 (12)
CHRYSLER 2.2L & 2.5L 4-Cylinder (Cont.)
103
Fig. 4: Aligning Crankshaft, Intermediate Shaft & Camshaft Timing Marks
104
CHRYSLER 2.4L 4-Cylinder DOHC, VIN B
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.4L 4-Cyl. DOHC, VIN B Caravan & Voyager 1996-00 .............. 1 3.6 Hours ................. 250265 1 - With Pwr. Strng. add .2 hours.


TIMING BELT
Removal: Raise vehicle on hoist and remove right front wheel. Remove right inner splash panel. Remove accessory drive belts. Remove crankshaft vibration damper. Remove generator drive belt idler pulley. Remove lower timing belt cover. Lower vehicle and remove upper timing belt cover. Place floor jack under vehicle to support weight of engine and transaxle assembly. Remove purge duty solenoid and wiring harness from right engine mount bracket (timing belt end of engine). Remove 2 right engine mount vertical bolts from frame rail. Remove the one horizontal fastener. DO NOT remove large nut from center bolt of insulator rubber. Remove horizontal and vertical fasteners from engine side of mount. Remove right engine mount assembly. Rotate crankshaft to align timing marks on camshafts and oil pump housing. See Fig. 1.
CAUTION: Crankshaft sprocket mark must be located on trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth with oil pump housing mark will cause camshaft marks to be misaligned.
On 1996 models equipped with hydraulic tensioner, remove hydraulic tensioner bolts and remove tensioner. Place hydraulic tensioner in vise and SLOWLY compress tensioner plunger. Align holes in tensioner body and plunger and insert a pin through body and plunger to lock plunger in place. Skip next step. On models with a mechanical timing belt tensioner, insert a 6 mm Allen wrench into tensioner. Insert long end of 3 mm Allen wrench into pin hole on front of tensioner. While rotating the tensioner counterclockwise, push in lightly on the 3 mm Allen wrench until it can be pushed into locking hole. See Fig. 3. On all models, if reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components.
NOTE: If timing belt tensioner needs to be replaced, camshaft sprockets and rear timing belt cover will need to be removed.
Fig. 2: Installing Timing Belt Tensioner Assembly
Installation: Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Set camshafts timing marks together by aligning notches on sprockets. Turn exhaust camshaft sprocket clockwise about 1/2 notch below intake camshaft sprocket. See Fig. 4. Install timing belt starting at crankshaft, around water pump sprocket, idler pulley, camshafts sprockets and then around tensioner pulley. Move exhaust camshaft counterclockwise to take out belt slack and align timing marks. See Fig. 1.
CHRYSLER 2.4L 4-Cylinder DOHC, VIN B (Cont.)
105
On 1996 models with hydraulic timing belt tensioner, install tensioner on engine block but do NOT final tighten bolts. Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley in a clockwise direction. See Fig. 5. With torque applied to tensioner pulley, push timing belt tensioner against tensioner pulley bracket and final tighten tensioner bolts. See TORQUE SPECIFICATIONS. Remove holding pin from 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. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................ 75 (101) Crankshaft Vibration Damper ................................. 105 (142) Engine Mount Bracket-To-Engine Bolts .......................... 45 (61) Generator Drive Belt Idle Pulley Bolt .............................. 40 (54) Lower Timing Belt Tensioner Bracket Bolt .............................................................. 45 (61) Right Engine Mount Frame Rail Fasteners ................................................. 50 (68) Horizontal Engine Fastener ..................................... 111 (150) Vertical Engine Fastener ........................................... 75 (102) Timing Belt Tensioner (Hydraulic) Mounting Bolt ............................................................ 24 (28) Timing Belt Tensioner (Mechanical) Center Bolt ................................................................... 24 (28) Timing Belt Tensioner Assembly Bolt ....................... 45 (61) Wheel Lug Nut .......................................................... 100 (135) INCH Lbs. (N.m) Timing Belt Cover Bolts M6 (Outer-To-Inner) ................................................. 40 (4.5) M6 (Inner-To-Head) ................................................ 105 (12) Water Pump Bolt ......................................................... 106 (12)
Fig. 4: Moving Exhaust Camshaft To 1/2 Notch Position
Fig. 5: Adjusting Timing Belt Tension (Hydraulic)
Fig. 3: Adjusting Timing Belt Tension (Mechanical)
106
CHRYSLER 2.4L 4-Cylinder DOHC, VIN X

the 3 mm Allen wrench until it can be pushed into locking hole. See Fig. 3. On all models, if reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.4L 4-Cyl. DOHC, VIN X Breeze 1996-00 ................ 1 3.6 Hours ................. 250265 Cirrus 1995-00 ................ 1 3.6 Hours ................. 250265 Sebring Convertible 1996-99 ................ 1 3.6 Hours ................. 250265 Stratus 1995-00 ................ 1 3.6 Hours ................. 250265 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.

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

TIMING BELT
Removal: Raise vehicle on hoist and remove right front wheel. Remove right inner splash panel. Remove accessory drive belts. Remove crankshaft vibration damper. Remove generator drive belt idler pulley. Remove lower timing belt cover. Remove right engine support assembly vertical bolts from bottom of frame rail (timing belt end of engine). Lower vehicle. Remove upper timing belt cover. Place floor jack under vehicle to support weight of engine and transaxle assembly. Remove 3 bolts attaching engine mount assembly to engine bracket. Move A/C drier aside. Remove coolant reservoir tank. Remove right engine mount. Remove 3 bolts attaching engine mount bracket to engine block.
CAUTION: Align timing marks by rotating crankshaft only. Do not rotate camshaft after timing belt is removed or engine damage may result.
Rotate crankshaft clockwise to align timing marks on camshafts and oil pump housing. See Fig. 1.
CAUTION: Crankshaft sprocket mark must be located on trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth with oil pump housing mark will cause camshaft marks to be misaligned.
On models equipped with hydraulic tensioner, remove hydraulic tensioner bolts and remove tensioner. Place hydraulic tensioner in vise and SLOWLY compress tensioner plunger. Align the holes in the tensioner body and plunger and insert a pin through the body and plunger to lock the plunger in place. Skip next step. 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
Fig. 2: Installing Timing Belt Tensioner Assembly
CHRYSLER 2.4L 4-Cylinder DOHC, VIN X (Cont.)
107
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 upper and lower timing belt covers. Install generator idler pulley. Install crankshaft vibration damper. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................ 75 (101) Crankshaft Vibration Damper ................................. 105 (142) Generator Drive Belt Idler Pulley Bolt ............................. 40 (54) Right Engine Mount Frame Rail Vertical Fasteners ..................................... 45 (61) To-Engine Support Bracket ......................................... 45 (61) Timing Belt Tensioner (Hydraulic) Mounting Bolt ............................................................ 21 (28) Timing Belt Tensioner (Mechanical) Bracket Mounting Bolt ............................................... 45 (61) Wheel Lug Nut .......................................................... 100 (135) INCH Lbs. (N.m) Timing Belt Cover Bolts M6 (Outer-To-Inner) ................................................. 40 (4.5) M6 (Inner-To-Head) ................................................ 105 (12) Water Pump Bolt ......................................................... 106 (12)
Fig. 4: Moving Exhaust Camshaft To 1/2 Notch Position NOTE: If timing belt tensioner needs to be replaced, camshaft sprockets and rear timing belt cover will need to be removed.
Installation: Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Set camshafts timing marks together by aligning notches on sprockets. Turn exhaust camshaft sprocket clockwise about 1/2 notch below intake camshaft sprocket. See Fig. 4. Install timing belt starting at crankshaft, around water pump sprocket, idler pulley, camshafts sprockets and then around tensioner pulley. On models with hydraulic timing belt tensioner, install tensioner on engine block but do NOT final tighten bolts. Apply 21 ft. lbs. (28 N.m) of torque to tensioner pulley in a clockwise direction. See Fig. 5. With torque applied to tensioner pulley, push timing belt tensioner against tensioner pulley bracket and final tighten tensioner bolts. See TORQUE SPECIFICATIONS. Remove holding pin from
108
CHRYSLER *2.5L V6

On all models, raise and support vehicle. Remove right front wheel. Remove side panel from right wheelwell. Remove accessory drive belts. Remove generator and bracket from engine block and set aside. Remove crankshaft vibration damper. Lower vehicle. Place floor jack under vehicle to support weight of engine and transaxle assembly. Remove engine mount-to-frame through bolt. Remove engine mount-to-engine bracket nuts and bolt. Remove engine mount. Remove 3 bolts attaching engine support bracket to engine block. Top reamer bolt may be heat seized on engine support bracket. Spray lubricant on bolt while removing.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L V6 Avenger & Sebring Coupe 1995-00 ................ 1 2.7 Hours ................ 250259 Cirrus & Stratus 1995-00 ................ 1 2.7 Hours ................ 250259 Sebring Convertible 1997-00 ................ 1 2.7 Hours ................ 250259 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.

The manufacturer recommends the belt be replaced at 60,000 mile intervals, except in California, Connecticut, and Massachusetts. In these states, inspect belt at 60,000 miles and replace if necessary. If not replaced at 60,000 miles, replace at 100,000 miles.
NOTE: Reamer bolt head will have a R marking for identification.
Remove power steering pump (hoses attached) and bracket from engine block and set aside. Remove timing belt covers. Rotate crankshaft to align camshaft and crankshaft timing marks. See Figs. 2 and 3. If reusing old timing belt, mark timing belt direction of rotation for installation reference. Loosen timing belt tensioner pulley bolt. Remove timing belt. Remove automatic tensioner.

TIMING BELT
Removal (Cirrus, Sebring Convertible & Stratus): Disconnect negative battery cable from jumper terminal. Raise and support vehicle. Remove right front wheel. Remove accessory drive belt splash shield from right wheelwell. Remove accessory drive belts. Remove right engine support assembly vertical bolts from bottom side of frame rail (timing belt end of engine). Lower vehicle. Place floor jack under vehicle to support weight of engine and transaxle assembly. Remove 3 bolts attaching engine support assembly to engine block bracket. Move the A/C drier aside with hoses attached. Remove coolant reservoir tank. Remove right engine support assembly. Remove 3 bolts attaching engine support bracket to engine block, and remove bracket. Remove crankshaft vibration damper. Remove power steering pump (hoses attached) and bracket from engine block. Remove timing belt covers. Rotate crankshaft to align camshaft and crankshaft timing marks. See Figs. 2 and 3. If reusing old timing belt, mark timing belt direction of rotation for installation reference. Loosen timing belt automatic tensioner bolts. Remove timing belt. Remove automatic tensioner.
CAUTION: DO NOT rotate crankshaft or camshaft with timing belt removed. NOTE: When automatic tensioner is removed from engine, it is necessary to compress plunger into tensioner body.
CAUTION: DO NOT rotate crankshaft or camshaft with timing belt removed. NOTE: When automatic tensioner is removed from engine, it is necessary to compress plunger into tensioner body.
Installation (All Models): Place automatic tensioner into vise and SLOWLY compress plunger. When plunger is compressed into tensioner body, install locking pin through body and plunger holes to retain plunger until tensioner is installed. See Fig. 1. Index tensioner in vise the same direction as installed. This will ensure proper pin orientation when tensioner is installed in engine. See Fig. 1. Set crankshaft mark with timing mark on oil pump housing, then back off 3 notches before TDC. See Fig. 2. Set camshaft sprockets by aligning timing marks on sprockets with marks on rear timing belt cover. See Fig. 3.
NOTE: If reusing old timing belt, install in original direction of rotation.
Removal (Avenger & Sebring Coupe): Disconnect negative battery cable. Remove coolant reservoir bottle. On models with cruise control, remove cruise control actuator and set aside.
Install timing belt on right (next to firewall) camshaft sprocket first. Install a spring clip to keep belt in position. Keeping belt taught, install belt under water pump pulley and then around front camshaft sprocket. Install spring clip on front sprocket and belt. Rotate crankshaft clockwise to TDC. Continue routing belt around idler pulley, crankshaft sprocket, and tensioner pulley. Apply rotating force to crankshaft sprocket in clockwise direction to tension belt. Ensure all timing marks are still aligned. Loosen tensioner pulley center bolt. Position tensioner pulley with pin holes facing down. Install Adapter (MD998767) or equivalent, and torque wrench, to tensioner pulley. See Fig. 4. Apply 39 INCH Ibs. (4.4 N.m) in a counterclockwise direction to tensioner. Tighten tensioner bolt to specification, without letting tensioner pulley rotate. With torque being applied to tensioner pulley, install automatic tensioner (with locking pin in place) to tensioner pulley bracket. Tighten bolts to specification. Pull tensioner plunger locking pin.
CHRYSLER *2.5L V6 (Cont.)
109
Rotate crankshaft 2 revolutions clockwise, and check alignment of timing marks. Install tensioner locking pin into automatic tensioner. Pin should slide in and out with no resistance. Even if locking pin cannot be easily inserted, belt tension is okay if automatic tensioner plunger projection is within .149-.177 (3.8-4.5 mm). Projection is measured between top edge of automatic tensioner housing and arm of tensioner pulley bracket. Retension timing belt, if necessary. Install timing belt covers. Install crankshaft vibration damper. Tighten crankshaft damper bolt to specification.
NOTE: Reamer bolt head will have a R marking for identification.
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 installation. Adjust the drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 65 (88) Crankshaft Vibration Damper Bolt .............................. 134 (182) Engine Mount Bracket-To-Engine Block Cirrus, Sebring Convertible & Stratus ....................... 33 (45) Engine Mount-To-Engine Support Bracket Bolt/Nut Avenger & Sebring Coupe .......................................... 64 (86) Engine Mount-To-Frame Through Bolt Avenger & Sebring Coupe ................................ 72-87 (98-118) Engine Support Assembly-To-Engine Mount Bracket Avenger & Sebring .......................................... 47-54 (64-74) Cirrus, Sebring Convertible & Stratus ....................... 45 (61) 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 Idler Pulley Bolt ........................................ 32 (44) Timing Belt Tensioner Pivot Arm Bolt ............................ 33 (44) Timing Belt Tensioner Pulley Bolt ............................... 35 (48) Timing Belt Tensioner-To-Engine Bolt ........................ 17 (23) Water Pump Bolt ........................................................ 18 (24) Wheel Lug Nut Cirrus, Sebring Convertible & Stratus ....................... 100 (135) Avenger & Sebring Coupe .............................. 65-80 (88-108) INCH Lbs. (N.m) Timing Belt Cover Bolts .................................... 89-106 (10-12)
Fig. 2: Setting Crankshaft Sprocket
Fig. 3: Aligning Camshaft Sprockets
110
CHRYSLER 3.0L V6 SOHC

timing marks on front and rear camshaft sprockets and timing mark on crankshaft sprocket. See Fig. 1. Remove crankshaft pulleys and vibration damper. Loosen timing belt tensioner bolt and remove timing belt. Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit, Sundance & TC (1990-96): Disconnect negative battery cable. Remove accessory drive belts. Remove A/C compressor and power steering pump with hoses attached and secure aside (if equipped). Remove A/C compressor mounting bracket and drive belt tensioner. Remove power steering/alternator belt tensioner. Raise and support vehicle. Remove right inner fender shield. Remove crankshaft pulleys and vibration damper. Lower vehicle. Support engine with floor jack. Separate right (timing belt side) engine mount from engine mount bracket located in front of timing belt cover. Slightly raise engine. Remove engine mount bracket. Remove timing belt covers, noting bolt length for installation reference. Rotate engine and align timing marks on camshaft sprockets and crankshaft sprocket. See Fig. 1. If reusing timing belt, mark direction of timing belt rotation for installation reference. Loosen timing belt tensioner bolt. Move timing belt tensioner away from timing belt. Remove timing belt. Note direction of flange installation on front of crankshaft, in front of crankshaft sprocket. Remove flange and crankshaft sprocket from crankshaft (if necessary). If removing camshaft sprocket, hold camshaft by engaging Camshaft Sprocket Holder (MB990775) in the holes on front of camshaft sprocket. Remove camshaft sprocket bolt and washer. Remove camshaft sprocket. Caravan & Voyager: Raise vehicle. Remove accessory drive belt splash shield. Remove accessory drive belts. Remove crankshaft pulleys and vibration damper. Lower vehicle. Support engine weight with floor jack. Remove purge duty solenoid and wiring harness from right engine mount bracket. Remove 2 right engine mount insulator vertical bolts Remove the one horizontal fastener. DO NOT remove large nut from center bolt of insulator rubber. Remove horizontal and vertical fasteners from engine side of mount. Remove engine mount.
TIMING BELT APPLICATION Application 3.0L V6 Acclaim & Spirit 1989-95 .......... 4.0 Hrs. ..... 2521390 ......... 250139 Caravan, Mini Ram Van & Voyager 1987-00 .......... 1 3.8 Hrs. ... 2521390 ......... 250139 Daytona (Includes Canadian) 1990-93 .......... 4.0 Hrs. ..... 2521390 ......... 250139 Dynasty (Includes Canadian) 1988-93 .......... 4.0 Hrs. ..... 2521390 ......... 250139 LeBaron 1990-95 .......... 4.0 Hrs. ..... 2521390 ......... 250139 New Yorker 1988-89 .......... 4.0 Hrs. ..... 2521390 ......... 250139 Raider 1989 ............... 3.5 Hrs. ..... 2521390 ......... 250139 Ram 50 1990-91 .......... 3.5 Hrs. ..... 2521390 ......... 250139 Shadow & Sundance 1992-94 .......... 4.0 Hrs. ..... 2521390 ......... 250139 Stealth 1991-96 .......... 2.0 Hrs. ..... 2521390 ......... 250139 TC Maserati 1990-91 .......... 4.0 Hrs. ..... 2521390 ......... 250139
1
- With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.

Up to 1993 model year, the manufacturer recommends the timing belt be replaced at 60,000. For 1994-96 model years, the manufacturer recommends the timing belt be replaced at 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles. Replace the timing belt at 100,000 miles, unless previously changed. For 1997-00 model years, the manufacturer recommends the belt be inspected at 60,000, and replaced if necessary. Inspect belt at 90,000 miles, and replace if necessary. This maintenance is NOT required if belt was replaced at 60,000. Inspect belt at 120,000 miles, and replace if necessary. This maintenance is NOT required if belt was replaced at 90,000 miles.

TIMING BELT REMOVAL
Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New Yorker, Shadow, Spirit & Sundance (1987-89): Disconnect negative battery cable. Support engine and transmission with floor jack. Remove front engine mount bracket. Remove upper (front outer) timing belt cover. Align
Fig. 1: Locating Timing Belt & Sprockets
CHRYSLER 3.0L V6 SOHC (Cont.)
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 actuator (if equipped). Remove all drive belts. Unplug electrical 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 timing cover cap, timing belt cover, and gaskets. Using Holder (MB990767) and Adapter Bolts (MD998719), remove crankshaft pulley. Remove lower timing belt cover, gaskets, and flange. Rotate crankshaft to align all timing marks. See Fig. 1. Loosen belt tensioner bolt. Rotate belt tensioner counterclockwise to relieve belt tension. If reusing timing belt, place arrow on belt to indicate belt running direction. Remove timing belt and belt tensioner.
TIMING BELT INSPECTION

Fig. 2: Exploded View Of Timing Belt Components (Raider & Ram 50)
Remove engine support bracket from front of engine. Remove timing belt covers, noting bolt length for installation reference. Note direction of flange installation on front of crankshaft, in front of crankshaft sprocket. Remove flange. Rotate crankshaft and align timing marks on camshaft sprockets and crankshaft sprocket. See Fig. 1. If reusing timing belt, mark direction of timing belt rotation for installation reference. Loosen timing belt tensioner bolt. Move timing belt tensioner away from timing belt and temporarily tighten bolt. Remove timing belt. Raider & Ram 50: Disconnect negative battery cable. Drain cooling system. Disconnect upper radiator hose. Remove upper radiator shroud. Remove cooling fan and fan clutch assembly. Remove 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 compressor with hoses connected and mounting bracket. Remove cooling fan bracket assembly. Remove timing belt No. 1 upper outer cover and gaskets. See Fig. 2. Remove timing belt No. 2 upper outer cover and gaskets. Remove timing belt lower outer cover and gaskets. Using Holder (MB998747) or equivalent, and a used V belt, remove crankshaft pulley bolt. Remove crankshaft pulley.
NOTE: V belt will be damaged by tool. DO NOT use engine V belt to hold crankshaft pulley unless belt is to be replaced.
Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner for smooth rotation. Replace if defective.
TIMING BELT INSTALLATION

Acclaim, Daytona, Dynasty, LeBaron, Mini Ram Van, New Yorker, Shadow, Spirit & Sundance (1987-89): Install belt tensioner and tensioner spring. Install tensioner spring between water pump retaining pin and tensioner bracket with hook of spring facing outward. Turn tensioner full counterclockwise in adjustment slot and tighten temporarily to hold tensioner in position. Install timing belt on crankshaft sprocket first while keeping belt tight on tension side. See Fig. 1. Install belt on radiator side camshaft sprocket. Then, install belt on water pump pulley and rear camshaft sprocket and finally on timing belt tensioner. Apply rotating force to front camshaft sprocket in opposite direction of tension side of belt. Ensure all timing marks are aligned. Install crankshaft sprocket flange. Loosen
Remove flange. See Fig. 2. Rotate crankshaft and align all timing marks. See Fig. 1. Loosen belt tensioner bolt and rotate belt tensioner counterclockwise to release belt tension.
Fig. 3: Engine Support Bracket (Stealth)
112
To install remaining components, reverse removal procedure. 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, ensure 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 crankshaft. Loosen timing belt tensioner bolt, allowing spring tension to be applied on timing belt tensioner and timing belt. Slowly rotate crankshaft clockwise 2 full revolutions. DO NOT rotate crankshaft counterclockwise. Realign all timing marks. Tighten timing belt tensioner bolt to specification. See TORQUE SPECIFICATIONS table. Install timing belt covers. Ensure bolts are installed in original locations. See Fig. 4. Install engine support bracket. Install right side engine mount. Install crankshaft vibration damper. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
CAUTION: Engine support bracket reamer bolt must be tightened slowly while spraying lubricant on bolt.
Fig. 4: Identifying Timing Belt Cover Bolt Lengths (Except Raider, Ram 50 & Stealth)
tensioner from temporary position and allow it to apply tension to timing belt. Turn crankshaft 2 full turns in a clockwise direction ONLY.
NOTE: Turn crankshaft smoothly and ONLY in a clockwise direction.
Again line up all timing marks and tighten tensioner against belt. Tighten tensioner locking bolt to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedures. Adjust the drive belts to proper tension. See page A-60 for belt tension ranges.
CAUTION: When reusing timing belt, ensure timing belt is installed in original direction of rotation.
Acclaim, Daytona, Dynasty, LeBaron, Shadow, Spirit, Sundance & TC (1990-96): Rotate timing belt tensioner counterclockwise and temporarily tighten bolt. Ensure all timing marks are aligned. See Fig. 1. Install timing belt on crankshaft sprocket while holding timing belt tight on tension side. If reusing timing belt, ensure timing belt is installed in original direction of rotation. Install timing belt on front (radiator side) camshaft sprocket, water pump pulley, rear camshaft sprocket and then on timing belt tensioner. Ensure timing belt is installed in this order. Apply rotating force on front (radiator side) camshaft sprocket in opposite direction to apply pressure on tension side of timing belt. Ensure all the timing marks align. See Fig. 1. Install flange on front of crankshaft sprocket (if removed) with flat side against timing belt and offset side toward front of crankshaft. Loosen timing belt tensioner bolt, allowing spring tension to be applied on timing belt tensioner and timing belt. Rotate crankshaft clockwise 2 full revolutions. DO NOT rotate crankshaft counterclockwise. Realign all timing marks. Tighten timing belt tensioner bolt to specification. See TORQUE SPECIFICATIONS table.
Raider & Ram 50: Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. Rotate belt tensioner counterclockwise as far as possible and temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Fig. 1. Install timing belt on crankshaft sprocket and then left camshaft sprocket with all slack removed from tension side of
Fig. 5: Identifying Timing Belt Cover Bolt Lengths (Raider & Ram 50)

belt. Route timing belt onto water pump pulley, right camshaft sprocket and tensioner. Remove any slack from belt by rotating left and then right camshaft sprockets counterclockwise. Ensure all timing marks are aligned. Install flange on crankshaft. Loosen belt tensioner bolts slightly and allow tensioner to apply belt tension. 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 tension 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 bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Stealth: Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner, with hook of spring pointing away from cylinder block. Rotate belt tensioner counterclockwise as far as possible. Temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Fig. 1. Install timing belt onto crankshaft sprocket, rear cylinder bank camshaft sprocket, water pump pulley, front cylinder bank camshaft sprocket, and timing belt tensioner. Ensure belt is installed in original direction of rotation, and all timing marks are aligned. Install flange onto crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner.
NOTE: Engine support bracket reamer bolt must be tightened slowly. Apply lubricant onto bolt during installation.
113
Fig. 6: Identifying Timing Belt Cover Bolt Lengths (Stealth)
TORQUE SPECIFICATIONS (RAIDER & RAM 50) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt Montero & Raider ................................... 108-116 (146-157) Pickup .................................................... 130-137 (176-186) Left Engine Support Bracket Bolt ...................... 15-21 (20-30) Rear Engine Support Bracket Bolt .................... 13-18 (18-25) Right Engine Support Bracket Bolt 10 X 22 mm .................................................... 25-36 (34-49) 10 X 40 mm .................................................... 25-36 (34-49) 12 X 22 mm & 12 X 32 mm ............................. 47-61 (64-83) Timing Belt Tensioner Bolt ............................... 16-21 (22-29) Water Pump Bolt .............................................. 14-20 (19-27) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Timing Belt Cover Cap Bolt .............................. 84-108 (9-12) TORQUE SPECIFICATIONS (STEALTH) Application Ft. Lbs. (N.m) Automatic Tensioner Bolt ............................................ 17 (23) Camshaft Sprocket Bolt .............................................. 66 (90) Crankshaft Pulley Bolt 1991 ....................................................... 108-116 (146-157) 1992-94 ................................................................ 136 (185) Engine Support Bracket Bolt 10 X 40 mm .................................................... 47-54 (64-73) Except 10 X 40 mm ..................................... 76-83 (103-113) Timing Belt Tensioner Arm Bolt .................................. 31 (42) Timing Belt Tensioner Pulley Nut ............................... 36 (49) Water Pump Bolt ........................................................ 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12)
Belt tension should be 44-66 lbs. (20-30 kg). To install remaining components, reverse removal procedure. Install bolts into proper holes. Install covers and engine support bracket. See Figs. 3 and 6. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS (EXCEPT RAIDER, RAM 50 & STEALTH) Application Ft. Lbs. (N.m) A/C Compressor Drive Belt Idler Pulley Bolt ......................................................... 40 (54) Camshaft Sprocket Bolt .............................................. 70 (95) Crankshaft Vibration Damper Bolt .......................... 100 (135) Engine Bracket-To-Engine Bolt ................................... 35 (47) Engine Mount-To-Frame Bolt ...................................... 50 (68) Engine Mount Vertical Bolt ........................................ 75 (102) Timing Belt Cover Bolt ................................................ 10 (14) Timing Belt Tensioner Pulley Bolt ....................... 18-21 (25-28) Water Pump Bolts .......................................................... 20 (27)
114
CHRYSLER & EAGLE *1.5L 4-Cylinder SOHC

Loosen timing belt tensioner bolts. Move tensioner inward toward water pump. Temporarily tighten bolt in slot side of tensioner. Remove timing belt from camshaft sprocket. Remove crankshaft pulley, and timing belt. Inspection: Inspect belt teeth for cracks, damage, or oil contamination. Inspect all sprockets for damage. Examine belt tensioner for grease leakage and roughness when pulley is rotated. Replace components if defective. Installation: Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. If tensioner was removed, ensure spring is installed correctly. See Fig. 2. Install timing belt onto crankshaft and camshaft sprockets. Ensure tension side is tight and all timing marks are aligned when camshaft sprocket is rotated. Install crankshaft pulley. Loosen tensioner mounting bolts. See Fig. 3. Ensure timing belt is not out of position and has not jumped a sprocket tooth. Tighten tensioner bolts.
CAUTION: If pivot bolt is tightened before side bolt, belt tensioner may rotate, causing belt to be over tightened.
TIMING BELT APPLICATION Application 1.5L 4-Cyl. Colt 1985-86 .......... 2.8 Hrs. ............................. 250073 1987-90 .......... 2.8 Hrs. ...... 2521280 ........ 250128 1991-94 .......... 2.4 Hrs. ...... 2521910 ........ 250191 Colt (Canadian) 1985-86 .......... 2.8 Hrs. ............................. 250073 1989-91 .......... 2.8 Hrs. ...... 2521280 ........ 250128 1992 & 1995 ... 2.4 Hrs. ...... 2521910 ........ 250191 Summit 1989-90 .......... 2.8 Hrs. ...... 2521280 ........ 250128 1991-96 .......... 2.4 Hrs. ...... 2521910 ........ 250191 Vista (Canadian) 1989-91 .......... 2.8 Hrs. ...... 2521280 ........ 250128 1992 ............... 2.4 Hrs. ...... 2521910 ........ 250191 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .3 hours.

Rotate crankshaft one full revolution clockwise, until crankshaft sprocket timing mark aligns with TDC position. Recheck belt tension. To check belt tension, hold belt tensioner and timing belt together. Apply slight thumb pressure at center point of belt tensioner. A tension gauge can also be used to check belt tension. See Fig. 4. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 1991-85 .......................................................... 47-54 (65-75) 1992-96 ........................................................ 52-74 (70-100) Crankshaft Pulley Bolt 1991-96 .......................................................... 10-11 (14-15) Crankshaft Sprocket Bolt 1985 ............................................................... 37-43 (50-58) 1986-96 ........................................................ 52-74 (70-100) Front Cover Bolt 1985-88 ............................................................ 9-10 (12-14) Rocker Arm Adjuster Lock Nut 1989-96 .......................................................... 10-13 (14-18) Timing Belt Tensioner Bolt 1985-96 .......................................................... 14-20 (19-27) INCH Lbs. (N.m) Crankshaft Pulley Bolt 1985-1990 .................................................... 90-102 (10-11) 1987-88 ..................................................... 108-120 (12-14) Front Cover Bolt 1989-96 .......................................................... 84-132 (9-15) Fuel Rail Bolt 1992-96 .......................................................... 84-108 (9-12) Rocker Cover Bolt 1989-96 ........................................................ 13-17 (1.5-1.9) Timing Belt Cover Bolt 1989-96 .......................................................... 84-108 (9-12) Water Pump Pulley Bolt 1986-88 ..................................................... 108-120 (12-14) 1989-96 .............................................................. 72-84 (8-9)

TIMING BELT
Removal: Disconnect negative battery cable. Remove air cleaner assembly, then disconnect accelerator cable and oxygen lead sensor. Mark position of spark plug wires for installation, then remove wires from spark plugs. Support engine using a suitable engine support bar. Remove left engine mount bracket. Remove all accessory drive belts and pulleys.
CAUTION: DO NOT rotate engine counterclockwise (as viewed from timing belt end of engine). If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removing.
Remove timing belt covers and gaskets, noting bolt lengths and locations as they are removed. Rotate engine clockwise to align timing mark on camshaft sprocket with mark on cylinder head. Ensure all timing marks are aligned. See Fig. 1.
CHRYSLER & EAGLE *1.5L 4-Cylinder SOHC (Cont.)
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Fig. 4: Checking Timing Belt Tension With A Gauge
116
CHRYSLER & EAGLE *2.0L 4-Cylinder DOHC, Except VIN Y

For 1995-97 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles. For 1998 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut and Massachusetts, timing belt replacement is recommended but not required at 60,000 miles. In these states, replace timing belt at 100,000 miles.
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 2.0L 4-Cyl. DOHC (4G6) Laser & Talon 1990-94 ....... 1 & 2 3.6 Hrs. ... 2521670 ...... 3 250167 1990-94 ....... 1 & 2 3.6 Hrs. ........................ 4 250168 Talon Turbo 1995-98 ....... 1 & 2 3.6 Hrs. ... 2521670 ...... 3 250167 1995-99 ....... 1 & 2 3.6 Hrs. ........................ 4 250168 2000 GTX (Canadian) 1989-93 ....... 1 & 2 3.6 Hrs. ... 2521670 ...... 3 250167 1989-93 ....... 1 & 2 3.6 Hrs. ........................ 4 250168 1 - Balance shaft labor time included in camshaft labor time. 2 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. 3 Timing belt. 4 Balance shaft belt. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.

NOTE: Replacement procedures includ revised information from Chrysler technical service bulletin 09-01-94; January 28, 1994.
TIMING BELT & BALANCE SHAFT BELT

Removal: Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan and raise engine slightly. Remove engine mount assembly near timing belt cover. Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner bracket. See Fig. 1. Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley.
CAUTION: DO NOT rotate crankshaft counterclockwise. Ensure timing marks are aligned. If reusing timing belts, mark timing belts for direction of rotation.

For 1990-94 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles.
Courtesy of Mitsubishi Motor Sales of America
Fig. 1: Exploded View Of Timing Belts & Components
117 CHRYSLER & EAGLE *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

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CHRYSLER & EAGLE *2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)
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.
Fig. 5: Holding Balance Shaft Stationary
Fig. 6: Inspecting Timing Belt Auto Tensioner
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 tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1. Remove plug from left side of cylinder block. Install a .31" (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 5. Screwdriver must go in at least 2.36 (60 mm) or more. If screwdriver will only go in about .79-.98 (20-25 mm), turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures that balance shaft driven by oil pump sprocket remains in correct position. To remove timing belt B (balance shaft belt), hold crankshaft 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 reference. Remove timing belt B. Inspection: Inspect timing belts for damaged teeth and cracking. Ensure belts are not contaminated with oil. Check tensioners for free rotation and grease leakage. Replace components if damaged or if grease leakage exists. 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 sprockets. If using old belt, install belt in original direction of rotation. Ensure there is no slack in tension side of belt.
CAUTION: Ensure tensioner pulley shaft does not rotate when bolt is tightened or excessive pressure will be applied to timing belt.
Fig. 7: Aligning Timing Belt B (1990-92 Models)
Install timing belt B tensioner so center of tensioner pulley is to the left and above of retaining bolt center. See Fig. 9. Rotate tensioner inward toward timing belt until belt is tight. Tighten tensioner retaining bolt without letting tensioner pulley rotate out of position. Check belt deflection at designated area. Belt deflection should be .20-.28" (5.0-7.0 mm). Readjust timing belt if belt deflection is not within specification.
119 CHRYSLER & EAGLE *2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)
CAUTION: Install crankshaft sensing blade and crankshaft sprockets in correct positions or timing belt may be damaged.
Install crankshaft sensing blade (if equipped) in front of crankshaft sprocket B, with offset in proper direction. See Fig. 10. Install crankshaft sprocket A. Apply light coat of engine oil to crankshaft sprocket bolt threads, and tighten bolt to specification. See TORQUE SPECIFICATIONS. Install idler pulley (if removed). Ensure camshaft, crankshaft and oil pump timing marks are still aligned. See Figs. 2 and 3. DO NOT remove screwdriver from side of engine block until timing belt is installed.
NOTE: Intake and exhaust camshafts use same camshaft sprocket. Camshaft sprockets are provided with 2 timing marks. For exhaust camshaft sprocket, use timing mark on right with dowel pin facing up. On intake camshaft sprocket, use timing mark on the left with dowel pin hole on top.
Rotate camshaft sprocket so dowel pins are upward and away from cylinder head and timing marks are aligned with cylinder head surface. Timing marks should face each other. See Figs. 2 and 3. Install timing belt on intake camshaft sprocket. Install spring clip to retain timing belt on sprocket. See Fig. 11. Place a wrench on each camshaft sprocket retaining bolt. Rotate camshafts so timing marks align with each other. Install timing belt over exhaust camshaft. Install spring clip to retain timing belt. Install timing belt over idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. Remove spring clips from camshaft sprockets. Timing Belt Tension Adjustment (1990-92): Position timing belt tensioner pulley so that the 2 pin holes in the center eccentric are facing to the left (as viewed from timing belt end of engine) of the center bolt. Hand tighten center bolt. Remove screwdriver from balance shaft hole in side of engine block. Install plug. Rotate crankshaft 1/4 turn counterclockwise, then rotate crankshaft 1/4 clockwise until timing marks are aligned again. No. 1 cylinder should be at TDC of compression stroke. Attach Adapter (MD998767) to tensioner pulley eccentric. Attach torque wrench to adapter and apply 24 INCH lbs. (2.7 N.m) of torque in a clockwise direction. See Fig. 15. With torque applied to eccentric, tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m). Insert Set Screw (MD998738) through inner timing belt cover until it contacts tensioner arm. See Fig. 12. Slowly rotate set screw until set pin can be removed. Remove set screw from engine.
Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes without turning crankshaft. Measure distance between top of auto tensioner body and tensioner arm. The distance should be .15-.18 (3.8-4.5 mm). See Fig. 16, Dimension A. If distance is not correct, timing belt tension will have to be readjusted. If distance is correct, go to FINAL ASSEMBLY. Timing Belt Tension Adjustment (1993-98): Lift tensioner pulley upward to apply tension on timing belt. The 2 pin holes in the center of the tensioner must face down. See Fig. 12. Screw the Set Screw (MD998738) into engine support bracket until it makes contact with tensioner arm. At that point, screw the set screw in a few more threads and remove the set pin from the auto tensioner. Remove the set screw. Tighten timing belt tensioner pulley center bolt to 35 ft. lbs (48 N.m). Remove screwdriver from side of engine block and install plug. To tension timing belt, rotate crankshaft about 1/4 turn counterclockwise, then 1/4 turn clockwise until all timing marks align. Loosen tensioner pulley center bolt. Install Adapter (MD998767) or equivalent to tensioner eccentric. Install torque wrench on adapter. See Fig. 13. Starting with eccentric pin holes still facing down, apply 31 INCH Ibs. (3.5 N.m) of torque counterclockwise on tensioner pulley. Hold tensioner pulley at specified torque, and tighten tensioner center bolt to specification. Do not let tensioner pulley turn with bolt. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 full revolutions clockwise so that timing marks are aligned. Allow engine to stand for 15 minutes without turning crankshaft. Distance between top of auto tensioner housing and tensioner arm should be .15.18" (3.8-4.5 mm). See Fig. 16, Dimension A. If distance is incorrect, repeat tensioning procedure until distance is correct. Once distance is correct, go to FINAL ASSEMBLY. Final Assembly: To install remaining components, reverse removal procedure. Ensure proper length bolts are installed in timing belt covers. See Fig. 14. See TIMING COVER BOLT LENGTH & TORQUE table. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TIMING COVER BOLT LENGTH & TORQUE Bolt INCH Lbs. (N.m) A 6 x 16 mm Flange Bolt .............................. 89-106 (10-12) B 6 x 18 Flange Bolt ..................................... 89-106 (10-12) C 6 x 25 Loose Washer Bolt ................................... 58 (6.5) D 6 x 25 Flange Bolt .................................... 89-106 (10-12) E 6 x 45 Flange Bolt ..................................... 89-106 (10-12)
Fig. 9: Installing Timing Belt B Tensioner
Fig. 10: Installing Crankshaft Sprocket & Crankshaft Sensing Blade
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CHRYSLER & EAGLE *2.0L 4-Cylinder DOHC, Except VIN Y (Cont.)
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
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Bolt .................................................... 17 (24) Balance Shaft Sprocket Bolt ......................................... 33 (46) Camshaft Sprocket Bolt .............................................. 65 (90) Crankshaft Pulley Bolt ................................................ 18 (25) Crankshaft Sprocket Bolt ............................. 80-94 (108-127) Drive Belt Tensioner Pulley Bracket ..................... 17-20 (23-26) Engine Mount-To-Body Through Bolt (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) Engine Mount-To-Engine 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. 13: Adjusting Timing Belt Tension (1993-98)
Fig. 14: Installing Timing Belt Cover Bolts
CHRYSLER & EAGLE 2.0L 4-Cylinder SOHC

TIMING BELT APPLICATION Application 2.0L 4-Cyl. SOHC Colt Vista 1984-86 Balance Shaft ..... 1 .................................. 250090 Camshaft ............ 2 2.8 Hrs. ..................... 250089 1987-91 Balance Shaft ..... 1 .................................. 250159 Camshaft ............ 2 2.8 Hrs. . 2521581 ..... 250158 Ram 50 1983-86 Balance Shaft ... 1 .................................. 250090 Camshaft ........... 3 2.3 Hrs. ..................... 250089 1987-89 Balance Shaft ... 1 .................................. 250159 Camshaft ........... 3 2.3 Hrs. . 2521581 ..... 250158 Vista (Canada) 1989-91 Balance Shaft ... 1 .................................. 250159 Camshaft ........... 2 2.8 Hrs .. 2521581 ..... 250158 2000GTX (Canada) 1989-92 Balance Shaft .. 1 .................................. 250159 Camshaft ......... 2 2.8 Hrs. ..................... 250155 1 - Balance Shaft labor time included in camshaft labor time. 2 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. 3 - With Air Cond. add .7 hours. With Pwr. Strng. add .2 hours NOTE: A timing belt component kit is available for this application. See page I for information on component kits. Labor Time Component Kit No. Belt Part No.
121

The manufacturer recommends the belt be replaced at 60,000 mile intervals.

TIMING BELT
Removal: Disconnect negative battery cable. On vehicles equipped with A/C, remove upper radiator shroud and cooling fan/ clutch assembly. On 1989-91 models, support engine and remove upper engine mount located near timing belt cover.
On all vehicles, position No. 1 cylinder at TDC of compression stroke. Loosen pulley bolts. Remove drive belts. Remove crankshaft, water pump and power steering pulleys. Remove upper and lower front timing belt covers. On 1989-91 models, remove tensioner pulley bracket. Relieve camshaft timing belt tensioner pressure and secure tensioner toward water pump. If camshaft timing belt is to be reused, mark belt with an arrow indicating direction of rotation and remove camshaft timing belt. Rotate crankshaft in direction of rotation and align timing marks. See Fig. 1. Remove crankshaft sprocket attaching bolt. Loosen main tensioner pivot and disengage spring from boss on water pump. Remove tensioner assembly. Remove balance shaft belt (belt A). Remove camshaft sprocket, then crankshaft sprocket and flange. Remove plug from lower left side of cylinder block, then insert screwdriver into hole to hold balance shaft in position while removing oil pump sprocket nut. See Fig. 2. Loosen right side balance shaft sprocket bolt, then remove balance shaft belt tensioner. Remove balance shaft timing belt (belt B). Inspection: Inspect back of belt for hardness, non-elasticity and glossy surface. If no mark is produced when fingernail is forced into it, replace belt. Check for rounded sides on belt, flaking, peeling, cracking and separating rubber. Cracks are most evident at base of tooth. Installation: Install timing belt B, ensuring tension side has no slack. Align crankshaft and balance shaft sprocket timing marks with marks on timing case. See Fig. 3. Install tensioner B so only light pressure is on belt. Ensure flange on tensioner is mounted away from engine and finger-tighten bolt. Ensure that the pulley is to left of installation bolt and pulley flange faces front of engine. See Fig. 4. Lift tensioner with finger tip until slack is removed from tension side of belt. Tighten tensioner bolt, being careful to prevent turning shaft. Ensure timing marks are in alignment. Tighten right silent shaft bolt. Check belt tension by pressing center of tension side inward, using index finger and measuring belt deflection. Deflection should be .195-.265" (5.0-7.0 mm). Readjust if not within specification. Ensure camshaft timing belt sprockets align with timing marks. Ensure tensioner is fully toward water pump and install camshaft timing belt (belt A) in order of crankshaft sprocket, oil pump sprocket and camshaft sprocket. Ensure tension side of belt has no slack. Loosen tensioner mounting bolt and nut and allow tensioner spring to tension belt. Tighten slot side bolt and then tighten nut. Ensure all timing marks are in correct alignment. Turn crankshaft clockwise one revolution. Loosen mounting nut and bolt to allow tensioner to readjust. Tighten slot side bolt, then tighten nut. Reverse removal procedure to complete reassembly. Adjust drive belts to proper tension. See page A-60 for belt tensiion ranges.
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CHRYSLER & EAGLE 2.0L 4-Cylinder SOHC (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .................................. 14-20 (19-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt 1983-85 .......................................................... 11-15 (15-20) 1986-91 .......................................................... 15-21 (20-29) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Front Cover Bolts 1983-88 .......................................................... 15-19 (20-26) 1989 M8 X 30 Bolt ........................................... 20-26 (27-35) Except 1989 M8 X 30 Bolt ............................... 14-20 (19-27) Idler Pulley Bolt ................................................. 25-30 (34-41) Tensioner Pulley Bracket Bolt ........................... 17-20 (23-27) Tensioner Pulley Center Bolt ............................ 31-40 (42-54) Timing Belt Cover Bolt Left Lower Rear Cover Bolt ............................. 22-30 (30-41) Timing Belt Tensioner Nut 1983-85 .......................................................... 16-21 (22-28) 1986-91 .......................................................... 32-39 (42-53) Water Pump Bolt Except 8 X 65 mm ............................................ 9-11 (12-15) 8 X 65 mm ...................................................... 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt All Except Left Lower Rear Cover Bolt ............ 84-108 (9-12)
Fig. 2: Locking Balance Shaft In Place
Fig. 3: Aligning Balance Shaft Sprocket
Fig. 4: Installing Balance Shaft Tensioning Pulley
CHRYSLER & EAGLE *3.2L & 3.5L V6

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.2L V6 Concord & Intrepid (Includes Canadian) 1998-00 .............. 1 2.8 Hours ................. 250295 3.5L V6 Concord & Intrepid (Includes Canadian) 1993-94 .............. 1 2.7 Hours ................. 250219 1995-97 ................ 1 2.7 Hours ................. 250255 2000 ................... 1 2.7 Hours ................. 250295 LHS & 300M 1994 ................... 1 2.7 Hours ................. 250219 1995-97 .............. 1 2.7 Hours ................. 250255 1998-00 .............. 1 2.7 Hours ................. 250295 New Yorker 1994 ................... 1 2.7 Hours ................. 250219 1995-96 .............. 1 2.7 Hours ................. 250255 Vision 1993-94 .............. 1 2.7 Hours ................. 250219 1995-97 .............. 1 2.7 Hours ................. 250255 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
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Rotate crankshaft to align crankshaft sprocket timing mark with TDC mark on oil pump housing. Align camshaft sprockets with marks on rear covers. See Figs. 1 and 2.
CAUTION: When timing belt tensioner is removed from engine, always store tensioner with plunger facing up.

The manufacturer recommends the belt be replaced every 105,000 miles up to the 1999 model year. For 2000 model years, the manufacturer recommends the timing belt be replaced at 100,000 miles for Federal vehicles, and 105,000 miles for California vehicles.
Remove timing belt tensioner. Store with plunger facing up. Remove timing belt. Installation: When tensioner is removed from engine, it is necessary to compress plunger into tensioner body. Place timing belt tensioner in vise with holes in plunger and housing aligned. SLOWLY compress plunger. See Fig. 3. Total bleed down of plunger should take about 5 minutes. When pin holes are aligned, install locking pin through tensioner and plunger. Ensure camshaft and crankshaft sprocket timing marks are still aligned. If camshaft timing marks are not aligned, always rotate camshafts towards nearest timing marks. DO NOT turn camshafts a full revolution. This could cause valves to contact pistons. Install timing belt starting at crankshaft sprocket, going in a counterclockwise direction. After belt is installed on right camshaft sprocket, keep tension on belt until it is past tensioner pulley. Holding tensioner pulley against belt, install tensioner into housing and tighten bolts to specification. See TORQUE SPECIFCATIONS. When tensioner is in place, pull locking pin to allow tensioner to extend to pulley bracket.
*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 cooling 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 timing belt, mark belt direction of rotation for reinstallation.
CAUTION: Align camshaft sprockets between marks on rear belt covers before removing timing belt or damage to valves and pistons may occur.
124
CHRYSLER & EAGLE *3.2L & 3.5L V6 (Cont.)
Fig. 3: Compressing Tensioner
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt .............................................. 85 (115) Timing Belt Cover Bolts M8 ............................................................................ 21 (28) M10 .......................................................................... 40 (54) Timing Belt Tensioner ................................................ 21 (28) Timing Belt Tensioner Pulley Assembly ....................... 45 (61) INCH Lbs. (N.m) Timing Belt Cover Bolts (M6) .................................... 106 (12) Upper Radiator Attaching Screws ............................. 123 (14) Water Pump Bolts .................................................... 106 (12)
Fig. 2: Removing/Installing Timing Belt
Rotate crankshaft sprocket 2 revolutions and check timing marks on camshafts and crankshaft. Marks should line up within their respective locations. If marks do not line up, repeat procedure. See Fig. 1. Install timing belt covers and crankshaft damper. Install accessory drive belts. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. 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 *1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.6L 4-Cyl. DOHC Colt & Summit 1989-90 ................. 3.6 Hours .................. 250165 Colt 100, Colt 200 & Vista (Canada) 1989-90 ................. 3.6 Hours .................. 250165 Mirage 1989 & 1991-92 ..... 3.6 Hours .................. 250165 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .3 hours.
1
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Inspection: Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged. Inspect auto tensioner for leaks. Replace, if necessary. Inspect tensioner pulley and idler pulley for smooth rotation. Replace if bearings are worn.
CAUTION: Install flange and crankshaft sprocket in correct direction to prevent damage to timing belt.


NOTE: Replacement procedures include revised information from Chrysler technical service bulletin 09-01-94; January 28, 1994.
TIMING BELT
Removal: Raise and support vehicle. Remove lower left engine compartment splash shield. Support weight of engine from above with Suppport Fixture (C-4852 or 7137) or equivalent. On timing belt end of engine, remove engine mount bracket connecting engine to body. Loosen, but do not remove water pump pulley bolts. Remove generator and power steering pump drive belts. Remove water pump pulley.
NOTE: It is necessary to lower engine slightly to remove the crankshaft pulley.
Remove accessory drive belt tensioner pulley bracket. See Fig. 1. Remove A/C compressor drive belt (if equipped). Remove water pump pulley. Remove crankshaft pulley-tocrankshaft sprocket bolts. Remove crankshaft pulley. It is NOT necessary to remove crankshaft pulley center bolt. Remove upper and lower timing belt covers.
CAUTION: Crankshaft may need to be rotated up to 6 revolutions before all sprockets are properly aligned.
Installation: Rotate timing belt tensioner pulley so that the 2 pin holes are to the left of the center bolt. See Fig. 4. Tighten center bolt finger tight. Leave Allen wrench or pin installed in auto tensioner. Rotate camshaft sprockets so dowel pins face upward and timing marks on sprockets align. See Fig. 2. Outer marks on sprockets should be aligned with cylinder head surface. When exhaust camshaft sprocket is released, camshaft will rotate one tooth in counterclockwise direction. When installing timing belt, ensure this rotation is compensated for. Rotate crankshaft and align timing marks on crankshaft and oil pump sprockets. If installing old timing belt, ensure it is installed in original direction of rotation. Install timing belt around intake camshaft sprocket. Install spring-type paper clip on timing belt and camshaft sprocket to hold belt on sprocket. Clip should be installed below cylinder head surface, on outer side of camshaft sprocket. Install box wrench on both camshaft sprocket bolts. Install timing belt around exhaust camshaft sprocket while holding camshaft sprocket bolt to align timing mark on camshaft sprocket with timing mark. Install another spring-type paper clip on timing belt and exhaust camshaft sprocket to hold belt on sprocket. Install clip below cylinder head surface, on outer side of camshaft sprocket. Install timing belt in the following order: around idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. Remove both spring-type paper clips. Rotate tensioner pulley inward toward timing belt until belt is NOT sagging. Temporarily tighten center bolt on tensioner pulley. Ensure all timing marks are aligned.
CAUTION: Ensure all timing belt teeth are engaged with teeth on camshaft, oil pump and crankshaft sprockets.
Rotate engine clockwise (as viewed from timing belt end of engine) to align all timing marks so No. 1 cylinder is at TDC of compression stroke. See Fig. 2. If reusing belt, mark belt with original rotation direction. Remove rubber plug from inner timing belt cover. Install Set Screw (MD998738) into engine support bracket until it contacts auto tensioner arm. See Fig. 3. Remove auto tensioner. Loosen timing belt tensioner pulley center retaining bolt. Compress auto tensioner push rod by SLOWLY rotating Set Screw (MD998738) until hole in auto tensioner aligns with hole in auto tensioner body. Push rod may need to be rotated to align holes. Insert a 1/16 Allen wrench or pin into aligned holes to hold push rod in compressed position. Remove timing belt.
To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise, then rotate clockwise until No. 1 cylinder is at TDC. Ensure timing marks are aligned. Loosen center bolt on tensioner pulley. Note pin holes in tensioner pulley. Use socket wrench to rotate tensioner pulley. Using INCH lb. torque wrench and Socket Wrench (MD998752), apply a clockwise torque of 24 INCH Ibs. (2.7 N.m) on tensioner pulley. See Fig. 5. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to 32-41 ft. Ibs. (43-55 N.m). SLOWLY rotate set screw until Allen wrench or pin can be removed from auto tensioner. Remove set screw. Rotate crankshaft clockwise 6 complete revolutions and leave in this position for approximately 15 minutes. After 15 minutes, measure distance between bottom edge of tensioner arm and top of auto tensioner body. Distance should be .15-.18" (3.8-4.5 mm). See Fig. 7, Dimension A.
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CHRYSLER, EAGLE & MITSUBISHI *1.6L 4-Cylinder DOHC (Cont.)
CHRYSLER, EAGLE & MITSUBISHI *1.6L 4-Cylinder DOHC (Cont.)
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Fig. 3: Retracting Auto Tensioner Rod
If distance is not correct, loosen timing belt tensioner pulley center bolt. Use Set Screw to compress auto tensioner again. Readjust timing belt tension using Socket Wrench (MD998752) and INCH lb. torque wrench until correct distance of .15-.18" (3.8-4.5 mm) is obtained. 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 steering pump drive belts. Adjust drive belts to correct tension. 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Tensioner Pulley Bracket Bolt ......................... 17-20 (23-27) Auto Tensioner Bolt .......................................... 14-20 (19-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley-To-Sprocket Bolt .................. 14-22 (19-30) Crankshaft Sprocket Center Bolt .................. 80-94 (109-127) Engine Mount Bracket To-Body Through Bolt ........................................ 43-58 (60-80) To-Engine Bracket Bolt/Nut ............................... 36-47 (50-65) Idler Pulley Bolt ................................................. 25-30 (34-41) Tensioner Pulley Center Bolt ............................ 32-41 (43-55) Timing Belt Cover Left Lower Rear Cover Bolt ............................. 22-30 (30-41) INCH Lbs. (N.m) Timing Belt Cover Bolt ....................................... 84-106 (10-12) Water Pump Pulley Bolt ........................................ 71-89 (8-10)
Fig. 4: Positioning Timing Belt Tensioner Pulley
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CHRYSLER, EAGLE & MITSUBISHI 1.8L 4-Cylinder

Inspection: Inspect timing belts for damaged teeth or cracks. Ensure belts are not contaminated by oil. Check tensioners for freedom of rotation. Replace components if damaged. Installation: Coat outer diameter of right silent shaft spacer with engine oil. Install spacer with chamfered side toward oil seal. Install right silent shaft sprocket. Align crankshaft sprocket B and right silent shaft timing marks. See Fig. 5. Install timing belt B on sprockets. Ensure belt is installed in original direction of rotation and no slack exists in belt.
CAUTION: Ensure right silent shaft spacer is installed with chamfered side toward oil seal, or damage to oil seal will result. CAUTION: When tightening bolt, ensure tensioner does not rotate, or excessive pressure will be applied to timing belt.
TIMING BELT APPLICATION Application 1.8L 4-Cyl. Eclipse & Laser 1990-94 Balance Shaft .... 2 ................................ 250159 Camshaft ......... 2.4 Hrs. .. 2521580 ....... 250158 Talon 1993-94 Balance Shaft .... 2 ................................ 250159 Camshaft ......... 2.4 Hrs. .. 2521580 ....... 250158 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. 2 Balance shaft labor time included in camshaft labor time.


TIMING BELT
CAUTlON: To prevent engine damage, DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine).
Removal: Disconnect negative battery cable. Disconnect power steering hose clamp. Remove engine undercover. Place wooden block between jack and oil pan. Raise engine slightly. Remove engine mount assembly near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1. Remove power steering, water pump and damper pulleys. Remove adapter and crankshaft pulley.
NOTE: Ensure timing marks are aligned. Mark direction of rotation of all timing belts.
Remove upper and lower timing belt covers and gaskets. Remove access cover. Remove crankshaft sprocket A bolt and washer. Rotate crankshaft clockwise (as viewed from timing belt side of engine), and align timing mark on camshaft sprocket with timing mark on rear upper timing belt cover. See Fig. 2. Loosen timing belt tensioner bolt for timing belt A. Move tensioner toward water pump, and tighten tensioner bolt. Remove timing belt. Remove timing belt tensioner, tensioner spacer and tensioner spring. See Fig. 1. Remove camshaft sprocket. Remove plug from side of cylinder block, and install a .31" (8.0 mm) diameter Phillips screwdriver to hold left silent shaft. See Fig. 3. Remove oil pump sprocket nut, and remove sprocket. Remove crankshaft sprocket A and flange. Remove timing belt tensioner B. If timing belt B is to be reused, mark direction of timing belt rotation for reassembly reference. Remove timing belt B.
Install timing belt tensioner B so center of pulley is located left of tensioner bolt. See Fig. 6. Ensure flange on tensioner pulley is toward front of engine. Rotate tensioner inward toward timing belt until belt is tight. Tighten tensioner bolt. Check belt deflection at designated area. See Fig. 6. Belt deflection should be .20-.28" (5.0-7.1 mm). Readjust timing belt if belt deflection is not within specification. Install flange in front of crankshaft sprocket B, with offset toward crankshaft. See Fig. 1. Install crankshaft sprocket A. install camshaft and oil pump sprockets. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install tensioner spring, tensioner spacer and timing belt A tensioner. Ensure upper end of tensioner spring contacts water pump. Rotate tensioner toward water pump, and temporarily tighten nut. Ensure all timing marks are aligned. See Fig. 2. When aligning oil pump sprocket timing marks, remove plug from cylinder block. See Fig. 3. Insert a .31" (8.0 mm) diameter Phillips screwdriver into plug hole. If screwdriver can only be inserted .79-.98" (20.0-24.9 mm), rotate oil pump sprocket one revolution, and realign timing mark. Insert screwdriver, and ensure it can be inserted at least 2.36" (59.9 mm). DO NOT remove screwdriver until timing belt is installed. Install timing belt A on sprockets. Ensure no slack exists on tension side of belt. See Fig. 2. Install timing belt on crankshaft sprocket A, oil pump sprocket, and then on camshaft sprocket. If reused, ensure belt is installed in original direction of rotation. Loosen tensioner nut to allow spring tension to be applied to timing belt. Ensure all timing marks are aligned. Remove screwdriver and install plug. To apply tension on timing belt, rotate crankshaft clockwise so camshaft sprocket moves 2 teeth past timing mark on rear timing belt cover. See Fig 7. DO NOT rotate crankshaft counterclockwise.
CAUTION: DO NOT tighten tensioner spacer nut before tightening tensioner bolt, or timing belt tensioner will rotate and apply excessive pressure on timing belt.
Rotate tensioner inward toward timing belt. Ensure timing belt fully engages camshaft sprocket. Tighten timing belt tensioner bolt. Tighten tensioner spacer nut. At midway location between camshaft sprocket and oil pump sprocket, push timing belt A outward toward lower timing belt cover. Note clearance between timing belt and cover. See Fig. 8. Clearance should be .47" (12.0 mm). Timing belt may need to be readjusted.
CHRYSLER, EAGLE & MITSUBISHI 1.8L 4-Cylinder (Cont.)
129
Fig. 1: Exploded View Of Timing Belts & Related Components
To complete installation, reverse removal procedure. Ensure proper length bolts are installed in designated areas in timing belt covers. See Fig. 9. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt ...................................... 11-13 (15-18) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Damper Pulley Bolt ........................................... 11-13 (15-18) Flywheel/Drive Plate Bolt ........................... 94-101 (127-137) Front Cover Bolt ................................................ 11-13 (15-18) Timing Belt A Tensioner Bolt .......................... 16-22 (22-30) Timing Belt B Tensioner Bolt .......................... 11-16 (15-22) Water Pump Bolt Except 8 X 65 mm .................................................... 10 (14) 8 X 65 mm ...................................................... 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Valve Cover Bolt .................................................... 48-60 (5-7) Water Pump Pulley Bolt ........................................ 72-84 (8-9)
Fig. 2: Aligning Timing Belt A Timing Marks
130
90C02590
Fig. 3: Holding Silent Shaft In Stationary Position
Fig. 4: Installing Crankshaft Sprockets
Fig. 7: Applying Tension To Timing Belt A
Fig. 5: Aligning Timing Belt B Timing Marks
Fig. 8: Checking Timing Belt A Tension
Fig. 9: Identifying Timing Belt Cover Bolt Locations
CHRYSLER, EAGLE & MITSUBISHI 1.8L 4-Cylinder VINs C & D

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.8L 4-Cyl. Colt 1992-94 ................ 2.4 Hours ................. 250201 Colt Vista 1992-94 ................ 2.4 Hours ................. 250201 Expo 1992-94 ................ 2.4 Hours ................. 250201 Mirage 1993-96 ................ 2.4 Hours ................. 250201 1997-01 ................ 2.4 Hours ................. 250288 Summit 1992-96 .............. 2.4 Hours ................. 250201 Summit Wagon 1992-96 .............. 2.4 Hours ................. 250201 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .3 hours.
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Chrysler & Eagle: The manufacturer recommends the belt be replaced every 60,000 miles. Mitsubishi: For 1992-93 models, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-00 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed. For 2001 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusettes and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.
Fig. 2: Installing Flange

TIMING BELT
Removal: Disconnect negative battery cable. On Expo models, remove condenser tank. On all models, remove A/C and power steering hose mounting bracket from upper engine mount at timing belt cover. Remove all accessory drive belts. Using End Yoke Holder (MB990767) and Crankshaft Pulley Holder (MD998718) or equivalent, remove crankshaft pulley bolt and pulley.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine).
Remove upper and lower timing belt covers. Remove flange. Rotate crankshaft clockwise (as viewed from tim-
ing belt end of engine) until cylinder No. 1 is at TDC of compression stroke, and timing mark on camshaft sprocket and crankshaft sprocket align with timing mark on engine. See Fig. 1. If timing belt is to be reused, mark direction of rotation before removing. Loosen timing belt tensioner bolt. Using a screwdriver, move tensioner away from timing belt. Tighten bolt to secure tensioner. Remove timing belt. Inspection: Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check belt tensioner for grease leakage or roughness in tensioner rotation. Replace components if damaged. Installation: Install timing belt tensioner, leaving bolt loose. Using a screwdriver, push tensioner toward engine mount. Tighten timing belt tensioner bolt. Align camshaft sprocket and crankshaft sprocket timing marks with timing marks on engine. Install timing belt. Loosen timing belt tensioner to apply spring pressure to timing belt. Ensure timing marks are still aligned. Tighten timing belt tensioner bolt. Rotate camshaft in reverse direction and ensure that there is no slack in timing belt. Rotate crankshaft 2 complete revolutions clockwise (as viewed from timing belt end of engine) and ensure timing marks are still aligned.
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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. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt ...................................... 11-13 (15-18) Crankshaft Center Pulley Bolt ..................... 80-94 (109-127) Damper Pulley Bolt ........................................... 11-13 (15-18) Front Cover Bolt ............................................... 11 -13 (15-18) Timing Belt A Tensioner Bolt .......................... 16-22 (22-30) Timing Belt B Tensioner Bolt ......................... 11 -16 (15-24) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Valve Cover Bolt .................................................... 48-60 (5-7)
CHRYSLER, EAGLE & MITSUBISHI 1.8L 4-Cylinder VINs C & D (Cont.)
Fig. 4: Identifying Timing Belt Cover Bolt Locations
CHRYSLER, EAGLE & MITSUBISHI *2.0L 4-Cylinder DOHC, VIN Y

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. DOHC, VIN Y Avenger, Neon, & Sebring Coupe 1995-99 ................ 1 3.6 Hours ................. 250246 Eclipse (Non-Turbo) 1995-99 ................ 1 3.6 Hours ................. 250246 Talon (Non-Turbo) 1995-98 ................ 1 3.6 Hours ................. 250246 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
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Chrysler: On Neon models, the manufacturer recommends replacing the timing belt at 105,000 miles. On Avenger and Sebring Coupe models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles. Eagle: For 1995-96 model years, the manufacturere recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-98 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed. Mitsubishi: For 1995-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1998-99 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.
Fig. 1: Aligning Timing Marks & Adjusting Belt Tension (Mechanical Timing Belt Tensioner)
Fig. 2: Aligning Timing Marks (Hydraulic Timing Belt Tensioner)
bracket from front of engine. Remove timing belt cover. Rotate engine clockwise to align the camshaft and crankshaft timing marks. See Fig. 1.
CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt.

TIMING BELT
Removal (Mechanical Timing Belt Tensioner): On Avenger and Sebring, remove coolant reservoir and place out of way. On all models, raise and support vehicle. 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. Remove right side engine mount. Remove engine mount
Install 8 mm Allen wrench into timing belt tensioner. See Fig. 1. Insert long end of a 3 mm Allen wrench into pin hole in the front of tensioner. Slowly rotate tensioner counterclockwise with 8 mm Allen wrench while pushing lightly on the 3 mm Allen wrench, until it slides into the locking hole. If reusing old timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt.
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.
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CHRYSLER, EAGLE & MITSUBISHI *2.0L 4-Cylinder DOHC, VIN Y (Cont.)

Loosen timing belt tensioner to remove timing belt. If reusing old belt, mark belt with arrow to indicated direction of rotateion. Remove timing belt. Remove tensioner from engine. It will be necessary to compress 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 0906-96; March 29, 1996. Also Mitsubishi technical service bulletin 96-11-004; May 1996. Timing Belt Tensioner Bracket Precaution:
Fig. 3: Aligning Crankshaft Timing Mark (Hydraulic Timing Belt Tensioner Shown; Mechanical Tensioner Similar)
Inspection: Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas fiber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Mechanical Timing Belt Tensioner): Ensure camshaft and crankshaft timing marks are aligned. Rotate crankshaft pulley sprocket 1/2 tooth counterclockwise 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 crankshaft sprocket to TDC to take up belt slack. Remove Allen wrench from timing belt tensioner pulley. Rotate crankshaft clockwise 2 revolutions. Check alignment of camshaft and crankshaft timing marks. If timing marks do not align, remove timing belt and realign timing marks. Continue installation in reverse of removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. On Neon models only, connect scan tool to Data Link Connector (DLC) under lower left edge of instrument panel. Follow scan tool instructions to access the cam/crank relearn procedure. Perform cam/crank relearn procedure. Removal (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. Remove right side engine mount. Remove engine mount bracket from front of engine. Remove timing belt cover. Rotate engine clockwise to align the camshaft and crankshaft timing marks. See Fig. 2.
CAUTION: To prevent pistons from hitting valves, do not rotate camshaft or crankshaft after removing the timing belt.
On models with hydraulic timig belt tensioner, do not loosen, tighten, or remove timing belt tensioner pivot bolt. Bolt is installed at factory with special threadlocking compound that is not reusable. If tensioner pivot bolt is disturbed, entire bracket assembly must be replaced. The tensioner pulley center bolt MAY be removed and installed. Inspection: Check belt teeth for damage or oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure the belt is not cracked, separated or showing canvas fiber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for signs of grease leakage or roughness in rotation. Replace components if damaged. Installation (Hydraulic Timing Belt Tensioner): Ensure camshaft and crankshaft timing marks are aligned. Rotate crankshaft pulley sprocket 1/2 tooth counterclockwise from TDC location. See Fig. 3.
Fig. 4: Adjusting Timing Belt Tension (Hydraulic Timing Belt Tensioner)
CHRYSLER, EAGLE & MITSUBISHI *2.0L 4-Cylinder DOHC, VIN Y (Cont.)

Install timing belt starting from crankshaft pulley sprocket, go around water pump sprocket, idler pulley, camshaft sprockets, and then around tensioner pulley. Move crankshaft sprocket to TDC to take up belt slack. Install timing belt tensioner, but do not final tighten fasteners yet. With 21 ft. lbs. (28 N.m) of torque applied to tensioner pulley, move tensioner against pulley bracket and tighten all bolts to specification. See TORQUE SPECIFICATIONS. See Fig. 4. Remove tensioner plunger locking pin. Pretension is correct when locking pin can be removed and installed again. Rotate crankshaft clockwise 2 revolutions and check timing belt alignment marks. Reset belt if marks are not aligned. Install timing belt covers. Continue installation in reverse of removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. On Neon models only, connect scan tool to Data Link Connector (DLC) under lower left edge of instrument panel. Follow scan tool instructions to access the cam/crank relearn procedure. Perform cam/crank relearn procedure. TORQUE SPECIFICATIONS
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Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 75 (101) Crankshaft Pulley Bolt ............................................ 105 (142) Engine Mount Bracket-To-Engine Nut/Bolt ..................... 30 (41) Engine Mount-To-Body Bracket Through Bolt ..................................................... 72-87 (98-118) Engine Mount-To-Engine Mount Bracket Nut/Bolt ........................................................................ 64 (86) Engine Mount-To-Frame Rail Bolt (Neon) ...................... 40 (54) Power Steering Pump Bolts ........................................... 29 (39) Timing Belt Tensioner Bolt Hydraulic Belt Tensioner .............................................. 30 (41) Timing Belt Tensioner Bolt Mechanical Belt Tensioner ........................................... 21 (28) Timing Belt Tensioner Pulley Bolt Hydraulic Belt Tensioner ............................................... 50 (68) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................. 106 (12) Water Pump Bolt ...................................................... 106 (12)
136
CHRYSLER, EAGLE & MITSUBISHI 2.4L 4-Cylinder

Installation: Align crankshaft and balance shaft sprocket timing marks with the marks on the timing case. See Fig. 2. Install balance shaft timing belt over crankshaft and balance shaft sprockets. When installing timing belt, be sure tension side of belt has no slack. Install balance shaft belt tensioner. Assemble tensioner so that pulley is to the left of the installation bolt and pulley flange is facing the front of engine. Raise the tensioner toward belt by hand. Apply sufficient pressure so that tension side of belt is taut, then tighten tensioner bolt. Ensure that tensioner does not rotate with bolt as it is tightened, as excessive tension will be placed on the belt. Ensure that timing marks are still aligned, then check belt tension. See Fig. 2. There should be approximately .20-.28" (5.0-7.0 mm) slack on tension side of belt when belt is moved by hand. Install crankshaft sprocket flange with the raised side facing outward, then install crankshaft sprocket. Measure protrusion of auto-tensioner plunger from tensioner housing. Protrusion should be .47" (11.9 mm). Position timing belt tensioner in a soft jawed vise, then carefully compress plunger. After plunger has been compressed, insert a .055 (1.4 mm) pin or wire through tensioner body to hold plunger in place. Remove auto-tensioner from vise and install on engine. Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. With oil pump sprocket timing marks aligned, remove plug from side of engine and insert a screwdriver, with a shaft diameter of .31" (8.0 mm), into the hole. See Fig. 3. If screwdriver can be inserted 2.4" (61.0 mm) or more, alignment is correct. If screwdriver can only be inserted .8-1" (20.3-25.4 mm), rotate oil pump sprocket one revolution and realign timing marks. Ensure screwdriver can be inserted 2.4" (61.0 mm) or more. Leave screwdriver inserted in hole until after timing belt has been installed. Install camshaft timing belt, first over crankshaft sprocket, then oil pump sprocket, idler pulley, camshaft sprocket and tensioner pulley. Hold belt so there is no slack on tension side. Apply counterclockwise force on camshaft sprocket to aid in tensioning belt. Ensure that all timing marks remain aligned. Carefully position timing belt tensioner pulley against timing belt, then tighten center bolt. Rotate crankshaft pulley 1/4 turn counterclockwise, then turn clockwise, aligning crankshaft and camshaft timing marks. Loosen tensioner pulley retaining bolt, then position socket tool and a suitable torque wrench to the pulley. See Fig. 4. Tighten to specification. Tighten retaining bolt while holding the pulley in position. Install set screw tool through left hand engine support bracket. Engine may need to be raised slightly to install set screw tool. Tighten set screw tool until it contacts tensioner arm, then tighten tool slightly more. Remove pin or wire retaining auto-tensioner plunger, then remove set screw tool. Rotate engine in the clockwise direction two turns. After approximately 15 minutes, measure auto-tensioner plunger protrusion from tensioner housing. Plunger protrusion should be .15-.18" (3.8-4.6 mm). See Fig. 5, Dimension A. If protrusion is not within limits, readjust timing belt tension. Install timing belt lower and upper front covers, and tighten bolts to specification. Install crankshaft pulley and water pump pulley, and tighten attaching bolts to specification. Install drive belt tensioner pulleys. Install A/C compressor, power steering pump and alternator drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Check and adjust ignition timing as necessary.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.4L 4-Cyl. Colt, Colt Vista & Colt Wagon (Canada) 1992 Balance Shaft ............ 1 ......................... 250159 Camshaft ........... 2 2.4 Hours ................. 250204 1993 Balance Shaft ............ 1 ......................... 250159 Camshaft ........... 2 2.4 Hours ................. 250230 1994 Balance Shaft ............ 1 ......................... 250168 Camshaft ........... 2 2.4 Hours ................. 250230 Expo 1992 Balance Shaft ............ 1 ......................... 250159 Camshaft ........... 2 2.4 Hours ................. 250204 1993-95 Balance Shaft ............ 1 ......................... 250168 Camshaft ........... 2 2.4 Hours ................. 250230 Summit 1992 Balance Shaft ............ 1 ......................... 250159 Camshaft ........... 2 2.4 Hours ................. 250204 1993-96 Balance Shaft ............ 1 ......................... 250168 Camshaft ......... 2 2.4 Hours ................. 250230 1 - Balance Shaft labor time included in camshaft labor time. 2 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.


TIMING BELT
Removal: Disconnect negative battery cable. Loosen left front wheel lug nuts, then raise and support vehicle with jack stands. Remove left front wheel and tire assembly. Remove left front inner splash shield through the wheel well. Remove coolant reservoir. Support engine with jack and wooden block placed under the oil pan. Remove right side engine mount. Remove accessory drive belts and pulleys. Remove timing belt upper and lower front covers. Rotate crankshaft in normal direction of rotation and align timing marks. See Fig. 1. Remove auto-tensioner assembly, then remove camshaft timing belt. Remove crankshaft sprocket bolt, then crankshaft sprocket and flange. Remove balance shaft timing belt tensioner pulley bolt, then remove tensioner pulley. Remove balance shaft timing belt. Ensure balance shaft (silent shaft) sprocket and crankshaft sprocket timing marks are properly aligned. See Fig. 2.
Install right side engine mount, and tighten bolts/nuts to specification. After completing installation of engine mount, remove jack and wooden block supporting engine. Install coolant reservoir. Install left front inner splash shield. Install left front wheel and tire assembly, then lower vehicle. Connect negative battery cable. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolts .............................................. 18 (25) Right Side Engine Mount Bolt/Nuts ............................ 42 (58) Through Bolt Attaching Nuts ....................................... 25 (34) Through Bolt Nut ........................................................ 51 (70) INCH Lbs. (N.m) Tensioner Pulley Bolt ................................................. 31 (3.5) Timing Belt Front Cover Bolts ........................ 84-108 (9.6-12) Water Pump Pulley Bolts ........................................... 78 (8.9)
Fig. 3: Checking Oil Pump Sprocket Timing Mark Alignment
137
Fig. 1: Aligning Camshaft Timing Belt Marks
Fig. 5: Measuring Timing Belt Auto-Tensioner Protrusion
Fig. 2: Aligning Balance Shaft Marks
138
CHRYSLER & MITSUBISHI *2.3L 4-Cylinder Diesel
TIMING BELT APPLICATION Belt Part No. Application Labor Time1 2.3L 4-Cyl. Turbo Diesel Pickup 1983-85 Balance Shaft ...... 1.8 Hours .................. 250092 Camshaft ............. 1.8 Hours .................. 250091 Ram 50 1983-85 Balance Shaft ...... 1.8 Hours .................. 250092 Camshaft ............. 1.8 Hours .................. 250091 1 - With Air Cond. add .7 hours. With Pwr. Strng. add .2 hours.

Fig. 2: Removing Silent Shaft Sprockets

TIMING BELTS & SPROCKETS
Removal: Disconnect negative battery cable. Remove drive belts, fan, pulleys, and timing belt covers. Position cylinder No. 1 at TDC of compression stroke and ensure timing marks are in alignment. See Fig. 1. Mark belts indicating direction of rotation. Loosen nuts and bolts securing belt tensioners. Pivot tensioners toward water pump and secure. Remove timing belts and all necessary sprockets. Remove silent shaft sprockets by removing plug from right side of block and cover from left side of block. Insert screwdriver and socket extension into holes to hold silent shafts in place. See Fig. 2.
Installation: Install crankshaft sprocket and flange ensuring flange on crankshaft sprocket B is installed correctly. See Fig. 3. Mount injection pump sprocket, if removed, and tighten nut to specifications. Install flange to injection pump sprocket, noting flange holes are offset to aid in correct installation. Lightly oil left silent shaft spacer and insert spacer with chamfered end toward seal. Install both silent shaft sprockets. Tighten nut and bolt to specifications. Keep silent shafts from turning by using method described in removal procedure. Position and secure tensioner B fully toward water pump. Align timing marks on crankshaft sprocket and silent shaft sprockets. See Fig. 4. Install timing belt B, noting reference mark if refitting old belt. 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" (45 mm). Position and secure camshaft timing belt tensioner fully toward water pump. Align camshaft, crankshaft and injection pump timing marks. See Fig. 1. Install timing belt on pulleys in order of crankshaft sprocket, injection pump sprocket and camshaft sprocket. 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.
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 fulcrum-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). Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TIGHTENING SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Tensioner Bolts ......................................... 16-21 (22-29) Camshaft Sprocket Bolts .................................. 47-54 (64-73) Crankshaft Pulley Bolt ...................................... 33-34 (45-47) Crankshaft Sprocket Bolt .......................... 123-137 (167-186) Front Case Bolts 1983-84 .......................................................... 15-19 (20-26) 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)
CHRYSLER & MITSUBISHI *2.3L 4-Cylinder Diesel (Cont.)
139
Fig. 4: Aligning Timing Belt B Marks
Fig. 3: Installing Crankshaft Sprocket
140
CHRYSLER & MITSUBISHI 2.4L 4-Cylinder
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 2.4L 4-Cyl. SOHC Pickup 1990-92 Balance Shaft ... 1 .................................. 250159 Camshaft .......... 22.3 Hrs. . 2521240 ........ 250124 1993-96 Balance Shaft ... 1 .................................. 250168 Camshaft .......... 2 2.3 Hrs. ....................... 250229 Ram 50 1990-92 Balance Shaft ... 1 .................................. 250159 Camshaft .......... 22.3 Hrs. . 2521240 ........ 250124 1993 Balance Shaft ... 1 .................................. 250168 Camshaft .......... 2 2.3 Hours .................... 250229 1 - Balance Shaft labor time included in Camshaft labor time. 2 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
Fig. 1: Aligning Front Timing Belt


TIMING BELT
Removal: Disconnect negative battery cable. Remove radiator shroud, cooling fan and pulley. Remove all drive belts and crankshaft pulley. Remove upper timing belt covers and gaskets. Note bolt length and location.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine). If timing belt is to be reused, mark direction of rotation before removing.
Remove crankshaft sprocket bolt and washer. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with mark on cylinder head. See Fig. 1. Loosen timing belt tensioner adjustment bolt, and move tensioner toward water pump. Tighten bolt to secure tensioner. Remove front timing belt (belt A) and tensioner. DO NOT rotate crankshaft after timing belt has been removed.
Remove camshaft sprocket (if necessary). Remove oil pump sprocket access plug from cylinder block. See Fig. 2. Insert a .31 (8.0 mm) diameter Phillips screwdriver to block left silent shaft. Remove oil pump sprocket nut, and remove sprocket. Remove front crankshaft sprocket and flange. Note direction and order of installation for reassembly reference. Remove rear timing belt tensioner assembly. Remove rear timing belt (belt B). Inspection: Check belt teeth for cracks, damage and contamination. Inspect sprockets for damage. Check belt tensioner for leakage and roughness in rotation. Replace components if damaged. Installation: Install rear crankshaft sprocket and flange. Install right silent shaft sprocket and spacer. Spacer should be installed with chamfered end into oil seal. Align timing marks. See Fig. 3. Install rear timing belt (belt B) on sprockets. Install rear tensioner. Hold tensioner tightly against belt while tightening bolts. Ensure deflection is .20-.28" (5.07.1 mm). See Fig. 4. Install camshaft sprocket. Tighten camshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS. Install front timing belt tensioner, tension spring and spacer. Ensure spring is properly engaged against water pump case. Rotate tensioner toward water pump, and temporarily tighten bolts. Ensure timing marks are aligned. See Fig. 1. Install front timing belt (belt A) on crankshaft. Apply pressure on tension side of timing belt while installing belt (in order) on crankshaft, oil pump and camshaft sprockets. Loosen tensioner to apply spring pressure to timing belt. To apply tension to belt, rotate crankshaft clockwise until camshaft sprocket timing mark is offset by 2 teeth. Tighten tensioner bolt. Tighten tensioner spacer nut.
To check belt tension, apply slight thumb pressure and measure deflection between camshaft and oil pump sprocket. Belt deflection should be .55" (14.0 mm). See Fig. 5. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt ...................................... 11-13 (15-18) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Damper Pulley Bolt ........................................... 11-13 (15-18) Engine Support Bracket Bolt ............................. 36-47 (49-64) Silent Shaft Sprocket Bolt .................................. 25-29 (34-39) Timing Belt A Tensioner Bolt .......................... 16-22 (22-30) Timing Belt B Tensioner Bolt .......................... 11-16 (15-22) Water Pump Bolt Except 8 X 65 mm .................................................... 10 (14) 8 X 65 mm ...................................................... 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Valve Cover Bolt .................................................... 48-60 (5-7) Water Pump Pulley Bolt ........................................ 72-84 (8-9)
CHRYSLER & MITSUBISHI 2.4L 4-Cylinder (Cont.)
141
Fig. 4: Installing Timing Belt B Tensioner (Typical)
Fig. 5: Checking Timing Belt A Tension (Typical)
Fig. 3: Aligning Rear Timing Belt
142
CHRYSLER & MITSUBISHI *3.0L V6 DOHC

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 3.0L V6 DOHC Diamante 1992-96 ................ 3.8 Hours ................. 250195 Stealth 1991-96 Non-Turbo ........ 3.4 Hours ................. 250195 Turbo ................. 3.6 Hours ................. 250195 3000GT 1991-98 Non-Turbo ........ 3.4 Hours ................. 250195 Turbo ................. 3.6 Hours ................. 250195 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.

TIMING BELT
Removal (Diamante): Disconnect negative battery cable. Remove left front and left side splash shields. Using engine hoist, lift engine to remove weight from engine mounts. Remove alternator and drive belt tensioner assembly. Remove engine support bracket. Disconnect power steering connections. On 1993-96 models, remove camshaft position sensor and crankshaft position sensor. Remove crankshaft pulley. On vehicles with ABS, remove overflow tank and bracket. Remove generator/air conditioning idler pulley.
NOTE: Remove remaining engine mount bracket bolts in sequence. Lubricate reamer bolt with penetrating oil before and during removal. See Fig. 1.

Chrysler: Up to 1993 model year, the manufacturer recommends the belt be replaced every 60,000 miles. For 1994-96 model years, the manufacturer recommends replacing the timing belt at 60,000 miles, except in California. In California, belt replacement is recommended, but not required at 60,000 miles. Replace belt at 100,000 miles, unless previously changed. Mitsubishi: For 1991-93 model years, the manufacturer recommends the belt be replaced every 60,000 miles. For 1995-94 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. Replace timing belt at 100,000 miles, unless previously changed. For 1996-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California and Massachusetts. In California and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. Replace timing belt at 100,000 miles, unless previously changed. For 1998-99 model years, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.
Remove timing belt covers. Turn crankshaft clockwise to align all timing marks. Loosen center bolt on tensioner pulley to relieve belt tension. Remove timing belt. Mark rotation direction if belt is to be reused.
Fig. 1: Removing Engine Support Bracket Bolts
CHRYSLER & MITSUBISHI *3.0L V6 DOHC (Cont.)

Removal (Stealth & 3000GT): Disconnect negative battery cable. Remove lower splash shields. Remove cruise control actuator (if equipped). Remove drive belts. Remove alternator. Remove drive belt tensioner. Using Holder (MB990767) and Adapter Bolts (MD998754) or equivalent, remove crankshaft pulley. See Fig. 2. Disconnect brake fluid level sensor. Remove upper timing belt covers. Support engine. Remove front engine mount through-bolt and front engine mount.
NOTE: Engine support bracket reamer bolt may be seized. Apply penetrating lubricant to bolt during remove.
143
Remove drive belt idler pulley. Remove engine support bracket bolts in sequence. See Fig. 1. Remove engine support bracket. Remove timing belt upper and lower covers, noting length and location of cover bolts. Rotate crankshaft to align all timing marks. See Fig. 3 . Loosen tensioner center bolt. Remove timing belt. Installation (Diamante, Stealth & 3000GT): Place automatic tensioner assembly in a soft-jawed vise. Slowly close vise to press rod back into tensioner until both rod and housing holes are aligned. Install a .055" (1.40 mm) diameter wire through both holes. Remove tensioner from vise, and install assembly with wire in place. Install crankshaft sprocket (if removed). Align timing marks on crankshaft and camshaft sprockets. See Fig. 3.
CAUTlON: Turning camshaft sprockets while No. 1 cylinder is at TDC may damage valve and piston. Use care when aligning timing marks.
Rotate timing belt tensioner pulley until pin holes are located above center bolt. See Fig. 7. Push tensioner pulley against belt, and tighten center bolt. Ensure all timing marks are aligned, and remove clips. Rotate crankshaft 1/4 revolution counterclockwise. Rotate crankshaft clockwise until timing marks are realigned. Loosen tensioner center bolt. Using Tensioner Pulley Socket (MD998767) or equivalent, apply approximately 90 INCH Ibs. (10 N.m) torque to tensioner pulley to prevent it from turning. See Fig. 7. Retighten center bolt to specification. See TORQUE SPECIFICATIONS. Ensure tensioner pulley does not rotate while tightening center bolt. Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes. Verify wire can still be moved easily, or automatic tensioner rod projects from tensioner body .15-.18" (3.8-4.5 mm). If wire does not move easily, or rod projection is not to specification, repeat previous five steps. Remove wire.
NOTE: Lubricate engine support bracket reamer bolt while it is tightened slowly.
To complete installation, reverse removal procedure. Install bolts into correct timing belt cover holes. Install bolts into engine support bracket in reverse order of removal sequence. See Fig. 1. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt ............................................ 17 (23) Camshaft Sprocket Bolt .............................................. 66 (90) Crankshaft Pulley Bolt ............................................ 136 (185) Engine Support Bracket Bolt 10 X 40 mm .................................................... 47-54 (64-73) Except 10 X 40mm ..................................... 76-83 (103-113) Timing Belt Tensioner Arm Bolt .................................. 31 (42) Timing Belt Tensioner Pulley Nut ............................... 36 (49) Water Pump Bolt ........................................................ 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12)
To lower No. 1 piston from TDC and prevent valve and piston contact, turn crankshaft back 3 sprocket teeth (measured at timing mark). Starting with front bank of cylinders, verify intake and exhaust camshaft timing marks are not within shaded area of figure. See Fig. 4.
WARNING: Use care when aligning timing marks. When camshaft sprocket timing marks are in indicated area, camshaft is under valve spring pressure and may rotate suddenly, pinching hand between sprockets.
If camshaft sprocket timing mark is within indicated area, carefully rotate camshaft sprocket until timing mark is located in nearest safe area. See Fig. 4. Rotate either camshaft sprocket clockwise to align timing marks as shown in illustration. See Fig. 5 . If camshaft sprocket is rotated past timing mark, rotate it counterclockwise to realign it. Repeat procedure for other front bank camshaft sprocket.
NOTE: If necessary, crankshaft sprocket may be turned one tooth counterclockwise to aid belt installation.
Repeat previous three steps and this step for rear cylinder bank camshafts. Align crankshaft timing mark. Install timing belt onto sprockets in sequence. See Fig. 6. Use springtype paper clips to secure belt on sprockets. Use wrenches on camshaft sprocket bolts to prevent camshafts from turning during belt installation.
144
CHRYSLER & MITSUBISHI *3.0L V6 DOHC (Cont.)
Fig. 6: Installing Timing Belt Fig. 4: Aligning Timing Marks To Prevent Valve & Piston Damage
Fig. 7: Adjusting Timing Belt Tensioner
Fig. 5: Aligning Timing Marks - Final Alignment
DAEWOO *1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1 1.6L 4-Cyl. DOHC Lanos 1999-2001 ............. 2.3 Hours .................. 250310 1 With Air Cond. add .2 hours.
145

The manufacturer recommends replacing the belt at 60,000 miles, except in California. In California, inspect the belt at 60,000 miles and replace the belt at 102,000 miles.

TIMING BELT
Removal: Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove the air filter housing. Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove accessory drive belts. See Fig. 1. Remove power steering pump pulley bolts (if equipped). Remove power steering pump pulley. Remove crankshaft pulley center bolt. Remove crankshaft pulley. Lower vehicle. Remove upper and lower timing belt covers. See Fig. 2. Remove power steering pump mount bolts (if equipped). Set power steering pump aside with hoses attached. Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3. Ensure camshaft sprocket timing marks face each other. See Fig. 4.
CAUTION: Engine damage could result if camshaft sprockets are not properly aligned with notches on valve cover.
Courtesy of Daewoo Motor America, Inc.
Fig. 1: Removing A/C Compressor Drive Belt
Slightly loosen water pump bolts. Using Timing Belt Adjuster (J-42492), rotate water pump counterclockwise to relieve tension on the timing belt. See Fig. 5. Remove timing belt. Installation: 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 automatic 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 automatic tensioner is aligned with the pointer on the automatic tensioner bracket. See Fig. 8. Final tighten water pump bolts. See TORQUE SPECIFICATIONS table. Remove crankshaft sprocket center bolt. Install power steering pump (if equipped). Tighten bolts to specification. Install timing belt covers. Install crankshaft pulley. Tighten center bolt to specification.
Fig. 2: Timing Belt Covers
Fig. 3: Aligning Crankshaft Sprocket Timing Mark
146
DAEWOO *1.6L 4-Cylinder DOHC (Cont.)

Install power steering pump pulley (if removed). Install accessory drive belts. Install right front splash shield. Install right front wheel. Install air filter housing. Connect air intake temperature sensor connector. Connect negative battery cable. Adjust drive belts to correct tension. See page A60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 49 (68) Crankshaft Pulley Center Bolt Step 1 ............................................................................ 70 (95) Step 2 ............................................................ Plus 30 Degrees Step 3 ............................................................ Plus 15 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) Timing Belt Cover Bolt ................................................ 89 (10)
Fig. 7: Aligning Timing Belt Tensioner WIth Notch

Fig. 5: Moving Water Pump To Relieve Timing Belt Tension
Fig. 8: Aligning Timing Belt Tensioner With Pointer
DAEWOO 1.6L & 2.0L 4-Cylinder

TIMING BELT APPLICATION Application 1.6L 4-Cyl. Optima 1988-91 .......... 2.9 Hrs. ............................. 250148 2.0L 4-Cyl. Optima 1988-89 .......... 2.9 Hrs. ............................. 250081 1990-91 .......... 2.9 Hrs. ...... 2521630 ........ 250163 1 - With Air Cond. add .5 hours. Labor Time1 Component Kit No. Belt Part No.
147
Loosen water pump attaching bolts. On water pump eccentric, use special tool (J-33039-A) or equivalent to release tension. Remove crankshaft pulley. Remove timing belt from camshaft and crankshaft sprockets. Installation (2.0L): Align timing marks on camshaft and crankshaft sprockets with marks on timing belt rear cover. Place timing belt on camshaft and crankshaft sprockets and tensioner. Use special tool (J-33039-A) or equivalent to rotate water pump eccentric until tensioner touches stop. Slightly tighten water pump attaching bolts. Rotate crankshaft clockwise 2 revolutions. Rotate water pump eccentric counterclockwise until hole in tensioner arm is in line with hole in base. Tighten water pump attaching bolts and make sure tensioner holes are still aligned. To complete installation, reverse removal procedure. Adjust drive belt to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Water Pump Bolts ..................................................... 18 (24)


TIMING BELT
Removal (1.6L): Disconnect negative battery cable. Remove accessory drive belts. Remove power steering pump. Remove timing belt cover. Remove air cleaner. Mark all hoses for installation reference and disconnect hoses from valve cover. Remove valve cover. Remove timing belt. Installation (1.6L): Align camshaft sprocket mark with mark on rear timing belt cover. Install timing belt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. Removal (2.0L): Disconnect negative battery cable. Remove drive belt. Remove power steering pump and bracket. Remove serpentine drive belt tensioner as an assembly. Remove timing belt cover. See Fig. 1.
Fig. 1: Exploded View Of Timing Belt & Related Components (2.0L)
148
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. DOHC Nubira 1999-2001 ............. 1.8 Hours .................. 250309


TIMING BELT
Removal: Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove the air filter housing. Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove 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). Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3. Align camshaft sprocket timing marks with notches on valve cover. See Fig. 4.
Daewoo Motor America, Inc.
Fig. 1: Supporting Engine Assembly
Fig. 2: Removing Engine Mount Bracket
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: Ensure crankshaft and camshaft timing timing marks are still aligned. Install the timing belt. See Fig. 6. Turn the timing belt tensioner clockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt. See TORQUE SPECIFICATIONS table. Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. If timing belt tensioner is correctly aligned, install timing belt cover. Install the engine mount bracket on the timing belt end of engine. Install crankshaft pulley. Install serpentine accessory drive belt. Install right front splash shield. Install right front wheel. Install air filter housing. Connect air intake temperature sensor connector. Connect negative battery cable.

149
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ............................................................................ 37 (50) Step 2 ............................................................ Plus 60 Degrees Step 3 ............................................................ Plus 15 Degrees Crankshaft Pulley Bolt ................................................ 15 (20) 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) Timing Belt Tensioner Bolt ......................................... 18 (25) Water Pump Bolt ............................................................ 15 (20) Wheel Lug Nuts ....................................................... 88 (120) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................. 53 (6)
Daewoo Motor America, Inc. Daewoo Motor America, Inc.
Fig. 5: Identifying Timing Belt Tensioner
150
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 4-Cyl. DOHC Leganza 1999-2001 ............. 1.8 Hours .................. 250305


TIMING BELT
Removal: Disconnect negative battery cable. Disconnect intake air temperature sensor connector from intake air duct. Disconnect the air intake tube from the throttle body. Disconnect the breather tube from the valve cover. Remove resonator from throttle body. Remove air filter housing. Raise and support the vehicle. Remove right front wheel. Remove right front splash shield from wheelwell. Remove serpentine accessory drive belt. Remove crankshaft pulley bolts. It is NOT necessary to remove crankshaft sprocket center bolt. Remove crankshaft pulley. Lower vehicle. Support engine assembly from above with Support Fixture (J-28467-B). See Fig. 1. Remove engine mount bracket from timing belt end of engine. See Fig. 2. Remove power steering hose clamp bolt, and position hose away from timing belt cover. Remove front timing belt cover. See Fig. 7. Using crankshaft center bolt, rotate crankshaft one full turn clockwise (as viewed from timing belt end of engine). Align mark on crankshaft sprocket with notch at bottom of rear timing belt cover. See Fig. 3. Align camshaft sprocket timing marks with notches on valve cover. See Fig. 4.
Fig. 1: Supporting Engine Assembly
Fig. 2: Removing Engine Mount Bracket
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: Ensure crankshaft and camshaft timing timing marks are still aligned. Install the timing belt. See Fig. 6. Turn the timing belt tensioner counterclockwise to tension the timing belt. Turn tensioner until the pointer aligns with the notch on the rear timing belt cover. Tighten automatic tensioner bolt. See TORQUE SPECIFICATIONS table. Using crankshaft center bolt, turn crankshaft clockwise (as viewed from timing belt end of engine) 2 full revolutions. Ensure timing belt tensioner pointer is still aligned with notch. 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 serpentine accessory drive belt.
Install right front splash shield. Install right front wheel. Install air filter housing and resonator. Connect air intake temperature sensor connector. Connect negative battery cable.

151
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ............................................................................ 37 (50) Step 2 ............................................................ Plus 60 Degrees Step 3 ............................................................ Plus 15 Degrees Crankshaft Pulley Bolt ................................................ 15 (20) 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) Timing Belt Tensioner Bolt ......................................... 18 (25) Water Pump Bolt ............................................................ 15 (20) Wheel Lug Nuts ....................................................... 88 (120) INCH Lbs. (N.m) Power Steering Hose Clamp Bolt .................................... 71 (8) Timing Belt Cover Bolt .................................................. 53 (6)
Fig. 7: Timing Belt Cover
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DAIHATSU *1.0L 3-Cylinder

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.0L 3-Cyl. Charade 1988-92 ................. 1.8 Hours .................. 250178 1 - With Air Cond. add .3 hours.
Inspection: Inspect idler pulley for smooth rotation. Replace if necessary. Inspect idler pulley tension spring for damage. Check tension spring free length and tension. Replace spring if free length and tension are not within specification. See TIMING BELT PULLEY SPECIFICATIONS. TIMING BELT PULLEY SPECIFICATIONS Application Specification Camshaft Belt Pulley Diamter .................... 4.72 (119.9 mm) Crankshaft Belt Pulley Diameter ...................... 2.33 (59.3 mm) Idler Pulley Tension Spring Free Length .......... 2.13 (54.0 mm) Spring Tension ................................................ 3.6 Lbs. @ 2.56


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 reference. Remove alternator electrical connector. On models equipped with A/C, loosen idler pulley mounting nut. Loosen adjusting bolt, and remove drive belt. On all models, remove alternator drive belt. Remove right lower engine cover. Using a wooden block and jack, apply slight pressure to oil pan to release pressure from front mounts. Remove front mount bracket-tomount nuts. Remove front mount bracket-to-cylinder head bolts. Remove the 3 front engine mounting bracket-to-cylinder 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 rotate crankshaft so No. 1 cylinder is at TDC of compression stroke. Ensure timing mark on flywheel aligns with mating mark on bellhousing. See Fig. 3. 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 crankshaft pulley. Remove upper and lower timing belt covers. Remove flange on front of crankshaft pulley. See Fig. 4. If reusing timing belt, mark belt rotation direction. Loosen idler pulley bolt. Position pulley as far left as possible, and tighten pulley bolt. Remove timing belt. Remove idler pulley 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.
Fig. 1: Removing Engine Front Mounting Bracket Nuts
Fig. 2: Removing Cylinder Head Mounting Bracket
DAIHATSU *1.0L 3-Cylinder (Cont.)

Inspect all belt pulleys for wear in belt areas. Measure diameter of crankshaft and camshaft belt pulleys. Replace pulleys if measurements are not to specification. Installation: Install camshaft belt pulley. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS. Install crankshaft belt pulley and inner flange in proper direction. See Fig. 4. Install idler pulley and tension spring. Position pulley as far left as possible. Align camshaft and crankshaft mating marks. See Fig. 5. Install timing belt on engine. If installing used belt, ensure it is installed in original rotation direction. If installing new belt, align the mark on back of belt with mating mark on each pulley. After belt is installed, loosen idler pulley to apply spring tension on idler pulley. Temporarily tighten idler pulley bolt. Temporarily install bolt in crankshaft and rotate crankshaft COUNTERCLOCKWISE 2 complete revolutions until No. 1 piston is at TDC. The F mark on camshaft drive pulley should be toward top when No. 1 piston is at TDC. Loosen idler pulley bolt to apply spring tension against timing belt. Tighten idler pulley bolt to specification. Ensure all timing marks align. Install outer flange on crankshaft pulley, with protruding side toward crankshaft belt pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 22-33 (30-44) Crankshaft Sprocket Bolt .................................. 65-72 (88-98) Timing Belt Tensioner Bolt ............................... 25-33 (34-44) Water Pump Bolts ............................................ 11-16 (15-22) INCH Lbs. (N.m) Timing Belt Cover Bolts ........................................ 18-36 (2-4) Water Pump Pulley Bolt ........................................ 53-80 (6-9)
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Fig. 4: Installing Crankshaft Pulley & Flanges
Fig. 5: Aligning Crankshaft & Camshaft Mating Marks
Fig. 3: Aligning Flywheel Timing Marks
154
DAIHATSU *1.3L & *1.6L 4-Cylinder

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.3L 4-Cyl. Charade 1988-92 ................. 1.8 Hours .................. 250181 1.6L 4-Cyl. Rocky 1990-92 ................. 2.3 Hours .................. 250182 1 - With Air Cond. add .3 hours.


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 remove 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 pulley and belt. Slightly raise engine, and disconnect engine mount bracket and insulators. Remove service hole cover to access crankshaft pulley bolts. See Fig. 1. Remove crankshaft pulley by removing 4 small attaching bolts. Remove upper and lower timing belt covers. Rotate engine until F mark on camshaft sprocket aligns with timing mark on cylinder head cover. See Fig. 2. If reusing belt, mark arrow on belt to indicate direction of rotation. Loosen timing belt tensioner bolt, and move tensioner away from belt. Tighten timing belt tensioner. Remove timing belt from engine. Remove cylinder head cover.
Removal (1.6L): Disconnect negative battery cable. Remove air cleaner assembly. Loosen and remove drive belts. Remove radiator reserve tank. Disconnect clutch cable clamps from upper radiator shroud. Disconnect fan clutch. Remove radiator fan shroud and fan clutch. Remove water pump pulley and belt. Remove crankshaft pulley attaching bolts and remove pulley. Remove 8 timing belt cover bolts. Remove timing belt cover. Rotate engine until F mark on camshaft sprocket aligns with timing indicator on cylinder head cover. See Fig. 2. If reusing belt, mark arrow on belt to indicate direction of rotation. Loosen timing belt tensioner bolt, and move tensioner away from belt. Tighten timing belt tensioner, and remove timing belt from engine. Inspection (1.3L & 1.6L): Inspect timing belt for wear and defects. Check timing belt tensioner for smooth rotation. Ensure tensioner contact surface is clean and not damaged. Check camshaft for smooth rotation. Check sides of belt. If belt side is damaged, check sprocket flange.
Fig. 2: Locating Timing Belt Alignment Marks
Fig. 1: Locating Service Hole Cover (Charade) Fig. 3: Adjusting Timing Belt
DAIHATSU *1.3L & *1.6L 4-Cylinder (Cont.)

Check for dirt or contamination on sprocket teeth. Measure sprocket diameter. Camshaft sprocket should be 4.717" (119.8 mm). Crankshaft sprocket should be 2.335' (59.37 mm). Clean and/or repair as necessary. Installation (1.3L & 1.6L): Install crankshaft timing belt sprocket (if removed). Ensure recessed side of crankshaft sprocket flange faces engine block. Ensure crankshaft sprocket timing notch (drilled mark) aligns with timing indicator on engine. See Fig. 2. Tighten crankshaft timing belt sprocket bolt to 65-72 ft. lbs. (88-98 N.m). Install camshaft timing belt sprocket (if removed). Tighten camshaft sprocket bolts to 11-16 ft. lbs. (15-22 N.m). Apply Sealant (Three Bond 1104) or equivalent, to cylinder head near camshaft bearing cap contact areas. Install cylinder head cover. Ensure camshaft and crankshaft sprockets are aligned. See Fig. 2. Install timing belt on sprockets. If installing used belt, ensure there are 35 teeth between sprocket timing notches (drilled marks), and belt rotates in same direction. If installing new belt, align marks on belt with timing notches (drilled marks) on sprockets. See Fig. 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.
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Check belt tension. At midpoint, belt should deflect 0.2" (5 mm) with a pushing force of 1.8-3.5 Ibs. (0.8-1.6 kg). To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Idler Pulley Bolt .......................................... 23-35 (31-47) Camshaft Sprocket Bolts .................................. 11-16 (15-22) Crankshaft Pulley Bolts .................................... 15-22 (20-30) Crankshaft Sprocket Bolt .................................. 65-72 (88-98) Timing Belt Tensioner Bolt ................................. 2-32 (30-44) Water Pump Bolts ............................................ 11-16 (15-22) INCH Lbs. (N.m) Timing Belt Cover Bolts ........................................ 18-35 (2-4) Water Pump Pulley Bolt ........................................ 53-80 (6-9)
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
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 4-Cyl. Medallion 1989 ................... 2.3 Hours ................ 250140


TIMING BELT
Removal: Remove hood. Disconnect negative battery cable. Drain coolant and discharge A/C system. Remove grille, radiator support and facia panel. Disconnect cooling fan and thermoswitch wires. Remove radiator, cooling fan and A/C condenser. Loosen power steering pump belt. Remove timing belt cover. Loosen serpentine drive belt adjustment bolt and nut. Loosen belt and remove from water pump pulley. Remove water pump pulley bolt and pulley. Remove water pump attaching bolts. Remove water pump, gasket, timing belt and timing belt tensioner. Installation: Use feeler gauge to measure clearance between intermediate shaft cover and timing belt tensioner. Clearance should be .004" (.10 mm). See Fig. 1. Turn adjusting screw to adjust clearance. Position camshaft sprocket timing index in line with static timing mark. Position crankshaft so No. 1 piston is at TDC of compression stroke. Remove plug in cylinder block and insert TDC Rod (Mot. 861) into TDC hole in crankcase. Install timing belt. See Fig. 2. Position timing belt cover over sprockets and check camshaft timing mark with index on cover. Remove TDC rod and install plug in cylinder block. Rotate camshaft clockwise 2 complete revolutions. DO NOT rotate counterclockwise. Remove timing belt cover and loosen timing belt tensioner bolts a maximum of 1/4 turn. Spring loaded timing belt tensioner will automatically adjust to correct position. Ensure clearance between timing belt tensioner and intermediate shaft cover is .004" (.10 mm). Tighten lower timing belt tensioner bolt. Tighten upper bolt. Test belt tension with Tension Gauge (Ele 343). Deflection should be .216-.276" (5.5-7.0 mm). Install water pump with new gasket. Loosen timing belt tensioner bolts and allow tensioner spring to tighten timing belt. Retighten timing belt tensioner bolts. Install timing belt cover, water pump pulley and water pump pulley bolt. Reverse removal procedures to complete installation. Adjust drive belts to proper tension. See page A60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 37 (50) Crankshaft Pulley Bolt .............................................. 96 (130)
Fig. 1: Checking Timing Belt Tensioner Clearance
FIAT *1.3L & *1.5L 4-Cylinder

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.3L 4-Cyl. 128 1973-78 ................ 2.3 Hours ................. 250018 1979 ..................... 2.4 Hours ................. 250018 X1/9 1974-78 ................ 2.3 Hours ................. 250018 1.5L 4-Cyl. Strada 1979-82 ................ 2.0 Hours ................. 250069 X1/9 1979-83 ................ 2.0 Hours ................. 250069 1 - With Air Cond. add .2 hours.
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NOTE: If camshaft is turned independently of engine, valves may hit pistons causing engine damage.
Remove right guard from under engine. Remove timing belt cover. Loosen alternator and remove alternator/water pump drive belt. Loosen air pump and remove drive belt. Remove valve cover and check that camshaft lobes of No. 4 cylinder are pointing up. Remove distributor. Loosen idler pulley lock nut. Remove timing belt starting at idler pulley. Installation (X1/9): Install timing belt making sure that teeth are properly engaged in sprockets. Start installation of timing belt at crankshaft pulley. Release idler pulley lock nut and retighten after tension is on belt.
NOTE: Never allow engine to rotate backwards, or slack will develop in belt and belt will jump timing.

The manufacturer recommends the belt be replaced at the following intervals: On 1974-78 models, replace belt every 36,000 miles. On 1979 1.3L 4-Cylinder, replace belt every 36,000 miles. On 1979-83 1.5L 4-Cylinder, replace belt every 30,000 miles.
Rotate engine 2 turns in direction of engine rotation. Loosen idler pulley lock nut to ensure all slack is removed. Retighten lock nut. Rotate engine until No. 4 cylinder is in firing position (cam lobe up). Install remaining components in reverse of removal order. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 61 (85) Crankshaft Pulley/Sprocket Nut .............................. 101 (137) Timing Belt Tensioner Pulley Nut ............................... 33 (45)

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 vehicle. Remove timing belt cover. Check timing by aligning index marks on top and bottom of camshaft sprocket with index marks on engine mounting and upper case. 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 transmission into 4th gear, to prevent crankshaft from turning. Apply parking brake.
158
FIAT *1.6L & *1.8L 4-Cylinder

NOTE: Anytime tension is relieved from timing belt, timing belt must be replaced.
TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.6L 4-Cyl. 124 1971-74 ................ 1.9 Hours ................. 250020 1.8L 4-Cyl. Brava 1974-78 ................ 2.4 Hours ................. 250020 124 1974-78 ................ 1.9 Hours ................. 250020 131 1975-78 ................ 1.9 Hours ................. 250020 1 - With Air Cond. add .2 hours.
Install timing belt make sure not to move sprockets. Ensure hole in auxiliary shaft pulley is lined up with tensioner pulley bolt. To adjust timing belt tension, loosen idler pulley tensioner nut and allow pulley to tension timing belt. Rotate crankshaft pulley 2 full turns and recheck timing marks. Tighten tensioner nut and bracket bolt. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 87 (118) 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 belts. Disconnect coolant extension union at cylinder head. Loosen timing belt idler pulley nut and mounting bracket bolt and release timing belt tension. On 1.6L engines before No. 42577, pry pulley to release tension. Tighten pulley nut and bracket bolt, and remove belt.
Fig. 1: Camshaft & Crankshaft Timing Marks (1.8L)
FIAT *1.6L & *1.8L 4-Cylinder (Cont.)
159
Courtesy of Fiat Motor Co.
Fig. 2: Aligning Timing Marks (1.6L)
160
FIAT *2.0L 4-Cylinder
TIMING BELT APPLICATION Belt Part No. Application Labor Time1 2.0L 4-Cyl. Brava 1979-83 ................ 2.4 Hours ................. 250068 Spider 2000 1979-82 ................ 3.1 Hours ................. 250068 1 - With Air Cond. add .2 hours.


TIMING BELT
WARNING: Timing belts must not be reused once tension is relieved. Crankshaft and/or camshafts must not be turned with belt removed due to resultant valve and/or piston damage. Fig. 1: Camshaft & Crankshaft Timing Marks
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. Remove 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 tension and timing. To complete installation, reverse removal procedures. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 87 (118) Timing Belt Tensioner Nut .......................................... 33 (45)
Fig. 2: Sprocket Alignment For Timing Belt Installation
FORD 1.3L 4-Cylinder

TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time1 1.3L 4-Cyl. VIN H Aspire 1994-97 .......... 2.0 Hrs. ............................. 250185 Festiva 1988-89 .......... 2.0 Hrs. ...... 2521410 ........ 250141 1990-93 .......... 2.0 Hrs. ............................. 250185 1 - 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.
161

For Aspire, the manufacturer recommends the belt be replaced every 60,000 miles on Federal vehicles, and 105,000 miles on California vehicles. For Festiva, the manufacturer recommends the belt be replaced every 60,000 miles.
Fig. 1: Removing Right Inner Fender Panel

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 reference. Remove timing belt tensioner pulley bolt. Remove tensioner pulley, spring, and spring cover. Remove timing belt.
Fig. 2: Timing Belt Upper & Lower Covers
CAUTION: Never twist, turn inside out, or bend timing belt. Keep belt away from grease and oil.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ....................................... 29-40 (39-54) Camshaft Pulley Bolt .......................................... 9-13 (12-17) Camshaft Sprocket Bolt .................................... 36-45 (49-61) Crankshaft Pulley Bolts .................................... 10-13 (12-17) Crankshaft Sprocket Bolt .............................. 80-87 (108-118) Power Steering Adjuster Nut ............................. 27-38 (37-52) Timing Belt Tensioner Adjuster Bolt ................. 14-19 (19-26) Water Pump Pulley Bolts .................................. 36-45 (49-61) INCH Lbs. (N.m) Camshaft Cover ................................................. 71-97 (8-11) Timing Belt Cover Bolt ........................................ 71-97 (8-11) Valve Cover Bolt .................................................... 44-79 (5-9)
Installation: Ensure timing belt and sprockets are clean and not worn or damaged. Align crankshaft and camshaft timing marks. See Fig. 3. Position belt onto sprockets, in original running direction. Install timing belt tensioner spring, spring cover, and pulley. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
162
FORD 1.3L 4-Cylinder (Cont.)
Fig. 3: Aligning Camshaft & Crankshaft Timing Marks
FORD 1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 1.6L 4-Cyl. -- DOHC Capri 1991-94 ........ 3.6 Hrs. ...... 2521790 ....... 250179 NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
163
Application Ft. Lbs. (N.m) A/C Compressor Bolt ....................................... 29-40 (39-54) Camshaft Pulley Bolt ........................................ 37-45 (49-61) Crankshaft Pulley Bolts .................................... 10-13 (12-17) Crankshaft Pulley Center Bolt ................... 115-123 (157-167) Power Steering Adjuster Nut ............................. 27-38 (37-52) Timing Belt Tensioner Adjuster Bolt ................. 14-19 (19-26) NCH Lbs. (N.m) Camshaft Cover ................................................. 71-97 (8-11) Timing Belt Cover Bolt ........................................ 71-97 (8-11) Valve Cover Bolt .................................................... 44-79 (5-9) Water Pump Pulley Bolt ...................................... 71-97 (8-11)


TIMING BELT
NOTE: Always rotate engine in direction of normal operation. Rotating crankshaft backwards may cause belt to jump timing.
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove right front tire and wheel assembly. Remove right front splash guard. Lower vehicle. Remove spark plugs and set No. 1 cylinder to TDC of compression stroke. Remove accessory drive belts. Remove dipstick. Remove water pump pulley. Remove crankshaft pulley, damper and baffle plate. See Fig. 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 letter I aligned with arrow on belt cover. Exhaust cam should have letter E aligned with arrow on belt cover. Crankshaft key should align with arrow. See Fig. 1.
CAUTION: DO NOT clean pulleys, tensioner, or idler pulleys with solvents. Wipe them clean only.
TECHNICAL SERVICE BULLETIN REVISION

NOTE: Information on revised service procedure is from Ford technical service bulletin 94-17-5; August 24, 1994. This bulletin supercedes 94-15-10; July 21, 1993.
Unloaded free length of timing belt tension spring should be 2.315" (58.8mm). Replace spring as necessary. Tighten tension pulley with tension spring fully extended. If reusing timing belt, install belt in original direction of rotation. Keep tension on opposite side of tensioner as tight as possible. Rotate crankshaft 2 full turns. Inspect alignment of timing marks. If any mark is not aligned, remove timing belt and reset timing. Loosen tension pulley retaining bolt to allow tension spring to tighten belt. Tighten tension pulley to specification. See TORQUE SPECIFICATIONS. Rotate engine 2 full turns. Verify timing mark alignment. Measure timing belt tension between camshaft pulleys. Belt deflection should be 0.33-0.45" (8.5-11.5 mm). See Fig. 3. If incorrect, loosen tension pulley and repeat procedure. If correct tension cannot be achieved, replace tension spring. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
SWISH NOISE FROM TIMING BELT
Issue: Some 1990 1.6L and 1.6L engines built up to 10/1/ 1990 may exibit a swish noise from the timing belt. This is caused be a belt guide plate that does not maintain correct timing belt alignment. Action: A revised timing belt guide plate and pulley boss is available to correct the noise. See Fig. 4. This procedure will also require replacement of the crankshaft and associated hardware. This procedure is also recommended when replacing a damaged crankshaft to prevent timing belt noise.
164
FORD 1.6L 4-Cylinder DOHC (Cont.)
Courtesy of Ford Motor Co.
Fig. 4: New & Revised Timing Belt Pulley
TIMING BELT PULLEY PARTS (1990)

Part Name Part No. Crankshaft ............................................................ F1JY-6303-A Crankshaft Accessory Pulley (With FEAD Belt) With A/C & Power Steering ................................ F1JY-6A312-A Crankshaft Damper Pulley (With V Belt) Generator & Water Pump ................................. F1JY-6A312-A Crankshaft Pulley Boss w/Pin ........................... F1CZ-6C337-A Crankshaft Pulley Plate ........................................ F1CZ-6378-A Crankshaft Timing Pulley ..................................... F1CZ-6306-B Oil Pan Gasket ..................................................... F1CZ-6701-B Oil Pump Assembly .............................................. F2CZ-6600-A Oil Pump Body-To-Inlet Tube Gasket ................... E7GZ-6626-A Oil Pump-To-Cylinder Block Gasket ..................... E7G7-6659-A Timing Pulley Bolt ............................................... F1CZ-6A340-A Timing Pulley Key .............................................. F1CZ-6B316-B
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 center bolt listed in the TORQUE SPECIFICATION table is the revised bolt torque. Use Crankshaft Pulley Holder (T92C-6316AH).
FORD *1.6L & 1.9L 4-Cylinder

TIMING BELT APPLICATION Labor Application Time1 1.6L 4-Cyl. SOHC Escort, EXP, Lynx, LN7 1981-85 ............... 2.2 Hrs. ..... Tracer 1987-90 ............... 2.2 Hrs. ..... 1.9L 4-Cyl. SOHC Escort, EXP 1985-90 ............... 2.2 Hrs. ..... 1991 thru: 3-25-91 ..... 2.2 Hrs. ..... from: 3-26-91 .... 2.2 Hrs. ..... 1992-96 ............... 2.2 Hrs. ..... Lynx 1985-87 ............... 2.2 Hrs. ..... Tracer 1991-96 to: 3-25-91 ......... 2.2 Hrs. ..... from: 3-26-91 .... 2.2 Hrs. ..... 1 - With Air Cond. add .2 hours. Belt Component Part Kit No. No. 2520670 ... 250067 2521410 ... 250141 2520670 ... 250067 2520670 ... 250067 2521940 ... 250194 2521940 ... 250194 2520670 ... 250067 2520670 ... 250067 2521940 ... 250194
165
Raise and support vehicle. Remove right front splash shield. Remove retaining bolt and crankshaft pulley. Remove timing belt.
CAUTION: DO NOT rotate crankshaft or camshaft with timing belt removed. If camshaft must be rotated, install crankshaft pulley and position crankshaft with cylinder No. 1 at 90 degrees BTDC.
Installation: Install timing belt over sprockets in counterclockwise direction, starting at crankshaft.
CAUTION: Maintain tension on timing belt between crankshaft and camshaft sprockets when installing belt over remaining sprockets.
Loosen belt tensioner bolt. Allow belt tensioner to apply tension on timing belt. Rotate crankshaft 2 full revolutions clockwise and realign timing marks. DO NOT rotate crankshaft counterclockwise. Tighten belt tensioner bolt to specification. To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.

* NOTE: The 1.6L engine is an interference engine. See page A-59 for interference engine cautions.

TIMING BELT
Removal: Disconnect negative battery cable. Remove accessory drive belt. Remove timing belt cover. Rotate crankshaft clockwise, and align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 1. Ensure crankshaft sprocket timing mark aligns with oil pump housing timing mark. 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 engine mount at timing belt end of engine.
91H07180
165
166
FORD *1.6L & 1.9L 4-Cylinder (Cont.)
96E14831
Fig. 2: Removing Timing Belt Tensioner Pulley (Tracer)
Fig. 3: Releasing Timing Belt Tension (Except Tracer)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt ........................ 15-22 (20-30) Belt tensioner Bolt ............................................ 17-22 (23-30) Crankshaft Pulley Bolt .................................. 81-96 (110-130) Power Steering Pump Bolt ................................ 30-41 (41-56) Water Pump Bolt .............................................. 15-22 (20-30) INCH Lbs. (N.m) Timing Belt Cover Nut .......................................... 44-62 (5-7) Valve Cover Bolt ................................................ 44-106 (5-12)
Fig. 5: Aligning Camshaft Sprocket Marks (Tracer)
FORD *1.6L & 1.9L 4-Cylinder (Cont.)
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

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.6L 4-Cyl. Capri 1972 ...................... 1.3 Hours .................. 250013 2.0L 4-Cyl. Capri 1971-74 ................. 1.3 Hours .................. 250013 Pinto 1971-74 ................. 1.3 Hours .................. 250013 1 - With Air Cond. add .6 hours.
ment bolt and pivot bolt to specification. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Tensioner .................................................. 32-36 (42-48) Crankshaft Pulley ............................................. 39-43 (54-60) Timing Belt Cover ................................................. 7-9 (10-12) Water Pump Bolts 8 mm .............................................................. 12-15 (15-21) 10 mm ............................................................ 26-31 (35-41)


TIMING BELT
Removal: Disconnect negative battery cable. Remove accessory drive belts. Ensure that crankshaft is at TDC of No. 1 cylinder compression stroke. See Fig. 1. Remove camshaft belt cover. Loosen belt tensioner adjustment bolt and force tensioner to one side to relieve belt tension. Hold tensioner in this position and tighten bolt to hold tensioner. Lift belt off sprockets.
NOTE: DO NOT rotate crankshaft or camshaft with belt removed.
Installation: Place new belt over sprockets and loosen tensioner adjustment bolt to place tension on belt. Rotate crankshaft 2 complete turns to place timing marks in proper position and to remove all slack from belt. Torque tensioner adjust-
Fig. 1: Visual Camshaft Timing Check
FORD 1.8L 4-Cylinder DOHC

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Escort & Tracer 1991-96 .......... 2.8 Hrs. ...... 2521790 ........ 250179 1 - With Air Cond. add .2 hours. Labor Time Component Kit No. Belt Part No.
169


TIMING BELT
NOTE: Mark direction of timing belt rotation if timing belt is to be reused.
170
Fig. 4: Identifying Crankshaft Pulley & Guide Plates
Fig. 5: Checking Timing Belt Deflection Fig. 3: Aligning Crankshaft Sprocket Timing Marks
Removal: Disconnect negative battery cable. Remove accessory drive belts. Remove upper timing belt cover. See Fig. 1. Remove water pump pulley. Raise and support vehicle. Remove right front wheel. Remove right upper and lower splash shield. Remove middle and lower timing belt covers. Rotate crankshaft clockwise until No. 1 piston is at TDC. Ensure camshaft timing marks are aligned. See Figs. 2 and 6. Remove crankshaft pulley and hub. Mark direction of timing belt rotation if timing belt is to be reused. Loosen timing belt tensioner bolt, and remove timing belt.
CAUTION: DO NOT rotate camshafts with timing belt removed, as engine damage could result.
Installation: Temporarily position belt tensioner with spring fully extended, and tighten tensioner bolt. Ensure timing marks on crankshaft sprocket and oil pump align. See Fig. 3.
CAUTION: Ensure I and E camshaft sprocket timing marks are facing up. Camshaft sprockets may be stamped with more than one mark.
Fig. 6: Identifying Camshaft Sprocket Timing Marks
Ensure camshaft sprocket timing marks are still aligned. See Figs. 2 and 6. Install timing belt. If reusing timing belt, ensure belt is installed in original direction of rotation. Loosen tensioner bolt. Position tensioner so slack is removed from timing belt. Tighten tensioner bolt. Rotate crankshaft clockwise 2 full revolutions. Ensure all timing marks are aligned. If timing marks are not aligned, remove timing belt and repeat timing belt tensioning procedure.
Rotate crankshaft clockwise 1 5/6 revolutions. Align crankshaft timing mark with tension set mark (at approximately 10 oclock position). See Fig. 3. Loosen tensioner bolt. Apply tension to the tensioner. Tighten tensioner bolt to 27-38 ft. lbs. (37-52 N.m). Rotate crankshaft clockwise 2 1/6 revolutions. Ensure timing marks align. If timing marks are not aligned, repeat installation procedure. Measure timing belt deflection by applying 22 lbs. (10 kg) of pressure on timing belt at a point halfway between camshaft sprockets. See Fig. 5.
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. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt ........................ 15-22 (20-30) Belt Tensioner Bolt ........................................... 17-22 (23-30) Camshaft Sprocket Bolt .................................... 36-45 (49-61) Crankshaft Sprocket Bolt .............................. 80-87 (109-118) Power Steering Pump Bolt ................................ 30-45 (40-62) Timing Belt Tensioner Bolt ............................... 27-38 (37-52) Water Pump Bolt .............................................. 15-22 (20-30) INCH Lbs. (N.m) Timing Belt Cover Nut .......................................... 44-61 (5-7) Valve Cover Bolt ................................................ 48-106 (5-12)
171
172
FORD *2.0L 4-Cylinder Diesel

1
Belt Part No. Application Labor Time 2.0L 4-Cyl. Diesel Escort & Lynx 1984-87 Camshaft ............ 6.2 Hours .................. 250103 Injection Pump ... 1.3 Hours .................. 250102 Tempo & Topaz 1984-86 Camshaft ............ 6.2 Hours .................. 250103 Injection Pump... 1.3 Hours .................. 250102 1 - With Air Cond. add .6 hours.
Lower vehicle. Attach engine hoist to lifting eyes. Remove engine support tool. Disconnect right-hand insulator intermediate bracket from engine bracket and insulator. Remove bracket. Lower engine and transaxle assembly to floor. To install engine, reverse removal procedures.
CAUTION: DO NOT allow front wheels to touch ground.
TIMING BELT

Removal: With engine out of vehicle, remove front upper timing belt cover and flywheel timing mark case. Rotate crankshaft in normal direction of rotation to align timing marks of flywheel and front camshaft sprocket with pointers. Loosen tensioner pulley lock bolt to slide timing belt off water pump and camshaft.
NOTE: DO NOT allow crankshaft to rotate with timing belt removed.

ENGINE REMOVAL
NOTE: Engine/transaxle must be removed to replace timing belt. The engine/transaxle is removed as an assembly.
Installation: Align camshaft and crankshaft sprockets with their respective timing marks. See Fig. 1. Remove tensioner spring from front timing belt upper cover pocket and install in tensioner lever slot and over crankcase stud. See Fig. 4. Push tensioner lever as far as possible toward water pump and tighten lock bolt. Install timing belt. With tensioner pulley loose, adjust belt tension by rotating crankshaft pulley in direction of rotation twice until No. 1 cylinder is at TDC (camshaft timing marks aligned). Tighten tensioner lock bolt. Adjust belt tension to 33-44 lbs. (15-20 kg). Remove tensioner spring and place in front cover pocket.
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 under 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 exhaust bracket at oil pan. Disconnect both exhaust pipes from manifold. Pull exhaust system from grommets and set aside. Disconnect speedometer cable from transaxle. Disconnect heater hoses at water pump inlet tube and at oil cooler. Disconnect control arms at body. Remove stabilizer bar brackets. Remove half-shaft assemblies and install alignment plugs in differential side gears. On manual transaxle models, remove shift stabilizer bar-to-transaxle bolts. Remove shift mechanism-to-shift shaft attaching bolt at transaxle. Remove left-hand rear insulator mount bracket from body bracket. Remove left-hand front insulator-to-transaxle bolts.
Fig. 1: Cross Section Of 2.0L Diesel Engine
FORD *2.0L 4-Cylinder Diesel (Cont.)

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.
173
REAR TIMING BELT

Removal: Remove rear timing belt cover and flywheel timing mark case. Rotate crankshaft until No. 1 cylinder is at TDC (flywheel timing mark at TDC, camshaft sprocket and injection pump timing marks aligned). See Figs. 2 and 5. Loosen tensioner lock nut. Turn tensioner clockwise with a screwdriver to loosen timing belt. Tighten lock nut and remove timing belt. Installation: Install timing belt and adjust belt tension as follows: with tensioner pulley loose, rotate crankshaft twice until flywheel TDC timing mark aligns with pointer. Tighten tensioner lock nut and adjust belt tension to 22-33 lbs. (10-15 kg). Install timing belt cover and flywheel timing mark case. Adjust drive belts to proper tension.See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket (Front & Rear) .............................. 45 (61) Crankshaft Pulley ................................................... 119 (165) CV Hub Nut ............................................... 180-200 (244-271) Insulator 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. 2: Aligning Camshaft & Injection Pump Timing Marks
174
Fig. 6: Aligning Camshaft Timing Mark
Fig. 7: Installing Rear Timing Belt
FORD 2.0L 4-Cylinder DOHC, Escape

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. VIN 3 Escape 2001 ...................... 3.6 Hours .................. 250294
175
Rotate crankshaft to just before No. 1 cylinder TDC. See Fig. 2. Remove stud and install Crankshaft TDC Timing Peg (303-574). See Fig. 3.
NOTE: Make sure second notch in pulley is indexed to lower cylinder block. See Fig. 2.


TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed, damage to valves and pistons may result.
Rotate crankshaft clockwise against peg to bring it to TDC. Loosen water pump pulley bolts. Remove timing belt cover by removing crankshaft pulley, then remove lower timing belt cover bolts and lower timing belt cover. See Fig. 4. Install Engine Support Bar (303-F072). See Fig. 5. Remove ground strap and engine mount upper bracket and studs. See Fig. 6. Remove upper timing belt cover bolts and cover. See Fig. 7. Remove water pump pulley and accessory drive belt idler pulley. Install Camshaft Alignment Tool (303-465) and align camshafts. See Fig. 8.
Removal: Disconnect negative battery cable. Remove accessory drive belt. Remove air cleaner outlet pipe and ignition wires from spark plugs. Disconnect throttle cables and cruise control actuator cable. Disconnect accelerator cable. Remove valve cover. See Fig. 1. Remove spark plugs. Remove catalytic converter. Remove coolant tube bolt and nut. Position coolant tube to side.
NOTE: Installation of Camshaft Alignment Tool (303-465) into exhaust camshaft may require camshafts to be rotated slightly clockwise.
Raise and support vehicle. Remove engine mount lower bracket. See Fig. 9. Loosen timing belt tensioner pulley and allow it to slide down to bottom of its travel. Slide timing belt off of camshaft and crankshaft sprockets.
CAUTION: DO NOT reuse old timing belt. Replace with a new belt.
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
Fig. 6: Removing Engine Mount Upper Bracket
Fig. 7: Removing Upper Timing Belt Cover
Installation: Slide crankshaft pulley onto crankshaft. Ensure crankshaft position is at No, 1 TDC by rotating it clockwise against Crankshaft TDC Timing Peg (303-574). Ensure second notch in pulley is indexed to lower cylinder block. See Fig. 2. Remove crankshaft pulley. Ensure timing belt tensioner is installed correctly with tab positioned in slot in inner timing cover. See Fig. 10. Install new timing belt onto timing belt sprockets and adjust timing belt tensioner by using a 6 mm Allen wrench to rotate adjuster counterclockwise and align marks. See Figs. 11 and 12. Tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS table. Install front engine mount lower bracket. Install accessory drive belt idler pulley. Install water pump pulley, but hand tighten only. Install timing belt covers. Install crankshaft pulley. Tighten water pump pulley bolts to specification. See TORQUE SPECIFICATIONS. Remove Crankshaft TDC Timing Peg (303-574). Install stud. Install engine mount upper bracket and ground strap. Remove 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. Reconnect negative battery cable.
Fig. 8: Installing Camshaft Alignment Tool (303-465)
FORD 2.0L 4-Cylinder DOHC, Escape (Cont.)

177
Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Pulley Bolt .......................... 35 (45) Coolant Tube Attachments ............................................. 15 (20) Crankshaft Pulley Bolt .................................. 81-89 (110-121) Engine Mount Lower Bracket Nuts ................................. 37 (50) Engine Mount Upper Bracket Nuts ................................. 61 (83) Engine Mount Upper Bracket Studs .............................. 25 (34) Exhaust Camshaft Center Plug ..................................... 27 (37) Ground Strap .................................................................. 25 (34) Spark Plugs ................................................................... 11 (15) Stud (For Crankshaft TDC Timing Peg) .......................... 18 (24) Timing Belt Tensioner Bolt ............................................ 18 (25) Water Pump Pulley Bolt ................................................. 18 (24) INCH Lbs. (N.m) Lower Timing Belt Cover Bolt ....................................... 62 (7) Upper Timing Belt Cover Bolt ....................................... 71 (8) Valve Cover ...................................................................... 80 (9)
178
FORD 2.0L 4-Cylinder VIN 3, 1995-97
Ensure crankshaft timing marks are aligned. See Fig. 1. Loosen timing belt tensioner pulley, and allow spring to pull pulley against timing belt. Remove camshaft alignment tool. Rotate crankshaft clockwise 2 full revolutions. Tighten timing belt tensioner pulley to specification. See TORQUE SPECIFICATIONS. Align crankshaft timing marks. See Fig. 1. Ensure camshafts are still aligned by installing Camshaft Alignment Tool (T94P-6256-CH) on rear of camshafts. If crankshaft and camshaft alignment is correct, continue with installation procedure. If camshaft alignment tool cannot be installed on camshafts with crankshaft at TDC, hold camshaft sprocket with Camshaft Sprocket Holding Tool (T74P-6256-B) or spanner wrench. Loosen, but do not remove, camshaft sprocket center bolt. Rotate camshafts until camshaft alignment tool can be installed on rear of camshafts. Crankshaft MUST remain at TDC when aligning camshafts. Tighten camshaft sprocket center bolts to specification. Continue with installation procedure. Install timing belt covers. Install crankshaft pulley. Tighten bolt to specification. Install valve cover. Install spark plugs. Install upper front engine mount. Remove engine support tool. Install water pump pulley. Install serpentine belt idler pulley and serpentine bolt. Install coolant recovery reservoir. Continue installation in reverse of removal procedure. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt ........................ 15-22 (20-30) Alternator Mounting Bolt .................................... 30-41 (41-56) Camshaft Sprocket Bolt .................................... 47-53 (64-72) Crankshaft Pulley Bolt .................................. 81-89 (110-121) Serpentine Belt Idler Pulley Bolt ..................................... 35 (48) Timing Belt Tensioner Bolt .................................. 26-30 (35-40) Upper Front Engine Mount Nuts .......................... 52-70 (70-95) Water Pump Bolt .............................................. 12-15 (16-20) INCH Lbs. (N.m) Center Timing Belt Cover Bolt .............................. 53-71 (6-8) Lower Timing Belt Cover Bolt ............................... 53-71 (6-8) Spark Plug ................................................... 106-156 (12-18) Upper Timing Belt Cover Bolt ............................... 27-44 (3-5) Valve Cover ........................................................... 53-71 (6-8) Water Pump Pulley Bolt .................................. 89-124 (10-14)
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. Contour & Mystique 1995-97 .................. 2.6 Hours .................. 250258


TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed, damage to valve/piston may result.
Removal: Noting position for installation reference, disconnect secondary wires from spark plugs. Remove spark plugs. Disconnect negative battery cable. Remove air intake resonators. Remove power steering pressure hose bracket from lifting eye, and position aside. Support engine from above using Three Bar Engine Support (D88L-6000-A) or equivalent. Remove upper timing belt cover. Mark position of upper front engine mount before removal. Remove upper front mount. If equipped, disconnect coolant level sensor connector from coolant recovery reservoir. Remove retainers attaching recovery reservoir, and position aside. Remove upper front mount insulator. Loosen water pump pulley bolts. Remove serpentine drive belt. Remove drive belt idler pulley from alternator mounting bracket. Remove water pump pulley. Remove center timing belt cover. Raise and support vehicle. Remove crankshaft pulley. Remove lower timing belt cover. Remove valve cover. Temporarily install crankshaft pulley. Rotate crankshaft to align timing mark on block with larger notch on pulley. See Fig. 1. Use Camshaft Alignment Tool (T94P-6256-CH) or equivalent to align camshafts. See Fig. 2. Install tool in slots on camshafts at rear of engine. Loosen timing belt tensioning pulley. See Fig. 4. Move pulley to relieve tension on timing belt, and retighten pulley. If reusing timing belt, mark direction of rotation before removal. Remove timing belt. Installation: Temporarily install crankshaft pulley. Ensure crankshaft pulley 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 clockwise direction, install timing belt around camshaft sprockets. Ensure timing belt span between crankshaft sprocket and exhaust camshaft is not loose. Ensure timing belt is aligned on all sprockets. Install lower timing belt cover. Apply Silicone Gasket Sealer (F1AZ 9562-A) or equivalent to crankshaft keyway. Install crankshaft pulley. Tighten bolt to specification. See TORQUE SPECIFICATIONS.
FORD 2.0L 4-Cylinder VIN 3, 1995-97 (Cont.)
179
Courtesy of For Motor Co.
Fig. 2: Installing Camshaft Alignment Tool
180
FORD 2.0L 4-Cylinder VIN 3, 1998-01
Loosen timing belt tensioner center attaching bolt about 4 turns. Position tensioner locating tab at approximately the 4 oclock position. See Fig. 4. Line up hex key slot in tensioner adjusting washer with pointer that is located behind pulley. See Fig. 4.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. VIN 3 Cougar 1999-01 ................. 3.2 Hours .................. 250294 Contour & Mystique 1998-00 ................. 3.2 Hours .................. 250294 Escort ZX2 1998-01 ................. 2.8 Hours .................. 250294 Focus 2000-01 ................. 2.8 Hours ................. 250294
CAUTION: To achieve proper tension when installing timing belt, camshaft sprocket bolts must be loose enough to allow sprockets to turn freely on the camshafts.

For 1998-00 model years, the manufacturer recommends the belt be inspected every 120,000 miles. Replace, if necessary. For 2001 model year, the manufacturer recommends the belt be replaced every 120,000 miles.

TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed, damage to valve/piston may result.
Removal (Contour, Cougar & Mystique): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove engine splash shield from right wheelwell. Remove engine undercover, if equipped. Loosen, but do not remove, water pump pulley bolts. Turn serpentine drive belt tensioner clockwise and remove serpentine drive belt. If belt is to be reused, mark belt with arrow to indicate direction of rotation. Remove water pump pulley. Remove serpentine belt idler pulley. Remove crankshaft pulley center bolt and remove pulley. Remove lower timing belt cover. Working from under vehicle, 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 engine. Marking installed position for installation reference, remove engine front support insulator from timing belt end of engine. Remove power steering pressure hose bracket from engine lifting eye, and position aside. Remove upper and center timing belt covers.
NOTE: Spark plug removal is necessary for final timing adjustment.
Remove plug from center of exhaust camshaft pulley. Hold exhaust camshaft with open end wrench on hex portion of camshaft. See Fig. 3. Loosen, but do not remove, exhaust camshaft sprocket bolt. Loosen, but do not remove, intake camshaft sprocket bolt. If reusing timing belt, mark direction of rotation before removal. Remove timing belt. To lock crankshaft in correct position, remove plug from lower, left part of engine block. See Fig. 1. Rotate crankshaft to a few degrees before TDC position. Install locking Crankshaft Position Timing Peg (T97P-6000A) into plug hole. Rotate crankshaft clockwise to lock crankshaft against timing peg. Removal (Escort): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove engine splash shield from right wheelwell. Disconnect HO2S electrical connectors. Unbolt catalytic converter from exhaust manifold and from muffler inlet pipe. Remove crossmember bolts and crossmember. Remove catalytic converter bracket bolts. Remove catalytic converter. Lower vehicle. Remove center trim cover from valve cover. Noting installed position for installation reference, disconnect spark plug wires. Remove spark plugs. Remove valve cover bolts (10). Remove valve cover. Loosen, but do not remove, water pump pulley bolts. Turn serpentine drive belt tensioner clockwise and remove ser-
Remove top engine appearance cover from between valve covers. Remove secondary wires from spark plugs. Working 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 crankshaft pulley Woodruff key points straight up.

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. Marking installed position for installation reference, remove engine front support insulator. Remove upper and center timing belt covers. Temporarily install crankshaft pulley. Rotate crankshaft to align timing mark on block with larger notch on pulley. See Fig. 1. To lock crankshaft in correct position, remove plug from lower, left part of engine block. See Fig. 1. Rotate crankshaft to a few degrees before TDC position. Install locking Crankshaft Position Timing Peg (T97P-6000-A) into plug hole. Rotate crankshaft clockwise to lock crankshaft against timing peg. Loosen timing belt tensioner center attaching bolt about 4 turns. Position tensioner locating tab at approximately the 4 oclock position. See Fig. 4. Line up hex key slot in tensioner adjusting washer with pointer that is located behind pulley. See Fig. 4.
Fig. 2: Timing Belt Installed Position
Fig. 3: Installing Camshaft Alignment Tool
Fig. 4: Aligning Timing Belt Tensioner For Belt Removal
Remove plug from center of exhaust camshaft pulley. Hold exhaust camshaft with open end wrench on hex portion of camshaft. See Fig. 3. Loosen, but do not remove, exhaust camshaft sprocket bolt. Loosen, but do not remove, intake camshaft sprocket bolt. If reusing timing belt, mark direction of rotation before removal. 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 rotation direction. Remove serpentine drive belt. Remove water pump pulley. Remove serpentine belt idler 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 steering 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 engine. 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. Working from the outer ends to the center, loosen valve cover bolts. Remove valve cover. Remove secondary wires and spark plugs. Remove PCV hose. Temporarily install crankshaft pulley. Rotate crankshaft to align timing mark on block with larger notch on pulley. See Fig. 1. To lock crankshaft in correct position, remove plug from lower, left part of engine block. See Fig. 1. Rotate crankshaft to a few degrees before TDC position. Install locking Crankshaft Position Timing Peg (T97P-6000-A) into plug hole. Rotate crankshaft clockwise to lock crankshaft against timing peg.
182
Loosen timing belt tensioner center attaching bolt about 4 turns. Position tensioner locating tab at approximately the 4 oclock position. See Fig. 4. Line up hex key slot in tensioner adjusting washer with pointer that is located behind pulley. See Fig. 4.
Holding exhaust camshaft stationary with Holding Tool (303098) or spanner wrench, loosen, but do not remove, exhaust camshaft sprocket bolt. Holding intake camshaft sprocket stationary, loosen, but do not remove, intake camshaft sprocket bolt. If reusing timing belt, mark direction of rotation before removal. 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 timing peg during timing belt installation. Position cylinder No. 4 to valves overlap position. Install Camshaft Alignment Tool (T94P-6256-CH) or equivalent to align camshafts. See Fig. 3. Camshafts may be turned slightly with open end wrench, in normal direction of rotation, 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.
Fig. 5: Positioning Tensioner Hex Key Slot
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 sprockets in counterclockwise direction. Remove all slack from belt during installation.
CAUTION: Incorrect timing belt tension will cause incorrect valve timing.
To tension the timing belt, rotate timing belt tensioner tab counterclockwise and insert tab into slot in rear cover. Position hex key slot in tensioner adjusting washer to the 4 oclock position. See Fig. 5. Tighten attaching bolt enough to seat the tensioner firmly against rear timing cover, BUT still allow the tensioner adjusting washer to be rotated with a 6 mm hex key. Working counterclockwise, tension the timing belt. Ensure all slack is removed from belt. Using a 6 mm hex key, rotate adjusting washer until notch in pointer is centered over index line on locating tab. See Fig. 6. Pointer will move clockwise during adjustment. While holding adjusting washer in position so that it does not rotate, tighten tensioner center attaching bolt to 18 ft. lbs. (25 N.m).
Fig. 6: Final Timing Belt Tensioning
NOTE: DO NOT use Camshaft Alignment Tool (T94P-6256-CH) to hold camshafts stationary while tightening camshaft sprocket bolts.
On Focus models, hold intake camshaft sprocket stationary, and tighten intake camshaft sprocket bolt to 50 ft. lbs.
(68 N.m). Hold exhaust camshaft stationary and tighten exhaust camshaft sprocket bolt to 50 ft. lbs. (68 N.m). On Escort ZX2, Contour, Cougar and Mystique, hold intake camshaft with Holding Tool (303-098) or spanner wrench, and tighten camshaft sprocket bolt to 50 ft. lbs. (68 N.m). On Escort ZX2, Contour, Cougar and Mystique, hold exhaust camshaft with open end wrench. Tighten exhaust camshaft sprocket bolt to 44 ft. lbs. (60 N.m). Final tighten exhaust camshaft sprocket bolt to 88 ft. lbs. (120 N.m). On all models, remove camshaft alignment tool. Remove timing peg from side of engine block. Rotate crankshaft 2 revolutions in normal direction of rotation. Align crankshaft pulley with timing mark. Install locking Crankshaft Position Timing Peg (T97P-6000-A) into plug hole. Rotate crankshaft clockwise to lock crankshaft against timing peg. Camshaft Alignment Tool (T94P-6256-CH) should slide into slots in rear of camshafts. If not, readjust camshaft pulley positions.

On all models except Focus, install NEW center plug into exhaust camshaft sprocket after all timing marks are aligned and belt is tensioned. On all models, install valve covers. Install spark plugs and secondary wiring. Install appearance cover between valve covers. Connect solenoid valve electrical connector in appearance cover (if equipped) and press in rubber seal. Install upper and center timing belt covers. Install front engine front support insulator. Remove floor jack. On Contour, Cougar, and Mystique, attach power steering pipe bracket to engine lifting eye. Install coolant reservoir tank. Raise and support vehicle. Verify that center bolt is centered in right-hand and left-hand lower engine support insulators. Tighten center bolt to specification. See TORQUE SPECIFICATIONS. On Escort, install catalytic converter and crossmember. On all models, install lower timing belt cover. Install crankshaft pulley and tighten bolt to specification. Install serpentine drive belt idler pulley. Install water pump pulley. Install serpentine drive belt. Install engine splash shield and undercover (if equipped). Install right front wheel. Tighten lug nuts to specification. When battery is disconnected, some abnormal driveability symptoms may occur until the PCM relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to complete a relearn cycle. TORQUE SPECIFICATIONS
183
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt (Except Focus) Intake .......................................................................... 50 (68) Exhaust Step 1 ....................................................................... 44 (60) Step 2 ..................................................................... 88 (120) Camshaft Sprocket Bolt (Focus) Intake & Exhaust ......................................................... 50 (68) Catalytic Converter (Escort) Bracket Bolts ..................................................... 41-47 (55-64) To-Exhaust Manifold Bolts ................................. 41-47 (55-64) To-Muffler Pipe Flange Bolts ............................. 34-39 (46-54) Crankshaft Pulley Bolt .................................. 81-89 (110-121) Crossmember Bolts (Escort) ............................ 69-93 (94-126) Engine Front Support Insulator Bolt/Nut (Except Focus) ................................. 61 (83) Engine Front Support (Focus) To-Engine Bracket Nut ................................................ 59 (80) To-Frame Bolts ............................................................ 42 (48) Engine Lower Support Insulators (Contour, Cougar & Mystique) Right-Hand Auto. Trans. ............................................................. 88 (120) Man. Trans. ............................................................... 42 (48) Left-Hand All Vehicles .............................................................. 88 (120) Exhaust Camshaft Center Plug ..................................... 27 (37) Serpentine Drive Belt Idler Pulley Bolt ............................ 35 (40) Spark Plugs ................................................................... 11 (15) Timing Belt Tensioner Attaching Bolt ............................. 18 (25) Water Pump Bolt ........................................................ 13 (18) Water Pump Pulley Bolt ................................................. 17 (24) 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) Lower Timing Belt Cover Bolt ....................................... 62 (7) 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

Installation (Escort & Tracer): Ensure timing marks are still aligned. Install timing belt. If reusing old belt, ensure it is installed in original direction of rotation. Remove drill bit and tighten tensioner bolt. Rotate crankshaft clockwise 2 revolutions. Recheck timing mark alignment. To complete installation, reverse removal procedure. Removal (Focus) Disconnect negative battery cable. Detach coolant expansion tank and set to one side. Remove power steering fluid reservoir from shock tower and set aside with hoses attached. Turn serpentine belt tensioner clockwise to relieve tension and remove serpentine drive belt. Remove power steering drive belt. Hold power steering pump pulley stationary and remove power steering pump center nut. Remove power steering pump pulley. Remove power steering pump mounting nuts. Set power steering pump aside with hoses attached. Raise and support vehicle. Remove right front wheel. Remove the lower drive belt cover. Remove the crankshaft pulley and vibration damper. Lower vehicle. Noting position for reassembly reference, disconnect spark plug secondary cables from spark plugs. Remove spark plugs. Place jack under engine to support weight. Remove front engine mount and upper timing belt cover from timing belt end of engine. Remove center timing belt cover. Remove engine mount bracket from timing belt end of engine. Turn the crankshaft so that timing marks are aligned. See Fig. 1. Loosen timing belt tensioner. Using an 8 mm hex wrench, turn tensioner 1/4 turn counterclockwise. Insert 1/ 8 drill bit to lock tensioner in place. See Fig. 2. If reusing old belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Installation (Focus): Ensure timing marks are still aligned. Install timing belt in a counterclockwise direction starting at crankshaft sprocket. Keep slack out of belt span from crankshaft to camshaft sprocket. If reusing old belt, ensure it is installed in original direction of rotation. Remove drill bit and tighten tensioner bolt. Rotate crankshaft clockwise 2 revolutions. Recheck timing mark alignment. If not correct, readjust timing belt. Install engine mount bracket and upper timing belt cover to engine. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Install lower timing belt cover. Install engine 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 center 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 negative battery cable.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. VIN P Escort & Tracer 1997-01 ................. 2.2 Hours .................. 250283 Focus 2000-01 ................. 2.2 Hours .................. 250283

Up to 2000 model year, the manufacturer recommends that the timing belt be inspected at 120,000 miles. Replace, if necessary. For 2001 model year, the manufacturer recommends that the timing belt be replaced at 120,000 miles.

TIMING BELT
Removal (Escort & Tracer): Disconnect negative battery cable. Place cylinder No. 1 to TDC of compression stroke. Remove accessory drive belt and tensioner. Remove timing belt cover. Raise and support vehicle. Remove right hand splash guard. Remove crankshaft pulley. Align timing marks. See Fig. 1. Loosen timing belt tensioner. Using an 8 mm hex wrench, turn tensioner 1/4 turn counterclockwise. Insert 1/8 drill bit to lock tensioner in place. See Fig. 2. If reusing old belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt.
FORD 2.0L 4-Cylinder SOHC, VIN P (Cont.)

185
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................. 70-85 (95-115) Crankshaft Pulley Bolt ...................................... 81-96 (110-130) 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

TIMING BELT APPLICATION Application 2.0L 4-Cyl. Probe 1993-97 .......... 2.5 Hrs. ...... 2522280 ....... 250228 2.2L 4-Cyl. Probe 1989-92 .......... 2.3 Hrs. ...... 2521340 ....... 250134 1 - With Air Cond. add .2 hours.

For the 2.0L engine, the manufacturer recommends the belt be replaced at every 60,000 miles, except in California. For California 2.0L engine, replace belt at 105,000 miles. For the 2.2L engine, the manufacturer recommends the belt be replaced at every 60,000 miles.
Fig. 2: Exploded View Of Timing Belt Components (2.2L)
Fig. 1: Exploded View Of Timing Belt Components (2.0L)
FORD *2.0L & *2.2L 4-Cylinder Probe (Cont.)
187
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.

TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed. Damage to valve/piston may result.
Rotate crankshaft clockwise and align crankshaft sprocket timing notch with line on oil pump. Ensure camshaft sprocket timing marks align. Install Camshaft Pulley Holder (T92C6256-AH) or equivalent. Using an Allen wrench, turn timing chain tensioner and remove tensioner spring. Remove timing belt. Installation: Install timing belt. Rotate tensioner clockwise with an Allen wrench, and install tensioner spring. Ensure timing marks on crankshaft sprocket and engine block align. Remove camshaft pulley holder, and ensure camshaft sprocket timing marks are still aligned. Rotate crankshaft clockwise 2 full revolutions. Ensure all timing marks align. If timing marks do not align, remove timing belt. Repeat previous two steps. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Removal: Disconnect negative battery cable. Remove accessory drive belts. Remove spark plug wires and valve cover. Install Three Bar Engine Support (014-00750) or equivalent. Slightly raise engine with a jack. Remove right engine mount. Remove dipstick bolt. Remove upper timing belt cover.
188
FORD *2.0L & *2.2L 4-Cylinder Probe (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt ........................ 18-26 (24-35) Alternator Mounting Bolt ......................................... 27-38 (52) Camshaft Sprocket Bolt .................................... 36-45 (49-61) Crankshaft Sprocket Bolt .......................... 116-123 (157-167) Tensioner Bolt .................................................. 27-38 (39-50) Water Pump Bolt .............................................. 14-19 (19-26) INCH Lbs. (N.m) Timing Belt Cover Bolt ........................................ 61-87 (8-10) Valve Cover ........................................................... 53-62 (6-7) Water Pump Pulley Bolt ...................................... 71-89 (8-10)
FORD 2.0L & 2.3L 4-Cylinder

TIMING BELT APPLICATION Labor Component Application Time Kit No. 2.0L 4-Cyl. OHC Ranger 1983-88 .......... 12.2 Hrs. ..... 2520140 ........ 250014 2.3L 4-Cyl. OHC Aerostar 1987 ............... 12.2 Hrs. ..... 2520140 ........ 250014 Cougar 1981 ............... 11.3 Hrs. ..... 2520140 ........ 250014 1984-86 .......... 11.3 Hrs. ..... 2520140 ........ 250014 Courier 1977-82 .......... 22.2 Hrs. ..... 2520140 ........ 250014 Fairmont & Zephyr 1978-83 .......... 21.6 Hrs. ..... 2520140 ........ 250014 Granada 1981-82 .......... 21.6 Hrs. ..... 2520140 ........ 250014 LTD & Marquis 1983-86 .......... 21.5 Hrs. ..... 2520140 ........ 250014 Merkur XR4Ti 1985-89 .......... 11.5 Hrs. ..... 2520140 ........ 250014 Mustang, Mustang II & Capri 1974-91 .......... 21.6 Hrs. ..... 2520140 ........ 250014 1992 With Round Tooth Sprockets ... 11.5 Hrs. ............................ 250210 With SquareTooth Sprockets ... 11.5 Hrs. ..... 2520140 ........ 250014 Mustang 1993 ............... 21.5 Hrs. ............................ 250210 Pinto & Bobcat 1974-80 .......... 22.0 Hrs. ..... 2520140 ........ 250014 Ranger 1983-91 .......... 12.2 Hrs. ..... 2520140 ........ 250014 1992 With Round Tooth Sprockets ... 12.2 Hrs. ............................ 250210 With SquareTooth Sprockets ... 12.2 Hrs. ..... 2520140 ........ 250014 1993-94 .......... 12.2 Hrs. ............................ 250210 Thunderbird 1983-88 .......... 21.3 Hrs. ..... 2520140 ........ 250014 1 - With Air Cond. add 1.0 hours. 2 - With Air Cond. add .5 hours Belt Part No.
189


TIMING BELT
CAUTION: Rotate crankshaft clockwise (in normal rotation direction) only. Timing belt may come off if engine is rotated counterclockwise.
Removal: Disconnect negative battery cable. Rotate engine clockwise and position cylinder No. 1 on TDC of compression stroke. Ensure O mark on crankshaft pulley aligns with O mark on outer timing belt cover. Looking through plug hole of outer timing belt cover, ensure camshaft sprocket timing mark aligns with cover pointer. See Fig 1. Remove fan guard, cooling shroud, cooling fan and fan shroud. Remove drive belt, water pump pulley and automatic belt tensioner. Discharge A/C System (if equipped) using approved refrigerant recovery equipment. Remove A/ C compressor mounting bracket with power steering pump attached, and position aside. Drain cooling system. Remove upper radiator hose. Remove thermostat housing and gasket. Remove retaining bolt and crankshaft pulley. Remove hub assembly retaining bolt from crankshaft. Remove outer timing belt cover. Ensure camshaft sprocket timing mark aligns with cover pointer. See Fig. 1. Loosen belt tensioner bolts. Using Camshaft Belt Tensioner (T74P-6254-A) or equivalent, release spring tension on belt tensioner. Rotate belt tensioner away from timing belt and tighten bolts. Remove retaining bolts and pull crankshaft sensor from dowel pins. See Fig. 1. Remove hub assembly and belt guide. Note direction of belt guide installation. Remove timing belt. Installation: Install crankshaft sprocket (if removed) with recessed area toward crankshaft. See Fig. 1. Install belt guide with flat side toward camshaft sprocket. Install camshaft sprocket with timing mark outward. Install NEW camshaft sprocket bolt and tighten to specification while holding camshaft with camshaft sprocket holder. See TORQUE SPECIFICATIONS.
CAUTION: Install NEW camshaft sprocket bolt. DO NOT reuse bolt.
Align camshaft sprocket timing mark with pointer. Properly position crankshaft so timing mark aligns with notch in front cover casting. See Fig. 3. Install timing belt over crankshaft sprocket, then counterclockwise over auxiliary shaft and camshaft sprockets. Loosen belt tensioner bolt, allowing tension to be applied on timing belt.
NOTE: It may be necessary to push belt tensioner against timing belt, as spring tension may not move belt tensioner against timing belt.
190
Remove one spark plug from each cylinder. Rotate engine clockwise (viewed from front of engine) 2 complete revolutions. Tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Ensure all timing marks align properly. Install belt guide on crankshaft. Install crankshaft sensor over dowel pins. Tighten long crankshaft sensor bolts to 14-22 ft. lbs. (19-30 N.m). Rotate crankshaft counterclockwise approximately 45 degrees so outer vane of hub assembly does not engage with crankshaft sensor positioner. Install hub assembly and crankshaft pulley. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install crankshaft sensor positioner. See Fig. 2. Rotate crankshaft clockwise approximately 90 degrees so outer vane of hub assembly engages with crankshaft sensor positioner. Tighten short crankshaft sensor bolts to 14-22 ft. lbs. (19-30 N.m). To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Disconnect heater hose from fitting on thermostat housing to bleed air from cooling system when filling. Fill cooling system with Ford Coolant (E2FZ-19549-AA) or equivalent, until coolant flows from fitting. Install heater hose. Refill radiator. Adjust drive belts to proper tension. See page a-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auxiliary Shaft Sprocket Bolt .............................. 29-40 (39-54) Belt Tensioner Adjusting Bolt ................................................. 14-22 (19-30) Pivot Bolt ....................................................... 29-40 (39-54) Camshaft Plug ................................................. 12-18 (16-24) Camshaft Sprocket Bolt 1 .................................. 52-70 (71-95) Crankshaft Pulley-To-Hub Assembly Bolt ......... 15-22 (20-30) Water Pump Bolt 2 ............................................ 14-21 (19-29) Water Pump Pulley Bolt .................................... 14-22 (19-30) INCH Lbs. (N.m) Auxiliary Shaft Cover Bolt .................................. 72-108 (8-12) Auxiliary Shaft Retainer Plate Bolt ..................... 72-108 (8-12) Camshaft Retainer Thrust Plate Box ................ 72-108 (8-12) Outer Timing Belt Cover Bolt ............................ 72-108 (8-12) Valve Cover Bolt .................................................. 60-96 (6-11) 1 - Install NEW bolt. DO NOT reuse bolt. 2 - Apply thread sealant on bolt threads.
FORD 2.0L & 2.3L 4-Cylinder (Cont.)
Fig. 2: Positioning Crankshaft Sensor
FORD 2.0L & 2.3L 4-Cylinder (Cont.)
191
Fig. 3: Positioning Crankshaft
Fig. 4: Aligning Camshaft & Oil Pump Timing Marks
192
FORD *2.3L 4-Cylinder Diesel
TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.3L 4-Cyl. Diesel Ranger 1985-87 Balance Shaft ..... 2.2 Hours .................. 250092 Camshaft ............. 2.2 Hours .................. 250091 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours.
Check timing belts for missing teeth, cracking or excessive wear. Replace timing belt if necessary. Camshaft/injection pump timing belt must be removed to access silent shaft timing belt.
NOTE: DO NOT loosen nut near timing scale unless removing silent shaft timing belt. This nut is for silent shaft timing belt tensioner. Loosening this nut may change silent shaft timing belt tension. See Fig. 1.

Installation: Fabricate timing belt tensioner, using a pivot nut from rear brake adjuster and bar stock. See Fig. 3. Release tension on tensioner spring, using belt tensioner. Rotate tensioner toward water pump and tighten top bolt. Install camshaft/injection pump timing belt. Ensure belt is installed to rotate in original rotation. Maintain tension on belt. Loosen top tensioner bolt to tension timing belt. See Fig. 4. Tighten tensioner hold-down bolts. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.

TIMING BELT
Removal: Disconnect negative battery cable. Remove drive belts. Remove 5 upper front timing belt cover retaining bolts. Remove upper front cover. Remove cooling fan and shroud. Remove water pump pulley. Remove crankshaft pulley attaching bolt. Rotate crankshaft until No. 1 piston is at TDC on compression stroke. Remove vibration damper using Damper Remover (T58P6316-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

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 47-54 (64-73) Crankshaft Pulley Bolts ............................ 123-137 (167-186) Injection Pump Sprocket Nut ............................ 40-50 (54-68) Silent Shaft Sprocket Bolt .................................. 25-28 (34-39) Timing Belt Tensioner Nut ................................ 16-21 (22-29) INCH Lbs. (N.m) Front Case Bolts ......................................... 108-120 (12-14) Rocker Cover Bolts ............................................... 48-60 (5-7) Silent Shaft Chamber Cover Bolts ........................ 36-48 (4-5)
193
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

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.3L 4-Cyl. Ranger 1995-97 ................. 2.2 Hours .................. 250276 1 - With Air Cond. add 1.0 hours. With Pwr. Strng. add .3 hours.
release tension. See Fig. 2. Pry tensioner away from timing belt and tighten bolt to hold tensioner in place. Remove timing belt.
CAUTION: Always rotate engine in direction of normal rotation (clockwise as viewed from front of engine). Reverse rotation may cause timing belt to jump time, causing engine damage.


TIMING BELT
Removal: Remove spark plugs. Ensure crankshaft is set at TDC and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. See Fig. 1. Remove fan guard. Remove fan shroud and position aside. Remove fan retaining screws, and remove fan and shroud. Rotate drive belt tensioner and remove belt. Remove cooling fan and water pump pulley. Discharge A/C system (if equipped) using approved refrigerant recovery/ recycling equipment. Remove A/C compressor and position aside. Remove A/C compressor mounting bracket with power steering pump attached, and position aside. Remove timing belt outer cover retaining bolt. Release 7 cover interlocking tabs. Remove timing belt cover. Holding timing belt tensioner with Camshaft Belt Tension Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt and slowly
Installation: Ensure crankshaft is set at TDC and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. Install NEW timing belt. Loosen tensioner bolt. Allow tensioner to adjust itself, and retighten bolt. Rotate crankshaft clockwise 2 complete revolutions to remove slack from belt. Loosen tensioner bolt. Allow tensioner to adjust itself and retighten bolt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolts ..................................... 15-21 (21-28) Alternator Bracket Bolts .................................... 30-40 (41-54) Alternator Retaining Bolts ................................. 30-40 (41-54) Camshaft Sprocket Bolt .................................... 50-71 (68-96) Cooling Fan Bolts ............................................. 13-16 (17-23) Crankshaft Damper Bolt ........................... 103-133 (140-180) Oil Pump Sprocket Bolt ..................................... 28-40 (38-54) Timing Belt Tensioner Adjusting Bolt ................ 14-21 (35-45) Timing Belt Tensioner Pivot Bolt ....................... 28-40 (40-55) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt .......................... 71-106 (8-12) Spark Plug ........................................................ 80-177 (9-20) Valve Cover Bolt ................................................ 80-115 (9-13)
Fig. 1: Aligning Camshaft & Oil Pump Timing Marks Fig. 2: Exploded View Of Timing Belt & Components

TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.5L 4-Cyl. Ranger 1998-01 ................. 2.2 Hours .................. 250276 1 - With Air Cond. add 1.0 hours. With Pwr. Strng. add .5 hours.
1
195

For 1998-00 model years, the manufacturer recommends the belt be inspected at 120,000 miles and replaced if necessary. For 2001 model year, the manufacturer recommends the belt be replaced at 120,000 miles.

TIMING BELT
Removal: Disconnect battery ground cable. Remove exhaust side spark plugs. Remove fan shroud bolts and position over fan blades. Loosen, but do not remove, water pump pulley bolts. Remove accessory drive serpentine belt. Remove fan and clutch assembly retaining screws. Remove fan and clutch assembly. Remove fan shroud. Remove water pump pulley. On models with A/C, discharge A/C system using approved refrigerant recovery/recycling equipment. Remove A/C compressor from mounting bracket. Remove A/C compressor mounting bracket with power steering pump attached, and position aside.
Remove timing belt outer cover retaining bolt. Release 7 cover interlocking tabs. Remove timing belt cover. Rotate crankshaft in normal direction of rotation so that No. 1 cylinder is at TDC of compression stroke. Align camshaft, crankshaft and oil pump timing marks. See Fig. 1. Crankshaft keyway should be pointing straight up and circle on crankshaft sprocket must align with notch in engine front cover. Holding timing belt tensioner with Camshaft Belt Tension Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt and pivot bolt. Slowly release spring tension. Pry tensioner away from timing belt and tighten bolt to hold tensioner in place. Remove timing belt. Installation: Ensure crankshaft is set at TDC and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. Install timing belt on crankshaft sprocket, oil pump sprocket and then the camshaft sprocket. Loosen timing belt tensioner bolt. Allow tensioner to adjust itself against timing belt. DO NOT tighten belt tensioner. Slowly rotate crankshaft clockwise 2 complete turns clockwise (as viewed from front of engine) so No. 1 cylinder is at TDC of compression stroke. Recheck timing alignment marks. If timing marks are not aligned, reposition timing belt. Repeat timing belt tensioning procedure. Tighten timing belt tensioner adjusting and pivot bolts to specification. See TORQUE SPECIFICATIONS. Install crankshaft pulley. Tighten center bolt to specification. Install timing belt cover. Install exhaust side spark plugs. Install A/C compressor mounting bracket to engine. Install A/C compressor to mounting bracket. To complete installation, reverse removal procedure. Recharge A/C system. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mount Bolts ............................. 15-21 (21-28) A/C Compressor Mounting Bracket-To-Engine M8 Bolt ......................................................................... 18 (25) M10 Bolt & Stud ............................................................ 35 (48) Alternator Bracket Bolts .................................... 30-40 (41-54) Alternator Retaining Bolts ................................. 30-40 (41-54) Camshaft Sprocket Bolt .................................... 52-70 (70-95) Cooling Fan-To-Water Pump Bolts ................... 13-16 (17-23) Crankshaft Damper Bolt ............................... 93-121 (125-165) Oil Pump Sprocket Bolt ..................................... 28-40 (38-54) Timing Belt Tensioner Adjusting Bolt ................ 14-21 (35-45) Timing Belt Tensioner Pivot Bolt ....................... 28-40 (40-55) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt .......................... 71-106 (8-12) Spark Plug ........................................................ 80-177 (9-20) Valve Cover Bolt ................................................ 80-115 (9-13)
196
FORD 2.5L V6
TIMING BELT APPLICATION Belt Part No. Application Labor Time1 2.5L V6 Probe 1993-97 ................. 4.0 Hours .................. 250214 1 - With Air Cond. add .2 hours.

The manufacturer recommends the belt be replaced every 60,000 miles for Federal vehicles and 105,000 miles for California vehicles.

TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed. Damage to valve/piston may result. Fig. 2: Checking & Compressing Automatic Belt Tensioner
FORD 2.5L V6 (Cont.)

Removal: Disconnect negative battery cable. Disconnect engine coolant temperature sensor and temperature gauge sender connectors from coolant elbow. Disconnect crankshaft position 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-6316AH) or equivalent. Remove crankshaft damper. Remove 2 timing belt cover bolts from behind crankshaft damper. Remove timing belt cover lower bolts. Using Power Steering Pump Pulley Remover (D85L-6000-A) or equivalent, remove power steering pump pulley. 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 engine rotation only. Remove timing belt tensioner arm by removing lower and then upper tensioner arm bolts. Mark direction of timing belt rotation if reusing belt. Using an Allen wrench, loosen timing belt tensioner bolt. Remove timing belt.
CAUTION: DO NOT rotate camshafts or crankshaft with timing belt removed, as engine damage could result.
197
Fig. 4: Positioning Crankshaft To Remove Slack From Timing Belt
Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure upper and lower timing belt idlers rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Measure timing belt tensioner rod protrusion (free length) from end of rod to edge of housing . See Fig. 1. Replace timing belt tensioner if distance is not .55-.63" (14-16 mm). Installation: Place timing belt tensioner in a press, using a flat washer to prevent damage to timing belt tensioner plug.
Compress automatic belt tensioner until hole in piston aligns with second hole in housing. Insert a .06" (1.5 mm) diameter pin, or drill through hole to keep piston in compressed position. See Fig. 1. Ensure camshafts and crankshaft timing marks align. See Fig. 3. Turn crankshaft counterclockwise until crankshaft timing sprocket is offset from TDC by one tooth. See Fig. 4. Install timing belt. Turn crankshaft clockwise until crankshaft timing mark is back to TDC. This should put slack on tensioner portion of belt. Install automatic timing belt tensioner, and tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove pin from automatic tensioner. Turn crankshaft 2 complete revolutions. Recheck timing marks to ensure timing is still correct. See Fig. 3. To complete installation, reverse removal procedure. Tighten bolts to specification. Check ignition timing. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ....................................... 28-38 (38-51) A/C Compressor Bracket-To-Cylinder Block Bolt ........................................................ 28-38 (38-51) Camshaft Sprocket Bolt ............................. 90-103 (122-140) Crankshaft Pulley Bolt .............................. 116-122 (157-165) Engine Mount Nuts ......................................... 54-76 (73-103) Engine Mount Through-Bolts .......................... 50-68 (86-116) Front Suspension Crossmember Bolt ........... 69-93 (94-126) Knock Sensor ................................................... 14-25 (20-34) Power Steering Pump Bracket Bolt ................... 24-33 (32-46) Spark Plug ....................................................... 11 -16 (15-23) Tensioner Pulley Bolt ........................................ 27-33 (37-45) Timing Belt Tensioner Bolt ............................... 28-32 (38-43) Water Pump Bolt .............................................. 14-18 (19-24) Wheel Lug Nut ................................................ 65-87 (88-118) INCH Lbs. (N.m) Timing Belt Cover Bolt ........................................ 71-88 (8-10) Valley Cover Bolts .............................................. 71 -88 (8-10) Valve Cover Bolt .................................................... 43-78 (5-8) Water Pump Pulley Bolt ...................................... 71-88 (8-10)
Fig. 3: Aligning Camshaft & Crankshaft To TDC
198
FORD *3.0L V6 SOHC, Villager

Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock nut. Rotate crankshaft clockwise at least 2 revolutions. Return cylinder No. 1 to TDC of compression stroke. Using Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs. (10.0 kg) pressure to timing belt between right camshaft sprocket and tensioner. Hold tensioner in position with Allen wrench, and loosen tensioner lock nut.
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 3.0L V6 SOHC Villager (Mercury) 1993 ............... 1 3.5 Hrs. .... 2521040 ....... 250104 1994-98 .......... 1 3.5 Hrs. .......................... 250249 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours. NOTE: A timing belt component kit is available for this application. See page.... for information on component kits.


TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove covers from below engine. Drain cooling system. Remove right front wheel and engine side cover. Remove accessory drive belts. Remove crankshaft pulley bolt and pulley. Remove upper radiator hose and water inlet hose. Remove A/C compressor idler pulley and bracket. Remove water pump pulley. Remove upper and lower timing belt front covers. Temporarily install crankshaft pulley bolt so crankshaft can be rotated. Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft until marks on camshaft sprockets align with marks on timing belt upper rear cover, and mark on crankshaft sprocket aligns with mark on front cover housing. See Fig. 2. Loosen timing belt tensioner nut. Release tension on belt. Remove timing belt. Check timing belt tensioner, spring and timing belt. Installation: Ensure cylinder No. 1 is at TDC of compression stroke. See Fig. 2. Install tensioner and return spring if removed. If return spring stud was removed, apply thread lock sealant to threads before installing stud. Insert an Allen wrench into hole in tensioner, turn tensioner fully clockwise, and temporarily tighten lock nut. Install timing belt with arrow on timing belt facing front of engine. Align White lines on timing belt with marks on camshaft sprockets and crankshaft sprocket. White lines ensure correct number of teeth exist between timing marks on sprockets.
Fig. 2: Installing Timing Belt & Sprocket
FORD *3.0L V6 SOHC, Villager (Cont.)
199
Fig. 3: Adjusting Timing Belt
Place a .0138" (.351 mm) feeler gauge at tensioner pulley and timing belt, and rotate crankshaft until feeler gauge is centered between tensioner pulley and timing belt. See Fig. 3. Tighten tensioner lock nut to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression stroke. Measure timing belt deflection halfway between camshaft sprockets. If deflection is not .51-.59" (13-15 mm), readjust timing belt tension. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-65 (79-88) Crankshaft Pulley Bolt ................................. 90-98 (122-133) Rocker Shaft Bolts ............................................ 13-16 (16-20) Timing Belt Tensioner Lock Nut/Bolt ................ 32-43 (43-58) Water Pump Bolt .............................................. 13-16 (16-20) INCH Lbs. (N.m) Timing Belt Cover ................................................. 27-43 (3-5)
200
FORD 3.0L & 3.2L V6 SHO

NOTE: To prevent timing belt whine on models with 3.0L engine and manual transaxle, the timing belt must be correctly tensioned. The revised tensioning procedure is from Ford technical service bulletin 95-22-10; November 6, 1995.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 SHO Taurus 1989-95 ................ 3.0 Hours ................. 250248 3.2L V6 SHO Taurus 1993-95 ................ 3.0 Hours ................. 250248


TIMING BELT
Removal (3.0L SHO): Remove battery. Remove engine roll damper, located near timing belt cover. Disconnect ignition control module. Remove intake manifold crossover tube. See Fig. 4. Remove accessory drive belts. Remove alternator belt tensioner pulley and bracket. Remove water pump tensioner pulley. Disconnect crankshaft sensor wiring assembly at lower timing belt cover. Remove upper timing belt cover. Ensure transaxle is in Neutral. Rotate crankshaft until No. 1 piston is at TDC. Ensure White mark on crankshaft damper aligns with 0 mark on lower timing belt cover and camshaft timing marks align with marks on timing belt cover. See Fig. 1. Raise and support vehicle. Remove right front wheel and splash shield. Using Puller (T67L-3600-A) or equivalent, remove crankshaft damper. Remove timing belt covers. Disconnect 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 sprockets, 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.
Installation (3.0L SHO): Ensure No. 1 piston is at TDC of compression stroke. Ensure camshaft timing marks align with timing belt cover marks and crankshaft sprocket timing mark aligns with mark on oil pump housing. See Fig. 2. Install timing belt on crankshaft and route around left camshaft and onto right camshaft sprockets. Ensure used timing belt is installed in original direction of rotation. Loosen timing belt tensioner lock nut and leave nut loose. Raise and support vehicle. Install center timing belt cover and ensure crankshaft sensor wiring is properly routed. Install lower timing belt cover. Install crankshaft damper. Tighten bolt to specification. See TORQUE SPECIFICATIONS table. Rotate crankshaft until Yellow mark on crankshaft damper aligns with 0 mark on lower timing belt cover. See Fig. 1. Remove plastic access cover in lower timing belt cover. Tighten timing belt tensioner lock nut to 25-37ft. lbs. (34-50 N.m). Install plastic access cover. Rotate crankshaft clockwise 60 degrees until White mark on crankshaft damper aligns with 0 mark on lower timing belt cover. Lower vehicle. Ensure camshaft timing marks align with timing belt cover marks. See Fig. 2. Install upper timing belt cover. Install intake manifold crossover tubes. Connect ignition electrical connector. Install splash shield and right front wheel. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
G93G56966
Fig. 1: Crankshaft Pulley Timing Marks
FORD 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. Remove 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 steering 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 camshaft timing marks align with marks on timing belt cover. See Fig. 2. Raise and support vehicle. Remove right front wheel and splash shield. Using Puller (T67L-3600-A), remove crankshaft damper. Remove lower timing belt cover. Remove timing belt guide located in front of crankshaft sprocket. Ensure timing marks align. See Fig. 2. If reusing timing belt, place reference mark on timing belt, camshaft sprockets, and crankshaft sprocket. Mark direction of belt rotation for reassembly reference. Slowly loosen timing belt tensioner bolt and remove tensioner. Lower vehicle. Remove timing belt. Installation (3.2L SHO): Ensure No. 1 piston is at TDC of compression stroke. Ensure camshaft timing marks align with timing belt cover marks and crankshaft sprocket timing mark aligns with mark on oil pump housing. See Fig. 2. Place timing belt tensioner in a soft jawed vise. Compress tensioner until hole in tensioner rod aligns with hole in tensioner housing. Install a 1.5 mm Allen wrench through hole, and lock tensioner in retracted position. See Fig. 3. Install timing belt on crankshaft and route belt around left camshaft and onto right camshaft sprockets. Ensure used timing belt is installed in original direction of rotation. Install timing belt tensioner while pushing tensioner pulley toward belt. Install rubber grommets between tensioner and oil pump. See Fig. 5. Remove Allen wrench from tensioner. If installing used belt, skip the next step. If installing new timing belt, go to next step. Mount Timing Belt Tensioner Tool (T93P-6254B) or equivalent, using power steering pump bracket bolt holes. Using INCH-lb. torque wrench and Torque Wrench Attachment (T93P-6254-A) or equivalent, rotate tensioner clockwise to 4.3 INCH lbs. (.5 N.m.). Tighten belt tensioner bolt. Remove tensioner tool. Tighten bolts to specification. Raise and support vehicle. Install timing belt guide and lower timing belt cover. Install crankshaft damper. Rotate crankshaft clockwise 60 degrees until White mark on crankshaft damper aligns with 0 mark on lower timing belt cover. Ensure camshaft timing marks align with timing belt cover marks. See Fig. 2. Ensure crankshaft sensor wiring is properly routed. Install remaining timing belt covers. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
201
Fig. 3: Compressing Timing Belt Tensioner (3.2L)
Fig. 4: Exploded View Of Intake Manifold & Brackets
Fig. 5: Installing Rubber Grommets (3.2L SHO)
202
FORD 3.0L & 3.2L V6 SHO (Cont.)

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolts ...................................... 15-18 (20-24) Camshaft Timing Belt Sprocket Bolt ................. 15-18 (20-24) Engine Damper Bracket Bolt ............................ 21-30 (28-41) Idler Pulley Nut ................................................. 25-37 (34-50) Intake Manifold Crossover Tube Bolt ................... 11-16 (15-22) Timing Belt Upper Cover Bolt (3.2L) ................. 12-17 (16-23) Timing Belt Tensioner Arm Nut (3.2L) ............... 27-37 (36-50) Timing Belt Tensioner Bolt (3.2L) ..................... 12-17 (16-23) Timing Belt Tensioner Lock Nut (3.0L ) ............ 25-37 (34-50) Water Pump Pulley Bolt .................................... 12-17 (16-23) Wheel Lug Nut .............................................. 85-105 (115-142) INCH Lbs. (N.m) Camshaft Sensor Bolt ........................................ 62-97 (7-11) Crankshaft Sensor ............................................... 18-27 (2-3) Timing Belt Cover Bolt (3.0L) ................................. 62-97 (7-11) Valve Cover Bolt .............................................. 89-142 (10-16)
G93F566965
Fig. 6: Adjusting Timing Belt Tension (3.0L)
GEO 1.6L 4-Cylinder DOHC, Prizm GSI

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. DOHC Prizm GSI 1990-92 ................ 1 3.1 Hours ................. 250176 1 - With Pwr. Strng. add .4 hours.
203
Remove water pump pulley. Remove upper, center and lower timing belt covers. Remove timing belt guide. Turn crankshaft so that camshaft and crankshaft timing marks are aligned. See Fig. 2. Loosen timing belt idler pulley bolt. Remove timing belt.
CAUTION: If timing belt is to be reused, mark direction of timing belt rotation. Place mating marks on belt and sprockets for reference.

The manufacturer recommends the belt be inspected and adjusted at 30,000 mile intervals, and replaced at 60,000 mile intervals.

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Turn front wheels all the way to the right. Remove right front wheel. Remove right lower stone shield from under vehicle. Remove accessory drive belts. Remove center bolt and crankshaft pulley. Lower vehicle. Label spark plug secondary cables for reassembly reference. Disconnect spark plug cables from spark plugs. Remove PCV valvefrom valve cover. Disconnect accelerator cable from valve cover. Disconnect wiring harness from valve cover. Remove valve covers. Remove windshield washer reservoir. Remove engine wiring harness from upper timing belt cover. Support engine from above using Engine Support Bar (J 28467-A) or equivalent. Remove engine mount through bolt from mount on timing belt end of engine.
Inspection: Inspect timing belt for cracks or damaged teeth. Ensure timing belt is not contaminated with oil. Check belt tensioner pulley for smooth rotation or grease leaks. Replace damaged components. Remove spring from timing belt idler pulley. Check free length of belt tensioner spring. Free length is measured between inside diameters of hooked portion of spring (not coil length). Replace spring if free length is greater than 1.618 (41.09 mm). See Fig. 3. Installation: Ensure all timing marks are aligned. See Fig. 2. Install timing belt. If reusing old timing belt, ensure belt is installed in original rotating direction. If removed, installed timing belt idler pulley spring. Loosen timing belt idler pulley bolt to allow tension to be applied on timing belt. Temporarily install crankshaft pulley center bolt. Rotate crankshaft clockwise 2 revolutions, to TDC. Ensure all timing marks are aligned. Final tighten timing belt idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Apply about 4.5 lbs. (2.04 kg) of downward pressure to timing belt between camshaft sprockets. Belt deflection should be about .16 (4 mm) if timing belt tension is correct. Remove crankshaft bolt. Install timing belt guide. Install upper, center, and lower timing belt covers. Install crankshaft pulley. Tighten center bolt to specification. Install water pump pulley. Install engine mount through-bolt and tighten to specification. 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.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts ............................................... 35 (47) Crankshaft Pulley Bolt .............................................. 87 (118) Engine Mount Through-Bolt ............................................ 64 (87) Timing Belt Idler Pulley Bolt ............................................ 27 (37) Water Pump Pulley Bolt .............................................. 17 (23) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................. 44 (5) Valve Cover Nut ............................................................ 53 (6)
Fig. 3: Checking Timing Belt Tensioner Spring Free Length
GEO *1.6L 4-Cylinder Storm SOHC

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.6L 4-Cyl. SOHC Storm 1990-93 ................ 1.5 Hours ................. 250177 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.
205


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 compression stroke. Ensure timing mark on crankshaft pulley aligns with O timing mark on timing belt cover. Remove timing belt cover. See Fig. 1. Ensure locating dowel on camshaft sprocket is at 12 oclock position and timing mark is aligned with cylinder head surface. See Fig. 2. Raise and support vehicle. Remove right side undercover. Remove crankshaft pulley-to-sprocket bolts. See Fig. 1. Remove crankshaft pulley. Lower vehicle. Ensure timing mark (notch) on rear of crankshaft 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 contamination. Ensure belt tensioner bearing rotates freely. Replace components if damaged.
NOTE: Revised timing belt tensioning procedure is from GEO technical service bulletin 91-487-6A; February 26, 1992.
Courtesy of General Motors Corp.
Fig. 1: Timing Belt Components
Installation: Rotate camshaft so locating dowel on camshaft sprocket is at 12 oclock position and timing mark aligns with cylinder head surface. See Fig. 2. Ensure timing mark (notch) on rear of crankshaft sprocket aligns with timing mark on oil pump. See Fig. 4. Install timing belt over crankshaft sprocket, tensioner pulley, water pump and camshaft sprocket. Insert a hex wrench into the tensioner pulley hexagonal hole. Rotate pulley counterclockwise to tension the belt. Hold pulley stationary and temporarily tighten the tensioner pulley bolt. Rotate crankshaft 2 revolutions counterclockwise and align crankshaft and camshaft timing marks. See Figs. 2 and 4.
Loosen belt tensioner pulley bolt. Insert a hex key wrench into tensioner pulley hexagonal hole. Rotate the tensioner pulley counterclockwise to tension the timing belt. Tighten tensioner pulley bolt to 37 ft. lbs. (50 N.m). Rotate crankshaft back to about 50 degrees BTDC and back to TDC of No. 4 cylinder. Align crankshaft sprocket timing mark with mark on oil pump housing. Align camshaft sprocket timing mark with upper surface of cylinder head.
206
GEO *1.6L 4-Cylinder Storm SOHC (Cont.)
Fig. 4: Crankshaft Sprocket Timing Mark
Measure timing belt deflection by applying 22 lbs. (98 N) of force to belt. See Fig. 5. Defection must be .63-.79 (16-20 mm). If deflection is not correct, retension timing belt. Ensure 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 tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley-To-Sprocket Bolt ................................ 17 (23) Crankshaft Sprocket Center Bolt ............................... 87 (118) Engine Mount Right Bracket Bolt ..................................................... 29 (39) Right Through-Bolt ................................................... 50 (68) Power Steering Pump Bolt .......................................... 15 (20) Timing Belt Tensioner Pulley Bolt ................................... 37 (50) Water Pump Bolt ............................................................ 18 (25) Wheel Lug Nut .......................................................... 87 (118) INCH Lbs. (N.m) Crankshaft Pulley-To-Flange Bolt ............................... 89 (10) Timing Belt Cover Bolt .................................................... 89 (10) Valve Cover Bolt .......................................................... 89 (10)
GEO *1.6L & 1.8L 4-Cylinder DOHC, Prizm

TIMING BELT APPLICATION Labor Component Application Time Kit No. 1.6L 4-Cyl. DOHC, VIN 6 Prizm (Except GSI) 1989-97 .......... 1 2.2 Hrs. .... 2522360 ........ 250236 1.8L 4-Cyl. DOHC, VIN 8 Prizm (Except GSI) 1993-97 .......... 1 2.2 Hrs. ........................... 250235 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .4 hours. Belt Part No.
207
CAUTION: 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 tensioner bolt, tensioner and tensioner spring. Remove timing belt. Inspection: Inspect timing belt for damaged teeth or cracking. Ensure timing belt is not contaminated with oil. Check tensioner pulley for rotation freedom or grease leaks. Replace components if damaged. Check free length of idler pulley spring. Free length is measured between inside edge of hooked portions of spring (not the coil area). See Fig. 4. Replace spring if free length is not as specified. See TENSIONER SPRING FREE LENGTH. TENSIONER SPRING FREE LENGTH Maximum Free Length Year In. (mm) 1989-92 .................................................................. 1.512 (38.4) 1993-94 .................................................................. 1.390 (35.3) 1995-97 .................................................................. 1.453 (36.9) Installation: Ensure all timing marks are still aligned. See Fig. 3. Install timing belt tensioner and spring. Move tensioner to the left and temporarily tighten bolt. Install timing belt. If old timing belt is reused, ensure belt is installed in original rotating direction. Ensure marks on belt align with camshaft and crankshaft sprockets. Loosen timing belt tensioner bolt and allow tension to be applied on timing belt. Rotate crankshaft CLOCKWISE 2 revolutions. DO NOT turn crankshaft counterclockwise. Ensure all timing marks are aligned. Tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.

The manufacturer recommends the belt be inspected and adjusted at 30,000 mile intervals, and replaced at 60,000 mile intervals.

TIMING BELT
Removal: Disconnect negative battery cable. Remove windshield washer reservoir. On vehicles equipped with cruise control, remove cruise control actuator cover. Disconnect cruise control electrical connector and actuator cable. Remove cruise control actuator 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 compressor 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. Noting installed position, remove timing belt guide from crankshaft.
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 specification, 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 crankshaft pulley. Tighten center bolt to specification. Install water pump pulley. Install engine mount. Install engine ground wire (if equipped) to right fender apron. Install valve cover with new gasket. Install spark plugs and spark plug secondary wires. 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 windshield washer reservoir. To install remaining components, reverse removal procedure. Adjust accessory drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket-To-Engine Bolt ................... 35 (47) A/C Compressor-To-Bracket Bolt ............................... 18 (25) Camshaft Sprocket Bolt .................................................. 43 (59) Crankshaft Pulley Bolt .............................................. 87 (118) Timing Belt Tensioner Bolt ............................................. 27 (37) Water Pump Bolt ........................................................ 11 (15) Water Pump Pulley Bolt .............................................. 17 (23) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................. 44 (5) Valve Cover Cap Nuts ................................................... 53 (6)
Fig 3: Aligning Camshaft & Crankshaft Timing Marks
Fig. 4: Checking Timing Belt Tensioner Spring Free Length
GEO 1.6L & 1.8L 4-Cylinder DOHC, Storm

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. DOHC Storm 1990-91 ................ 1 2.0 Hours ................. 250169 1.8L 4-Cyl. DOHC Asuna Sunfire (Canadian) 1993 ..................... 1 2.4 Hours ................. 250205 Storm 1992-93 ................ 1 2.4 Hours ................. 250205 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.
209
Loosen belt tensioner bolt to allow tension to be applied on timing belt. Rotate crankshaft clockwise 2 revolutions. Ensure all timing marks are still aligned. Tighten timing belt tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Install lower timing belt cover. Install engine mount bracket on engine. Install crankshaft pulley and tighten center bolt to specification. Install upper timing belt cover. Install engine mount. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 43 (59) Crankshaft Pulley Center Bolt 1.6L ............................................................................ 87 (118) 1.8L .......................................................................... 108 (147) Engine Mount Bracket-To-Engine Bolt ............................ 37 (50) Engine Mount Through-Bolt ............................................ 50 (68) Power Steering Pump Mounting Bolt .............................. 15 (20) Serpentine Drive Belt Tensioner Bolt ............................. 30 (40) Timing Belt Tensioner Pulley Bolt ................................... 31 (42) Water Pump Bolt 1.6L .............................................................................. 11 (15) 1.8L .............................................................................. 18 (24) Wheel Lug Nut .......................................................... 87 (118) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................... 89 (10)


TIMING BELT
Removal: Disconnect negative battery cable. Remove accessory drive belts or serpentine belt. Raise and support vehicle. Remove right splash shield. Rotate crankshaft so that No. 1 cylinder is at TDC of compression 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 installed in original rotating direction. Install timing belt on crankshaft pulley, then water pump pulley, timing belt idler pulley, exhaust camshaft sprocket, intake camshaft sprocket and timing belt tensioner pulley. See Fig. 2.
210
GEO 1.6L & 1.8L 4-Cylinder DOHC, Storm (Cont.)
Fig. 2: Timing Belt Installation
GEO/CHEVROLET 1.0L 3-Cylinder

TIMING BELT APPLICATION Application 1.0L 3-Cyl. Firefly (Canadian) 1985-88 .......... 1 2.2 Hrs. ........................... 250095 1989-91 .......... 1 2.2 Hrs. ........................... 250166 1994-95 .......... 1 2.2 Hrs. ........................... 250241 1996-00 .......... 1 1.8 Hrs. .... 2521941 ........ 250194 Metro 1989-92 .......... 1 2.2 Hrs. ........................... 250166 1993 ............... 1 2.2 Hrs. ......................... 2 250166 1993 ............... 1 2.2 Hrs. ......................... 3 250241 1994-95 .......... 1 2.2 Hrs. ........................... 250241 1996-97 .......... 1 2.2 Hrs. .... 2521941 ........ 250194 1996-00 .......... 1 1.8 Hrs. .... 2521941 ........ 250194 Sprint (Includes Canadian) 1985-88 .......... 1 2.2 Hrs. ........................... 250095 1989-91 .......... 1 2.2 Hrs. ........................... 250166 1 - With Air Cond. add .4 hours. 2 Four bolt sprocket. 3 Five bolt sprocket. Labor Time Component Kit No. Belt Part No.
211
Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure tensioner rotates freely. Replace damaged components.
CAUTION: Ensure concave side of timing belt guide faces oil pump. Flat side of timing belt guide goes against crankshaft sprocket. CAUTION: Ensure tensioner plate moves when tensioner is moved toward timing belt. If tensioner plate does not move, ensure lug is engaged in hole on tensioner.
Installation: If tensioner was removed, install tensioner plate on tensioner. Ensure tensioner plate lug engages hole on rear of tensioner. Install tensioner assembly on cylinder block. Tighten tensioner bolt finger tight to allow movement of tensioner. Ensure all timing marks align. See Fig. 2 or 5. If timing marks are not aligned, rotate camshaft or crankshaft to align timing marks. DO NOT rotate camshaft or crankshaft so timing mark moves more than 90 degrees or engine damage may occur. See Fig. 3.
CAUTION: Install timing belt so arrow on timing belt, or mark made during removal, points in direction of crankshaft rotation. Crankshaft rotates clockwise.

Up to 1997 model year, the manufacturer recommends the belt be replaced at 60,000 mile intervals. For 1998-00 model years, the manufacturer recommends the belt be inspected at 60,000 miles and replaced at 100,000 miles.
Install tensioner spring and spring damper, push tensioner plate upward and tighten tensioner bolt. Install timing belt so arrow on timing belt, or mark made during removal, points in direction of crankshaft rotation. Ensure no slack exists on drive side of timing belt. Loosen tensioner bolt and allow spring tension to remove slack in timing belt. Tighten tensioner bolt.

TIMING BELT
Removal: Disconnect negative battery cable. Remove air cleaner. Remove A/C suction pipe bracket (if equipped). Raise and support vehicle. Remove lower right engine undercover. Remove lower generator cover plate. Remove all accessory drive belts. Remove outer bolts retaining crankshaft pulley. Remove crankshaft pulley. DO NOT remove crankshaft pulley center bolt. Remove wire harness from timing belt cover. Remove timing belt cover and seal. See Fig. 1 or 4. Rotate crankshaft and align timing marks. See Fig. 2 or 5. Remove tensioner spring and tensioner stud. Loosen, but DO NOT remove, tensioner bolt. If reusing timing belt, mark rotation direction. Remove belt tensioner, tensioner plate, tensioner spring, spring damper and timing belt.
CAUTION: DO NOT rotate crankshaft or camshaft when timing belt is removed or piston damage may result. Note direction of timing belt guide for installation. Ensure concave side of timing belt guide faces away from timing belt.
212
GEO/CHEVROLET 1.0L 3-Cylinder (Cont.)
Fig. 4: Exploded View Of Timing Belt Components (1998-00) 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 timing marks are aligned. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt 12 mm ...................................................................... 21 (29) 14 mm ........................................................................ 33 (45) Crankshaft Pulley-To-Crankshaft Bolt ......................... 12 (16) Tensioner Bolt ............................................................ 20 (27) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 97 (11) Timing Belt Tensioner Stud ........................................ 97 (11) Valve Cover Bolt ............................................................ 44 (5) Water Pump Bolt (1998-00) .......................................... 115 (13) Water Pump Bolt (1995-97) ......................................... 97 (11)
Fig. 5: Aligning Timing Marks (1998-00)
GEO/CHEVROLET 1.3L 4-Cylinder

TIMING BELT APPLICATION Application 1.3L 4-Cyl. Firefly (Canadian) 1995-97 .......... 1 2.6 Hrs. ........................... 250272 1998-00 .......... 1 2.6 Hrs. .... 2521941 ........ 250194 Metro 1992-93 .......... 1 2.6 Hrs. ........................... 250095 1994 ............... 1 2.6 Hrs. ........................... 250243 1995-97 .......... 1 2.6 Hrs. ........................... 250272 1998-01 .......... 1 2.6 Hrs. .... 2521941 ........ 250194 1 - With Air Cond. add .4 hours. Labor Time Component Kit No. Belt Part No.
213
Turn crankshaft pulley bolt clockwise until punch mark on sprocket aligns with arrow mark on oil pump case. See Fig. 3. Install timing belt on sprockets with drive-side of belt free of any slack when tensioner plate is pushed up with fingers. Loosen tensioner bolt and allow tensioner to remove slack in timing belt. Skip the next step to continue.
NOTE: On 1998-01 models, camshaft sprocket is marked with a raised E for a timing mark.

Up to 1997 model year, the manufacturer recommends the belt be replaced at 60,000 mile intervals. For 1998-01 model years, the manufacturer recommends the belt be inspected at 60,000 miles and replaced at 100,000 miles.
On 1998-01 models, ensure camshaft and crankshaft timing marks are still aligned. See Fig. 6. If timing marks are not aligned, rotate camshaft or crankshaft to align timing marks. DO NOT rotate camshaft or crankshaft more than 90 degrees or engine damage may result. Install timing belt. Ensure no slack exists on drive-side of timing belt. Loosen tensioner bolt and allow tensioner to remove slack in timing belt. Go to next step. Turn crankshaft 2 rotations clockwise to take up slack. Ensure timing marks are still aligned. Tighten tensioner adjustment stud nut and tensioner bolt. Ensure seal is between water pump and oil pump case. See Fig. 5. Install timing belt outside cover.

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove right side fender apron extension. Do not push center pin in too far as it may fall into fender. Remove alternator/water pump drive belt and water pump pulley. Lock flywheel and loosen crankshaft pulley outer bolts. See Figs. 1 and 2. It is NOT necessary to remove crankshaft pulley center bolt. Remove crankshaft pulley. Remove timing belt outside cover. Rotate crankshaft to align camshaft and crankshaft timing marks. See Figs. 3 and 6. Loosen tensioner bolt and stud. Push tensioner plate fully upward and temporarily tighten tensioner bolt. Remove timing belt from sprockets. Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components.
NOTE: Ensure tensioner plate moves when tensioner is moved toward timing belt. If tensioner plate does not move, ensure lug is engaged in hole on rear of tensioner.
Fig. 1: Using Screwdriver To Lock Flywheel
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 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 clockwise until timing mark on pulley aligns with V mark on belt inside cover. See Fig. 3.
Fig. 2: Locking Flywheel In Position
214
GEO/CHEVROLET 1.3L 4-Cylinder (Cont.)
Fig. 4: Adjusting Valve Lash
Fig. 3: Identifying Timing Marks (Up To 1997)
On 1992-97 models, rotate crankshaft to position camshaft lobe and rocker arm to adjust valve lash. See Fig. 4. Ensure clearance is .010" ( .25 mm) at intake valves and .011" (.28 mm) at exhaust valves. To adjust clearance, turn adjusting screw until correct clearance is obtained. Tighten lock nut to 11-13.5 ft. lbs. (15-18 N.m). On all models, to complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt (1998-01) ................................ 12 (16) Crankshaft Sprocket Bolt (1992-97) ......................... 79 (110) Crankshaft Sprocket Bolt (1998-01) ......................... 96 (130) Timing Belt Tensioner Bolt ......................................... 20 (27) Valve Adjustment Lock Nut ................................ 11-13 (15-18) Water Pump Pulley Bolt .............................................. 18 (24) INCH Lbs. (N.m) Crankshaft Pulley Bolt (1992-97) ................................ 97 (11) Tensioner Stud ........................................................... 97 (11) Timing Belt Cover Nut/Bolts ....................................... 97 (11) Valve Cover Nuts .......................................................... 44 (5)
Fig. 5: Locating Oil Case Seal
Fig. 6: Identifying Timing Marks (1998-01)
GEO/CHEVROLET 1.6L 4-Cylinder Tracker, 8-Valve

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC, VIN U Tracker & Sunrunner (Asuna & Pontiac, Canada) 1989-95 ................ 1 3.6 Hours ............... 2 250164 1989-95 ................ 1 3.6 Hours ............... 3 250212 1 - With Air Cond. add .4 hours. 2 Except California. 3 California.
215


TIMING BELT
Removal: Disconnect negative battery cable. Remove accessory drive belts. Remove cooling fan, fan shroud and water pump pulley. Remove outer bolts retaining crankshaft pulley. Remove 5 crankshaft pulley-to-sprocket bolts. Remove crankshaft pulley. DO NOT remove center bolt from crankshaft 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 indicate rotation direction. Remove timing belt. Inspection: Inspect timing belt for damaged teeth or cracking. Ensure timing belt is not contaminated with oil. Check tensioner for freedom of rotation. Replace components if damaged. Installation: 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.
Install tensioner spring to tensioner plate and tensioner screw. Finger tighten tensioner stud. Rotate crankshaft 2 revolutions clockwise to ensure all slack is removed from timing belt. Ensure camshaft and crankshaft timing marks are still aligned. Tighten tensioner stud to specification. Tighten tensioner bolt to specification. See TORQUE SPECIFICATIONS. Ensure all timing marks align. Adjust valve lash between rocker arm adjusting screw and valve stem. See VALVE LASH SPECIFICATIONS. Turn crankshaft so No. 1 piston is at TDC of compression stroke. Ensure camshaft timing mark is aligned with V timing mark on rear timing belt cover. Adjust valve lash on No. 1 and No. 2 intake valves. Adjust valve lash on No. 1 and No. 3 exhaust valves. Rotate crankshaft one full revolution (360 degrees). Adjust remaining intake and exhaust valves. Install timing belt cover. Install crankshaft pulley. To complete installation, reverse removal procedures. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. VALVE LASH SPECIFICATIONS Clearance Clearance Valve Cold, In. (mm) Hot, In. (mm) Intake ................... .051-.067 (.13-.17) ......... .009-.011 (.23-.27) Exhaust .............. .0063-.0075 (.15-.19) .. .0102-.0114 (.25-.29)
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 crankshaft sprocket with timing mark on oil pump housing. See Fig. 3. Install timing belt on engine. If installing old belt, ensure arrow on timing belt aligns with direction of crankshaft rotation. Ensure no slack exists on side of timing belt opposite tensioner.
216
GEO/CHEVROLET 1.6L 4-Cylinder Tracker, 8-Valve (Cont.)
Fig. 2: Locking Camshaft During Sprocket Removal
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor 8 mm Bolt ................................................................. 21 (29) 10 mm Bolt ............................................................... 33 (45) Crankshaft Pulley-To-Sprocket Bolts .......................... 12 (16) Power Steering Pump Mounting Bolt .......................... 21 (29) Timing Belt Tensioner Bolt ......................................... 20 (27) Valve Adjusting Screw Locknut ....................................... 13 (17) INCH Lbs. (N.m) Fan Clutch Nuts ......................................................... 97 (11) Tensioner Stud ........................................................... 97 (11) Timing Belt Cover Bolt ................................................ 97 (11) Valve Cover Bolt ............................................................ 44 (5) Water Pump Bolt ...................................................... 106 (12)
GEO/CHEVROLET 1.6L 4-Cylinder Tracker, 16-Valve

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC, VIN 6 Tracker & Sunrunner (Canadian) 1994-98 ................ 1 4.0 Hours ............... 2 250164 1994-98 ................ 1 4.0 Hours ............... 3 250212 1999-01 ................ 1 4.0 Hours ................ 250212 1 - With Air Cond. add .4 hours. 2 Except California. 3 California.
217

Installation: If tensioner was removed, install tensioner plate, spring, and tensioner pulley on engine. Tighten tensioner bolt and stud nut finger tight to allow movement of tensioner. Ensure camshaft and crankshaft timing marks are still aligned. Install timing belt. If reusing old belt, ensure it is installed in original rotation direction. Loosen timing belt tensioner bolt and nut so it places tension on belt. Rotate crankshaft clockwise 2 revolutions. Ensure timing marks still align. See Fig. 2. Tighten tensioner stud nut and tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Install timing belt cover. To complete installation, reverse removal procedures. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. If cooling system was drained, refill and bleed air from system. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 44 (60) Crankshaft Pulley Center Bolt ..................................... 81 (110) Crankshaft Pulley-To-Crankshaft Bolt ......................... 12 (16) Front Skid Plate Bolt ...................................................... 40 (55) Power Steering Pump Mounting Bolt .......................... 21 (29) Timing Belt Tensioner Pulley Bolt ............................... 20 (27) INCH Lbs. (N.m) Cooling Fan-To-Pulley Nut .......................................... 97 (11) Timing Belt Cover Bolt .................................................. 89 (10) Timing Belt Tensioner Stud Nut ................................... 97 (11)

TIMING BELT
Removal: Disconnect negative battery cable. Remove cooling fan nuts and fan shroud fasterners. Remove accessory drive belts. Raise and support vehicle. Remove front skid plate (if equipped). Remove 2 lower radiator shroud bolts. Remove 5 outer bolts retaining crankshaft pulley to crankshaft. Remove crankshaft pulley. DO NOT remove center bolt from crankshaft pulley. The center bolt holds crankshaft sprocket to crankshaft. Lower vehicle. On models with air conditioning, remove A/ C suction line bracket bolts from radiator support. On all models, remove upper radiator shroud bolts and remove radiator shroud with cooling fan and water pump pulley.
NOTE: It may be necessary to drain cooling system and disconnect upper radiator hose to remove fan shroud.
Disconnect wiring harness from timing belt cover. Remove timing belt cover. See Fig. 1. Rotate crankshaft clockwise to align crankshaft and camshaft 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 upward 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 timing belt is not contaminated with oil. Check tensioner 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 *1.5L 4-Cylinder

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.5L 4-Cyl. I-Mark 1985-87 Thru 6/30/86 ....... 1.5 Hours ..................... T118 From 7/1/86 ......... 1.5 Hours ..................... T162 1988-89 ................. 1.5 Hours ..................... T162 Spectrum (Chevrolet & Geo) 1985-87 Thru 4/30/87 ....... 1.5 Hours ..................... T118 From 5/1/87 ........ 1.5 Hours ..................... T162 1988-89 ................. 1.5 Hours ..................... T162 Sunburst (Canada) 1985-88 ................. 1.5 Hours ..................... T118 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.
1
219
Check timing marks. Loosen tensioner bolt and remove slack from timing belt. There must be no slack in the belt after it has been installed. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt ............................................ 108 (147) Timing Belt Tensioner Bolt ......................................... 37 (50) Water Pump Bolts ...................................................... 17 (24) INCH Lbs. (N.m) Timing Cover Bolts ..................................................... 86 (10)


TIMING BELT & SPROCKETS
Removal: Disconnect negative battery cable. Drain cooling system. Place small piece of wood on jack under oil pan and carefully raise motor. Remove rear side torque rod and right engine mount. Remove body side and engine side mounts. Remove drive belts, crank pulley and timing belt cover. Ensure 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.
Fig. 1: Crankshaft Sprocket Timing Marks
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 *1.5L 4-Cylinder (Cont.)
GENERAL MOTORS 1.4L & 1.6L 4-Cylinder

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.4L 4-Cyl. Acadian, Chevette 1976 ...................... 1.4 Hours .................. 250037 1977 ...................... 1.4 Hours .................. 250039 1.6L 4-Cyl. Acadian, Chevette, T-1000, 1000 1976 ...................... 1.4 Hours .................. 250037 1977-78 ................. 1.4 Hours .................. 250039 1979-87 ................. 1.4 Hours .................. 250061 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .4 hours.
TIMING BELT ADJUSTMENT SPECIFICATIONS
221
Belt Size Operating Range Specification 3/4" (19 mm) ......... 50-80 Ibs. .......................... 63-77 Ibs. (110-176 kg) (140-160 kg)


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. Remove front cover retaining screws and nuts. Remove cover. Rotate crankshaft until timing mark on pulley is at zero degrees (No. 1 cylinder at TDC). Remove A/C compressor and brackets if necessary. Insert 1/8" drill bit or rod through hole in upper rear cover and through hole in camshaft drive sprocket. This is provided to verify camshaft timing. Remove timing belt front and lower cover. Loosen idler pulley and allow pulley to rotate clockwise. See Fig. 2. Remove timing belt from sprockets. Installation: With No. 1 piston at TDC, install belt on sprockets and use 1/ 4" Allen wrench to move idler pulley counterclockwise until all slack is removed from belt. Tighten idler pulley bolt. Rotate crankshaft clockwise a minimum of one revolution. Stop with No. 1 piston at TDC. DO NOT let timing belt back up. Use belt tension gauge between camshaft sprocket and idler pulley. See Fig. 3. Be sure gauge finger is engaged in slot between teeth of timing belt. Use 1/4" Allen wrench on idler pulley to obtain correct tension. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 1: Sprocket Timing Marks
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts .......................................... 75 (101) Crankshaft Pulley Bolt ............................................ 100 (135) Idler Pulley Bolts ......................................................... 15 (20) Water Pump Bolts ...................................................... 15 (20) INCH Lbs. (N.m) Front Cover (Nuts & Bolts) ............................................ 70 (8)
222
GENERAL MOTORS 1.4L & 1.6L 4-Cylinder (Cont.)
Fig. 2: Timing Belt Idler Pulley Fig. 3: Adjusting Timing Belt Tension
GENERAL MOTORS *1.6L 4-Cylinder LeMans

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.6L 4-Cyl. Le Mans 1988-89 ................. 2.0 Hours .................. 250148 1990 With Tensioner Pulley................. 2.0 Hours .................. 250203 Without Tensioner Pulley................. 2.0 Hours .................. 250148 1991-93 ................. 2.0 Hours .................. 250203 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .4 hours.
223

*NOTE: For 1990-93 models, this application is an interference engine. See page A-59 for interference engine cautions.

TIMING BELT
Removal: Disconnect negative battery cable. Remove all accessory drive belts. Remove power steering pump and lines. Remove crankshaft pulley. Remove timing belt covers starting with upper cover. Rotate engine to align timing marks on crankshaft and camshaft sprockets with reference mark on lower timing belt cover. See Fig. 1. Loosen water pump bolt to release belt tension. Remove timing belt.
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, measure belt tension between water pump and camshaft sprocket. Adjust belt tension to 35 Ibs. (16 kg). To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley-To-Sprocket Bolt ............................ 41 (56) INCH Lbs. (N.m) Timing Belt Cover Bolt (Front & Rear) ......................... 88 (10) Water Pump Bolt .......................................................... 71 (8)
Fig. 1: Timing Belt & Pulley Alignment
224
GENERAL MOTORS 1.6L 4-Cylinder Nova

TIMING BELT APPLICATION Application 1.6L 4-Cyl. Nova SOHC 1985-88 ........ 3.1 Hours .. 2520700 ......... 250070 DOHC 1988 ............. 3.1 Hours .......................... 250112 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .4 hours. With Cruise Control add .2 hours.


TIMING BELT
Removal: Disconnect negative battery cable. Drain cooling system. Remove fan shroud on models with power steering. On models with air conditioning, loosen idler pulley nut, adjusting bolt and remove drive belt. On DOHC models, raise and support vehicle and remove right front wheel and right side engine undercover. Remove radiator and air cleaner assembly. If equipped with cruise control, remove actuator and ignition coil. Remove drive belts, fan, water pump drive pulley and valve cover with gasket. Set No. 1 piston at TDC on compression stroke. On DOHC models, use jack to raise engine slightly, then remove right side engine mount through-bolt and mount. Remove crankshaft pulley No. 2 (power steering only).
Fig. 2: Timing Belt & Pulley Alignment
Fig. 1: Camshaft Sprocket Alignment (DOHC)
Fig. 3: Timing Belt Deflection Points
Using puller, remove crankshaft pulley. Remove upper and lower engine front cover mount bolts, gasket and covers. Mark timing belt location. Loosen idler pulley mount bolt, position pulley at far left and retighten mount bolt. Remove timing belt. Installation: Loosen timing belt idler pulley mount bolt, move pulley as far left as possible and retighten bolt. If reusing old belt, align marks made during removal. Install belt with arrow pointing in direction of rotation. DO NOT bend or twist belt. Release idler pulley and place tension on belt.
GENERAL MOTORS 1.6L 4-Cylinder Nova (Cont.)
225
If installing new belt, align camshaft(s) timing marks and crankshaft timing marks. See Fig. 1 and Fig. 2. Install timing belt. Release idler pulley and place tension on belt. After installing new or used belt, slowly turn crankshaft 2 revolutions clockwise. Recheck timing marks. Adjust belt tension and deflection. See Fig. 3. Belt tension should be 4.4 Ibs. (2 kg), with a deflection of .24-.28" (6-7 mm) on 8valve engines and .16" (4 mm) on 16-valve engines. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 34 (46) Crankshaft Pulley Bolt 8-Valve .................................................................... 87 (117) 16-Valve ................................................................ 137 (186) Timing Belt Idler Mount Bolt .............................. 26-36 (36-49)
226
GENERAL MOTORS *1.8L 4-Cylinder Diesel

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.8L 4-Cyl. Diesel Acadian (Canadian) 1981-85 ................. 3.1 Hours .................. 250076 Chevette 1981-86 ................. 3.1 Hours .................. 250076 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .4 hours.
Remove damper pulley and install belt holder in position away from timing bolt. Install by-pass hose, dust covers, and damper pulley. Install cooling fan, belt and pulley. Install fan shroud. Refill system with coolant and connect battery. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .................................................. 55 (75) Damper Pulley Bolt ..................................................... 12 (20) Tension Pulley Center Bolt ................................................................ 54 (73) Side Bolts ................................................................. 15 (20) Water Pump Bolts ...................................................... 15 (20)


TIMING BELT
Removal: Disconnect negative battery cable. Drain cooling system. 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 equivalent, to slot in rear of camshaft. This will prevent camshaft from rotating. Remove damper pulley and timing belt holder. Recheck to be sure No. 1 cylinder is at TDC. 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 tension pulley. Depress tension pulley with finger and install tension spring. Finger tighten tensioner bolts in sequence to prevent movement of tensioner pulley. See Fig. 3. Tighten camshaft pulley bolt. Remove injection pump gear lock bolt. Remove fixing plate on end of camshaft. 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 looseness on tensioner and tighten bolts in sequence. See Fig. 3. Belt tension should be checked at point between camshaft gear and injection pump gear using Belt Tension Gauge (J-29771) or equivalent. Belt tension should be 46-63 lbs (20-28 kg).
96E14856
Courtesy Of General Motors Corp.
Fig. 1: Injection Pump Alignment Marks & Lock Bolt
GENERAL MOTORS *1.8L 4-Cylinder Diesel (Cont)
227
Fig. 3: Locating/Tightening Tensioner Bolts
228
GENERAL MOTORS 1.8L 4-Cylinder

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.8L 4-Cyl. OHC J2000, 2000, 2000 Sunbird 1982-84 ................. 2.7 Hours .................. 250081 Firenza 1982-86 ................. 2.7 Hours .................. 250081 Skyhawk 1982-86 ................. 2.7 Hours .................. 250081 Sunbird 1985-86 ................. 2.7 Hours .................. 250081 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .4 hours.
If belt tension is incorrect, loosen water pump bolts and rotate pump until correct tension is obtained. Hot timing belt tension specification is 30 lbs. (13 kg). DO NOT leave tension gauge on belt during retightening or reading will be inaccurate. Tighten water pump bolts. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 34 (45) Crankshaft Pulley-To-Sprocket Bolt ............................ 20 (27) Crankshaft Sprocket Retaining Bolt ........................ 115 (156) Timing Belt Rear Cover Bolt ....................................... 19 (25) Water Pump Retaining Bolts ...................................... 19 (25) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt .......................................... 72 (8) Timing Belt Front Cover Bolt ......................................... 60 (7)


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 camshaft sprocket must align with mark on camshaft carrier. Remove crankshaft pulley. 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 pulley and check for alignment of timing marks. Using Adjuster (J-33039) or equivalent , rotate water pump clockwise until slack is removed from timing belt. Tighten water pump bolts. See Fig. 1.
NOTE: If new timing belt has been installed, check final tension with engine at operating temperature. If new head gasket is installed, cylinder head must be retightened AFTER initial warm up. Timing belt tension MUST then be rechecked.
Using Cam Drive Belt Tension Gauge (J-26486-A) or equivalent, check belt tension between water pump and camshaft sprocket. Initial new belt tension should be 38 lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16 kg). Reassemble components and run engine to operating temperature (thermostat open). As new belt takes a set position, substantial tension loss will occur. After belt has been run, recheck tension with gauge on belt.
Fig. 1: Timing Belt Tension Adjustment
GENERAL MOTORS 2.0L 4-Cylinder

TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time1 2.0L 4-Cyl. OHC Firenza 1987-88 ............ 2.7 Hrs. ........................... 250081 Grand Am 1987-88 ............ 2.7 Hrs. ........................... 250081 1989 ................. 2.7 Hrs. ..... 2521630 ....... 250163 Le Mans 1989 1st Design ..... 2.7 Hrs. ........................... 250081 2nd Design ... 2.7 Hrs. ..... 2521630 ....... 250163 1990 ................. 2.7 Hrs. ..... 2521630 ....... 250163 Skyhawk 1987-88 ............ 2.7 Hrs. ........................... 250081 Sunbird 1987-88 ............ 2.7 Hrs. ........................... 250081 1989-94 ............ 2.7 Hrs. ..... 2521630 ....... 250163 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .4 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
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Fig. 1: Timing Belt Tension Adjustment

TIMING BELT & SPROCKETS
Removal (1987-88): Disconnect negative battery cable. Remove belts, brackets and shields necessary to gain access to crankshaft pulley. Remove timing belt front cover. Rotate crankshaft so timing mark on crankshaft pulley lines up with 10 degrees BTDC mark on indicator scale. Mark on camshaft sprocket must align with mark on camshaft carrier. Remove crankshaft pulley. Remove timing probe holder. Verify timing marks are aligned and loosen water pump retaining bolts to remove timing belt. Installation (1987-88): Install new timing belt on sprockets. Install crankshaft pulley and check for alignment of timing marks. Using Adjuster (J33039) or equivalent, rotate water pump clockwise until slack is removed from timing belt. Tighten water pump bolts. See Fig. 1.
NOTE: If new timing belt has been installed, check final tension with engine at operating temperature. If new head gasket is installed, cylinder head must be retightened AFTER initial warm up. Timing belt tension MUST then be rechecked.
Using Cam Drive Belt Tension Gauge (J-26486-A) or equivalent, check belt tension between water pump and camshaft sprocket. Initial new belt tension should be 38 lbs. (17 kg). Used belt tension should be 27-36 lbs. (12-16 kg). Reassemble components and run engine to operating temperature (thermostat open). As new belt takes a set position, substantial tension loss will occur. After belt has been run, recheck tension withgauge on belt. If belt tension is incorrect, loosen water pump bolts and rotate pump until correct tension is obtained. Hot timing belt tension specification is 30 lbs. (13 kg). DO NOT leave tension gauge on belt during retightening or reading will be inaccurate. Tighten water pump bolts. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (1989-94): Disconnect negative battery cable. Remove serpentine belt, brackets, and shields necessary to gain access to crankshaft pulley. Remove front timing belt cover. See Fig. 2. Remove crankshaft pulley. Loosen water pump retaining bolts. Using Timing Belt Adjuster (J-33039-A) or equivalent, rotate water pump to release timing belt tension. Remove timing belt. Installation (1989-94): To install camshaft and crankshaft sprockets (if removed), reverse removal procedure. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS.
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GENERAL MOTORS 2.0L 4-Cylinder (Cont.)
Rotate crankshaft and camshaft clockwise to align timing marks on sprockets with marks on rear cover. Install new timing belt on sprockets. Ensure belt has tension on it between the camshaft sprocket and crankshaft sprocket.
NOTE: Adjust timing belt with engine coolant temperature at 68F (20C).
Using timing belt tension adjuster, rotate water pump clockwise until tensioner contacts the high torque stop. See Fig. 3. Slightly tighten water pump retaining bolts. Using crankshaft sprocket bolt, rotate engine clockwise 2 revolutions to fully seat timing belt. Rotate water pump eccentric counterclockwise until hole in tensioner arm aligns with hole in base. Tighten water pump bolts to specification. See TORQUE SPECIFICATIONS. Ensure tensioner holes remain in alignment as stated. Ensure all timing marks are properly aligned. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 3: Timing Belt Tensioner (1989-94)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley-To-Sprocket Bolt 1987-88 .................................................................... 20 (27) 1989-92 .................................................................... 15 (20) Serpentine Belt Tensioner Bolt ................................... 35 (47) Timing Belt Tensioner Bolt ......................................... 18 (24) Water Pump Bolt ........................................................ 18 (24) INCH Lbs. (N.m) Camshaft Carrier Cover Bolt ...................................... 84 (10) Timing Belt Cover Bolt .................................................. 62 (7)
GENERAL MOTORS *3.0L V6 DOHC, Catera

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Application Labor Time Belt Part No. 3.0L V6 DOHC Catera 1997-01 ................. 2.6 Hours .................. 250285

The manufacturer recommends the belt be replaced at 100,000 mile intervals. Using scan tool, check cold start counter (also called a heavy duty register). If there were any cold starts below -20F (-28C), visually inspect timing belt for cracks. If there are cracks present, DO NOT reuse the belt. Replace belt. If belt is okay and reused, DO NOT clear the cold start counter.
REMOVAL & INSTALLATION TIMING BELT

Precautions: When servicing timing belt, always turn crankshaft in normal 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 installation. If guide marks cannot be identified, a new belt must be installed. Removal: Disconnect negative battery cable. Remove air intake resonator 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 injection crossover pipe from hoses and front cover. Lower vehicle. Remove air injection crossover pipe from front cover. Loosen, but do not remove water pump pulley bolts. Loosen, but do not remove, power steering pump pulley bolts. Remove A/C compressor hose strap from AIR injection crossover bracket. Remove accessory drive serpentine 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 balancer-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 crankshaft clockwise until holder contacts water pump. See Fig. 3. Secure moveable lever of tool to water pump pulley flange. Camshaft timing marks should be aligned with marks on rear cover. See Figs. 4 and 5. If not aligned, crankshaft 180 degrees (one half turn) off.
Fig. 1: Timing Belt Front Cover
Fig. 2: Positioning Crankshaft At 60 Degrees BTDC
Fig. 3: Installing Crankshaft Holder
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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. Make sure belt is installed with arrows pointing in correct direction or rotation.
Fig. 4: Aligning Timing Belt Marks With Rear Cover Marks (Up To 1999 Early Design)
Installation: To install timing belt, remove crankshaft holder. Raise and support vehicle. Start installation of belt at crankshaft pulley. Install timing belt with double dash marks aligned with oil pump and drive gear marks. See Fig. 7. Install Timing Belt Holder (J42069-30) or equivalent plastic wedge to hold belt against crankshaft sprocket.
NOTE: Timing belt configuration changed in mid-1999 model year. For both designs, use the marks on each side of the direction of rotation arrows to line up the left (drivers side) camshaft sprockets. For early design (up to mid-1999), use the remaining 3 White marks on the NAPA timing belt. For later design (mid-1999 to present), use the remaining 3 Yellow marks on the NAPA timing belt. Correct belt application MUST be used on each engine design.
Lower vehicle. Route timing belt around tensioner, right bank (passengers side) camshaft gears, idler pulley, and left bank (drivers side) camshaft pulleys. Ensure timing belt marks are aligned with marks on camshaft sprockets and notches on rear timing belt cover. Keep timing belt taught between idler pulley and left bank camshaft pulleys. See Figs. 4 and 5.
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 reusing timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt.
CAUTION: Do not move camshafts with belt removed. Do not remove Camshaft Holders (J-42069) with timing belt removed.
Inspection: Check timing belt for excessive wear, cracks, or missing teeth. Inspect timing belt tensioner and idler pulleys for worn bearings. Replace as necessary.
Fig. 7: Aligning Timing Belt Marks On Crankshaft Pulley
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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 DEFLECTION ADJUSTMENT. Timing Belt Deflection Adjustment: If timing belt deflection adjustment is necessary, loosen left (drivers) side idler pulley bolt. (This is NOT the idler pulley positioned between camshaft sprockets in top, center of engine). Turn left idler pulley counterclockwise until high point of eccentric nut is in about 12 oclock position. See Fig 5. Snug idler pulley bolt while holding eccentric so it does not move. Go to next step. Apply additional tension to timing belt by loosening bolt for idler pulley located between camshaft sprockets (top, center of engine). Rotate high point of eccentric to 9 oclock position. Tighten idler pulley bolt while holding eccentric so it does not rotate. Go to TIMING BELT TENSION ADJUSTMENT. Timing Belt Tension Adjustment: Loosen timing belt tensioner lock nut. Turn tensioner eccentric counterclockwise to full stop. Turn eccentric back until reference mark is .039 (1 mm) from belt tension setting flange. See Fig 9. Tighten timing belt tensioner lock nut until snug. Lock nut will be final tightened after final adjustments are made. Go to CHECKING CAMSHAFT SPROCKET ALIGNMENT. Checking Camshaft Sprocket Alignment: Ensure timing belt alignment marks are still aligned with reference points on camshaft sprockets and rear timing belt cover. Remove all locking tools from camshafts and timing belt. Rotate crankshaft clockwise 2 revolutions, stopping at 60 degrees before TDC mark. See Fig. 2. Install Crankshaft Holder (J42069-10) to crankshaft flange. Secure moveable lever of tool to water pump pulley flange.
NOTE: Alignment marks on timing belt will no longer align with camshaft sprocket marks after one or more crankshaft revolutions.
Fig. 9: Adjusting Timing Belt Tension (New Design Engine Shown; Early Design Engine Tensioner Is The Same)
Ensure crankshaft timing mark aligns with mark on oil pump housing. Ensure camshaft timing marks align with notches on rear cover. Use Checking Gauge (J42069-20) to inspect alignment of left bank and right bank camshaft gears. See Fig. 10. The reference marks on both sets of camshaft sprockets must match exactly with marks on Checking Gauge (J4206920). If timing belt readjustment is NOT necessary, go to FINAL TIMING BELT TENSIONING & INSTALLATION. If timing belt readjustment IS necessary, go to TIMING BELT READJUSTMENT.
NOTE: When readjusting timing belt tension, Crankshaft Holder (J42069-10) must be in position on engine.
Timing Belt Readjustment (Left Bank Camshafts): If timing belt readjustment is required, always start with left bank (drivers side) camshafts first. Install Checking Gauge (J42069-20) to left bank camshafts. Loosen idler pulley on drivers side of engine. This is idler pulley below camshaft sprockets. Using Wrench (J4206940) or equivalent, turn idler pulley eccentric COUNTERCLOCKWISE until timing marks on camshaft sprockets and checking gauge are in alignment. High point of idler pulley eccentric should be in about the 12 oclock position. Tighten idler pulley bolt while holding eccentric from turning.
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Timing Belt
Fig. 10: Installing Checking Gauge on Camshaft Sprockets
Remove checking gauge and crankshaft holder. Rotate crankshaft clockwise 2 revolutions, stopping at 60 degree BTDC. Install Crankshaft Holder (J42069-10) to crankshaft drive gear. Rotate crankshaft to secure lever of holder to water pump flange. Install Checking Gauge (J42069-20) to left bank camshafts. If camshaft sprockets are now properly aligned, go to FINAL TIMING BELT TENSIONING & INSTALLATION. If not, repeat readjustment procedure. Timing Belt Readjustment (Right Bank Camshafts) If timing belt readjustment is required, always start with left bank (drivers side) camshafts first. Install Checking Gauge (J42069-20) to right bank (passengers side) camshafts. Loosen bolt on idler pulley that is located the center and below the left bank and right bank camshafts. Using Wrench (J42069-40) or equivalent, turn idler pulley eccentric COUNTERCLOCKWISE until timing marks on camshaft sprockets and checking gauge are in alignment. High point of idler pulley eccentric should be in about the 9 oclock position. Tighten idler pulley bolt while holding eccentric from turning. Remove checking gauge and crankshaft holder. Rotate crankshaft clockwise 2 revolutions, stopping at 60 degree BTDC. Install Crankshaft Holder (J42069-10) to crankshaft drive gear. Rotate crankshaft to secure lever of holder to water pump flange. Install Checking Gauge (J42069-20) to right bank camshafts. If camshaft sprockets are now properly aligned, go to FINAL TIMING BELT TENSIONING & INSTALLATION. If not, repeat readjustment procedure. Final Timing Belt Tensioning & Installation To set final timing belt tension, loosen timing belt tensioner eccentric lock nut. Turn timing belt eccentric counterclockwise to full stop. Turn tensioner back until reference mark is .079-.157 (2-4 mm) ABOVE reference mark on flange. See Fig. 9. Tighten tensioner eccentric lock nut to specification.
If timing belt idler pulley bolts were loosened, final tighten them to specification. See TORQUE SPECIFICATIONS. Inspect high points of timing belt tensioner eccentrics. Left side idler pulley (viewed from rear of engine) eccentric high point should be in about the 12 oclock position. Top center idler pulley eccentric high point should be in about the 9 oclock position. See Fig. 5. Remove crankshaft holding tool. Rotate crankshaft clockwise 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 contacts 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 inspect alignment of left bank and right bank camshaft gears. Adjust timing belt position, if necessary. Ensure all tools are removed from engine. Install timing belt front cover. Install crankshaft harmonic balancer. Tighten bolt to specification. Install timing belt cover. Install accessory drive belt tensioner. Install water pump and power steering pump pulleys. Install serpentine drive belt. Install air injection crossover pipe to front of engine. Install air intake resonator and ducting. Install engine splash shield. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ........................................................................... 37 (50) Step 2 ................................................... Additional 60 Degrees Step 3 ................................................... Additional 15 Degrees Crankshaft Harmonic Balancer Bolt ............................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 ....................................................................... 184 (250) Step 2 ................................................... Additional 45 Degrees Step 3 ................................................... Additional 15 Degrees Generator Bolt ............................................................... 30 (40) Power Steering Pump Pulley Bolt .................................. 15 (20) Serpentine Drive Belt Tensioner Bolt ............................ 30 (40) Timing Belt Idler Pulley Bolt ........................................... 30 (40) Timing Belt Tensioner Bracket Bolt ................................ 30 (40) Timing Belt Tensioner Eccentric Lock Nut ....................................................................... 15 (20) INCH Lbs. (N.m) Timing Belt Front Cover Bolt ............................................. 71 (8) Water Pump Pulley Bolt ................................................ 71 (8)
GENERAL MOTORS *3.0L V6 DOHC, Saturn

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 DOHC Saturn L Series 2000-01 ................. 4.0 Hours .................. 250285
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Removal: Disconnect negative battery cable. Remove air cleaner assembly. Raise and support vehicle. Remove right front wheel. Remove lower front splash shield.
NOTE: Right engine mount must be removed before accessory drive belt can be removed from vehicle.
Fig. 1: Positioning Crankshaft At 60 Degrees BTDC
Lower vehicle. Loosen, but do not remove water pump pulley bolts. Loosen, but do not remove power steering pump pulley bolts. Rotate accessory serpentine belt tensioner clockwise, and remove accessory serpentine belt from pulleys. Support weight of engine from above or below with floor jack. Remove front engine mount (timing belt end of engine) from engine and frame. Remove engine mount bracket from engine block. Remove water pump pulley bolts and pulley. Remove power steering pump pulley bolts and pulley. Remove accessory drive belt tensioner front engine block. Remove 6 harmonic balancer-to-crankshaft bolts. Remove harmonic balancer. It is NOT necessary to remove crankshaft center bolt. Remove wiring harness channel from front timing belt cover and secure away from engine. Remove front timing belt cover. Inspect sealing strip on outer edge of cover for cracks or tears. Replace, if necessary. Rotate crankshaft clockwise to 60 degrees before TDC. See Fig. 1. Ensure timing marks are not 180 degrees from TDC. Camshaft timing marks should be aligned with marks on rear cover. See Fig. 5. Install Crankshaft Holder (J-42069-10) and rotate crankshaft clockwise until holder contacts the water pump. See Fig. 2. Secure moveable lever of tool to water pump pulley flange. To lock camshafts in place, install Camshaft Gear Holders (J42069-1 and J-42069-2). See Fig. 3. It may be necessary to loosen timing belt idler pulley and turn eccentric until holder can be inserted. Loosen timing belt tensioner and idler pulley bolts. If reusing timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt.
Fig. 2: Installing Crankshaft Holder NOTE: Install timing belt at room temperature.
Inspection: Check timing belt for excessive wear, cracks, or missing teeth. Inspect timing belt tensioner and idler pulleys for grease leaks or worn bearings. Replace as necessary.
NOTE: Upper timing belt idler pulley uses a narrow .20 (5 mm) thick spacer and a Black bolt. The lower timing belt idler pulley uses a .40 (11 mm) thick spacer and a Silver bolt.
Installation: To install timing belt, remove crankshaft holder. Using a felt pen, mark the face of the upper and lower timing belt idler pulleys. The mark should line up with point farthest away from the Torx head mounting bolt. See Fig. 7. The idler pulleys provide adjustment by rotating on an eccentric circle around the mounting bolt. Loosen lower idler pulley mounting bolt just enough so that pulley will rotate with slight resistance. Remove upper timing belt pulley.
NOTE: Use the marks on each side of the direction of rotation arrows to line up the left (drivers side) camshaft sprockets. For this design (idler pulley located above crankshaft) engine, use the remaining 3 White marks on the NAPA timing belt. Correct belt marks MUST be used.
NOTE: DO NOT move camshafts with belt removed. DO NOT remove Camshaft Holders (J-42069) with timing belt removed.
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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 rear of engine), matching marks on timing belt with corresponding marks on camshaft sprockets. See Fig. 5. Keeping slack out of belt, route timing belt around lower idler pulley and around crankshaft sprocket. Ensure mark on timing belt mates with mark on crankshaft sprocket face. Hold timing belt in place against crankshaft sprocket using Plastic Wedge (J-42069-30). Route timing belt around right hand camshaft pulleys (as viewed from rear of engine). Ensure timing belt dash marks are aligned with marks on right hand camshaft sprockets. Install upper idler pulley. Tighten mounting bolt just enough so that the pulley will rotate with slight resistance. Install Timing Belt Holder (J42069-30) or equivalent to crankshaft. Tighten lever arm to water pump pulley flange. Ensure timing belt tension is taught (no slack). Loosen timing belt tensioner lock nut. Turn tensioner eccentric until center alignment mark is about .118 (3 mm) above alignment mark on spring loaded idler pulley. See Fig. 6. Remove plastic wedge holding timing belt against crankshaft sprocket. Tighten timing belt tensioner lock nut until snug. Lock nut will be final tightened after final adjustments are made. Adjust upper timing belt idler pulley so that the largest part of the eccentric is above and to the left of the mounting Torx bolt. Temporarily tighten Torx mounting bolt. See Fig. 7. Adjust lower idler pulley so that the largest part of the eccentric is above and to the left of the mounting Torx bolt. Temporarily tighten Torx mounting bolt. See Fig. 7.
Fig. 6: Setting Timing Belt Tension Setting
Remove camshaft holders from camshaft sprockets. Install Checking Gauge (J42069-20) to left hand (drivers side) camshafts. See Fig. 8. Pull timing belt between timing belt tensioner and crankshaft sprocket to take up slack between left hand camshaft sprocket and lower idler pulley. Ensure left hand camshaft timing marks are about 1 mm (about the width of the timing marks on the sprockets) on the retard side. See Fig. 8. If they are not, turn lower idler pulley clockwise to allow retard of left hand camshafts. Pull timing belt between timing belt tensioner and crankshaft sprocket to take up slack between left hand camshaft sprocket and lower idler pulley.
CAUTION: If TDC is passed while rotating crankshaft, DO NOT turn crankshaft counterclockwise. This will take out correct timing belt tension between timing belt tensioner and crankshaft sprocket. To correct for this, rotate crankshaft 2 additional turns.
Remove Crankshaft Holder (J42069-10). Rotate crankshaft clockwise 1 3/4 revolutions. Install Crankshaft Holder (J42069-10) to crankshaft flange, and then stop at TDC. Tighten lever arm to water pump pulley flange.
NOTE: Alignment marks on timing belt will no longer align with camshaft sprocket marks after one or more crankshaft revolutions. Timing marks on timing belt are used for initial installation only.
GENERAL MOTORS *3.0L V6 DOHC, Saturn (Cont.)
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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.
Fig. 7: Positioning Timing Belt Idler Pulleys
Remove Camshaft Gear Holder (J42069-2, Green) from left hand camshaft sprockets. Remove Crankshaft Holder (J42069-10) from crankshaft. Rotate crankshaft clockwise 1 3/4 revolutions. Install Crankshaft Holder (J42069-10) to crankshaft flange, and then stop at TDC. Tighten lever arm to water pump pulley flange. Recheck both camshaft timing marks on both banks with Checking Gauge (J42069-20). If timing marks are NOT aligned, readjust timing belt. It is NOT necessary to remove timing belt. If camshaft timing marks are aligned, final tighten upper and lower timing belt idler pulley Torx mounting bolts to 30 ft. lbs. (40 N.m). Adjust timing belt tensioner so that the center alignment mark is about 3 mm above alignment mark on spring loaded idler. See Fig. 6. Tighten timing belt tensioner pulley nut. Verify all timing marks are still aligned. Remove Crankshaft Holder (J42069-10). Remove Checking Gauge (J42069-20). Install timing belt front cover. Install crankshaft harmonic balancer. Tighten bolts to specification. Install water pump and power steering pump pulleys. Install 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Step 1 ........................................................................... 37 (50) Step 2 ................................................... Additional 60 Degrees Step 3 ................................................... Additional 15 Degrees Crankshaft Harmonic Balancer Bolt ............................... 15 (20) Crankshaft Sprocket Center Bolt Step 1 ....................................................................... 184 (250) Step 2 ................................................... Additional 45 Degrees Step 3 ................................................... Additional 15 Degrees Engine Mount-To-Bracket Bolt ........................................ 41 (55) Engine Mount Bracket-To-Engine Bolt ............................ 41 (55) Generator Bolt ............................................................... 30 (40) Power Steering Pump Pulley Bolt .................................. 15 (20) Serpentine Drive Belt Tensioner Unit Bolt ..................... 30 (40) Timing Belt Idler Pulley Torx Bolt ................................... 30 (40) Timing Belt Tensioner Bracket Bolt ................................ 30 (40) Timing Belt Tensioner Eccentric Lock Nut ....................................................................... 15 (20) Water Pump Bolt ............................................................ 18 (25) Wheel Lug Nut ............................................................. 92 (125) INCH Lbs. (N.m) Timing Belt Front Cover Bolt ............................................. 71 (8) Water Pump Pulley Bolt ................................................ 71 (8)
Fig. 8: Positioning Timing Belt On Left Hand Camshafts
Rotate lower timing belt idler pulley counterclockwise until the left hand camshaft timing marks on the sprockets are lined up with marks on the Checking Gauge (J42069-20). While holding lower idler pulley in this position, tighten lower idler pulley Torx mounting bolt to 15 ft. lbs. (20 N.m). Remove Crankshaft Holder (J42069-10). Rotate crankshaft 1 3/4 turns clockwise. DO NOT rotate crankshaft counterclockwise. Install Crankshaft Holder (J42069-10) to crankshaft flange, and then stop at TDC. Tighten lever arm to water pump pulley flange. Inspect left hand camshaft timing marks for alignment. Sprocket timing marks should align with marks on rear cover. Realign, if necessary. Remove Checking Gauge (J42069-20) from left hand camshaft sprockets. Install checking gauge on right hand sprockets (passenger side). Install Camshaft Gear Holder (J42069-2, Green) between left hand camshaft sprockets. Turn upper timing belt idler pulley counterclockwise until the right hand camshaft sprocket timing marks are aligned with marks on Checking Gauge (J42069-20). While holding idler pulley eccentric in this position, tighten upper idler pulley Torx mounting bolt to 15 ft. lbs. (20 N.m).
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GENERAL MOTORS *3.4L V6
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.4L V6 DOHC Cutlass Supreme & Grand Prix 1991-95 ............ 1 4.5 Hours ..................... 250192 1996 ................. 1 4.5 Hours ..................... 250273 Lumina 1991-95 ............ 1 4.5 Hours ..................... 250192 1997-96 ............ 1 4.5 Hours ..................... 250273 Monte Carlo 1995 ................. 1 4.5 Hours ..................... 250192 1996-97 ............ 1 4.5 Hours ..................... 250273
1
With Air. Cond. add .4 hours.


TIMING BELT
NOTE: Revised repair procedure are from GM technical service bulletin 47-61-34; December, 1994. Fig. 1: Timing Belt Assembly
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. Remove fuel lines from fuel rail. Remove fuel mounting bracket. Remove heater hose and bracket from lower intake manifold. Remove PCV valve and vacuum line from throttle body. Remove electrical connectors from EGR valve, canister purge solenoid and MAP sensor. Remove vacuum lines from upper intake manifold tee. Remove wiring loom bracket for rear spark plug wires. Remove upper intake manifold. Remove coolant recovery tank. Remove serpentine drive belt and drive belt tensioner. 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. Remove 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. Remove fuel line bracket. Remove timing belt covers. Remove breather hose from rear camshaft cover and crankcase vent from breather manifold. Remove camshaft carrier covers.
NOTE: Actuator assembly uses a tapered bushing between the actuator and mounting base. DO NOT lose or damage the bushing when removing the actuator assembly.
Fig. 2: Measuring Timing Belt Tensioner Actuator Length
Fig. 3: Reworking Paper Clip
Remove side plate bolts securing timing belt tensioner actuator. Rotate actuator assembly from tensioner pulley socket and out of mounting base. Remove timing belt tensioner pulley. See Fig. 1. Position timing belt tensioner actuator in vise with rod tip (rubber boot end) pointing down.
GENERAL MOTORS *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.
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Straighten out a standard paper clip (.032 with no serrations) and form a loop at one end. See Fig. 3. Remove rubber end plug from rear of tensioner actuator. Push paper clip through end of vent plug and into pilot hole. Insert a small screwdriver into the screw slot inside actuator, behind rubber end plug. Retract actuator plunger by rotating screw in a clockwise direction, until it is fully retracted. Push on paper clip and slowly rotate screw counterclockwise until paper clip engages. Remove timing belt.
NOTE: Remove timing marks from camshaft and intermediate shaft sprockets.
Fig. 5: Identifying Camshaft Sprocket Designs
Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Mark the timing indicator with White paint or equivalent on the crankshaft balancer and front cover. Position camshafts so that flat spots are UP for installation of Camshaft Hold-Down Tools (J 38613-A). Install Camshaft Hold-Down Tools (J 38613-A) on both camshaft carriers. See Fig. 4. Remove camshaft sprocket center bolts. Note difference between early and late designs. See Fig. 5. Lightly tap on rear of sprockets to remove from camshaft. Inspection: To determine if timing belt length is within specifications, measure tensioner actuator from centerline of tensioner actuator to end of rubber boot. See Fig. 2. If measurement
is 3.2-3.7 (80.5-94.0 mm) for a used belt, the belt is in acceptable range. Replace belt is measurement is more than 3.7 (94 mm). Inspect belt teeth and back side of belt for cracks, tears or other damage. Inspect components for excessive wear or unusual conditions. Note any evidence of oil or other fluid intrusion. Installation: Install camshaft sprockets with bolts and locks. Tighten bolts finger tight. Install timing belt onto camshaft sprockets in a counterclockwise direction. Continue installing timing belt, making sure timing belt teeth are fully engaged with all sprockets. Install timing belt tensioner pulley. Tighten timing belt tensioner pulley bolt to 37 ft. lbs. (50 N.m).
Fig. 4: Installing Camshaft Hold-Down Tools (J 38613-A)
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GENERAL MOTORS *3.4L V6 (Cont.)
Rotate engine clockwise (as viewed from front) 2 times to seat belt and verify correct valve timing. DO NOT reverse rotation. Make sure both camshaft flat spots are up on one bank and down on opposing bank. Install camshaft carrier covers. Install breather hose and crankcase vent onto rear cover. Install timing belt covers. Continue installation in reverse of removal procedure. Refill cooling system with 50/50 mix of water and coolant. Open air bleed valve on thermostat housing while filling cooling system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 96 (130) Crankshaft Balancer Bolt .......................................... 79 (107) Crankshaft Pulley Bolt ................................................ 37 (50) EGR Valve Bolts ............................................................. 18 (25) Front Cover Bolts Large Bolts ............................................................... 35 (47) Small Bolts ............................................................... 18 (25) Intermediate Shaft Belt Sprocket Bolt ........................ 96 (130) Serpentine Belt Tensioner Bolt ....................................... 33 (45) Timing Belt Actuator Side Plate Bolt ............................... 20 (27) Timing Belt Tensioner Pulley Bolt ................................... 37 (50) Timing Chain Tensioner Bolt ...................................... 18 (24) Upper Intake Manifold Bolts & Nuts ................................ 22 (27) INCH Lbs. (N.m) Camshaft Carrier Cover Bolts ........................................ 97 (11) Timing Belt Cover Bolts .................................................. 89 (10) Water Pump Bolt ........................................................ 97 (11)
NOTE: If tensioner oil has been lost, fill tensioner with Mobil 1 SAE 5W-30 synthetic engine oii through plug hole. Fill to bottom of plug hole only when plunger is fully retracted and pin is installed.
Install rubber end plug in rear of tensioner assembly until flush. Ensure plug is sealed against case.
NOTE: Ensure actuator bushings and appropriate holes in side plate are clean. DO NOT lubricate bushings.
Install actuator bushing into side plate. Install timing belt actuator and actuator side plate. Tighten side plate bolt to 20 ft. lbs. (27 N.m). Rotate pulley assembly into timing belt a maximum of 11 ft. lbs. (15 N.m) to allow engagement of actuator shaft into pulley pocket arm socket. Pull the paper clip from the actuator. Retighten pulley assembly counterclockwise to seat pulley into belt. Tighten both right hand camshaft sprockets (bank closest to firewall) to 96 ft. lbs. (130 N.m). Remove camshaft holddown from right hand camshaft carrier. Rotate crankshaft one full turn (360 degrees) clockwise, as viewed from front of engine. Align crankshaft reference marks. Make sure both right hand camshaft flat spots are down. Tighten both left hand camshaft sprockets (bank closest to radiator) to 96 ft. lbs. (130 N.m). Remove camshaft hold-down from left hand camshaft carrier.
HONDA *1.2L 4-Cylinder

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.2L 4-Cyl. Civic 1973-79 ................. 1.5 Hours .................. 250028 1 - With Air Cond. add .9 hours.
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TIMING BELT
Removal: Disconnect negative battery cable. Remove wheelwell splash shield. Remove air conditioning compressor adjustment pulley complete with bracket drive belt. Remove remaining accessory drive belt(s). Remove valve cover. Remove water pump pulley and crankshaft pulley. See Fig. 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. Remove lower timing belt cover from engine block. Loosen (do not remove) timing belt adjusting and pivot bolts. Slide belt off pulleys. Installation: To install, reverse removal procedure using care not to excessively bend or twist timing belt. Do not expose belt to engine oil as this will cause belt rubber to swell. Install belt in same direction of rotation to prevent premature wear or failure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. lbs (N.m) A/C Pulley Bolt ............................................................ 17 (23) Alternator Through-Bolt ............................................................. 33 (45) Adjustment Bolt ........................................................ 17 (23) Crankshaft Pulley Bolt ................................................ 61 (81) Engine Support Bolts/Nut ........................................... 40 (55) Side Bracket ............................................................... 33 (45) Timing Belt Tensioner Bolt ......................................... 33 (45) INCH Lbs. (N.m) Timing Belt Cover ...................................................... 84 (9.7) Valve Cover ................................................................ 84 (9.7)
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HONDA *1.2L 4-Cylinder (Cont.)
Fig. 2: Aligning Camshaft Marks

TIMING BELT APPLICATION Labor Component Application Time Kit No. 1.3L 4-Cyl. Civic 1980-83 Canada ........ 22.0 Hrs. ............................ 250028 US ............... 22.0 Hrs. ............................ 250073 1984-85 .......... 22.0 Hrs. ............................ 250099 1986-87 .......... 22.0 Hrs. ..... 2521610 ........ 250161 Civic CRX 1984 ............... 22.0 Hrs. ............................ 250099 1 - With Air Cond. add .9 hours. 2 - With Air Cond. add .4 hours. Belt Part No.
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CAUTION: Belt tension must be adjusted when engine temperature is cold.
Install washer on crankshaft bolt with flat side toward the pulley. See Figs. 2 and 4.Tighten retaining bolt to specification. Reverse removal procedure to complete installation. Tighten all bolts to specification. On specified Civic models, valve cover bolts must be tightened in proper sequence. See Fig. 3. Adjust drive belts to proper tension. See page A60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Adjustment Bolt .......................................... 17 (23) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Pulley Bolt .................................................. 27 (37) Crankshaft Pulley Bolt 1980-83 .................................................................... 61 (81) 1984-87 .................................................................. 83 (112) Timing Belt Adjuster Bolt ............................................. 35 (48) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................. 84 (9) Valve Cover Bolt ........................................................ 108 (12) Valve Cover Nut ............................................................ 84 (9) Water Pump Bolt ...................................................... 108 (12)


TIMING BELT
Removal: Disconnect negative battery cable. Remove wheelwell splash shield. Remove A/C compressor or adjusting pulley and bracket. Remove A/C belt. Remove accessory drive belts. Remove engine support bolts and nut. Remove side mount rubber. Rotate crankshaft counterclockwise to position No. 1 cylinder to TDC of compression stroke. Remove engine valve cover and upper timing belt cover. See Figs. 2 and 4. Ensure camshaft timing marks are aligned with valve cover surface and UP or ROUND mark is upward. See Figs. 1 and 5. Remove crankshaft pulley. Remove lower timing belt cover from engine block. Loosen timing belt tensioner to relieve timing belt tension. If timing belt is being reused, mark direction of belt rotation before removing. Remove timing belt from camshaft and crankshaft gears. Inspection: Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear in drive belt area. Replace as necessary. Installation : Ensure No. 1 piston is at TDC of compression stroke. Ensure camshaft timing marks are aligned with valve cover surface and UP or ROUND mark is upward. See Figs. 1 and 4. Install timing belt. Use care not to excessively bend or twist belt. Ensure belt is installed in original direction of rotation. Belt tension must be adjusted. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on belt. Tighten tensioner adjustment bolt to specification.
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Fig. 3: Valve Cover Tightening Sequence
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TIMING BELT APPLICATION Application 1.5L 4-Cyl. Civic CVCC 1975 ............... 2.0 Hrs. ...... 2520360 ........ 250036 1976-79 .......... 2.0 Hrs. ............................. 250041 Civic 1980-83 .......... 2.0 Hrs. ............................. 250041 1984-85 .......... 2.0 Hrs. ............................. 250099 1986-87 .......... 2.0 Hrs. ...... 2521610 ........ 250161 1988-95 .......... 2.0 Hrs. ...... 2521430 ........ 250143 Civic VX 1992-95 .......... 2.0 Hrs. ............................. 250223 Civic CRX 1984-85 .......... 2.0 Hrs. ............................. 250099 1986-87 .......... 2.0 Hrs. ...... 2521610 ........ 250161 Civic Del Sol 1993-95 Exc. VX ........ 2.0 Hrs. ...... 2521430 ........ 250143 VX ................ 2.0 Hrs. ............................. 250223 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.

Although the manufacturer does not recommend a specific scheduled maintenance interval for 1975-89 models, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1990-94 models, the manufacturer recommends the belt be replaced at 90,000 mile intervals. For 1995 models, the manufacturer recommends the belt be replaced at 90,000 mile intervals for normal service and 60,000 miles for severe service.

TIMING BELT
Removal (1975-79): Disconnect negative battery cable. Remove wheelwell splash shield. Remove A/C compressor adjusting pulley together with bracket and A/C belt. Remove alternator bracket and belt. Remove engine support bolts and nut. Remove rubber mount. Remove valve cover. Remove crankshaft pulley. Remove upper timing belt cover from cylinder head and remove lower timing belt cover from engine block. Ensure that No. 1 cylinder is at TDC on compression stroke with camshaft aligned with marks. Remove timing belt.
Installation (1975-79): Ensure camshaft and crankshaft timing marks are still aligned. See Figs. 1 and 5. Reverse removal procedure using care not to excessively twist or bend belt. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (1980-95): Disconnect negative battery cable. Rotate crankshaft counterclockwise until No. 1 cylinder is at TDC of compression stroke. Remove splash shield. Remove power steering pump, leaving hoses attached. Remove A/C belt idler pulley bracket and belt. Remove alternator belt. Remove power steering pump bracket. Remove cruise control actuator (if equipped). Remove power steering reservoir bracket. Remove engine mount nuts. Loosen engine mount bolt. Pivot side engine mount cushion aside. Remove valve cover. Remove upper timing belt cover. Remove crankshaft pulley. Loosen timing belt tension adjuster bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjuster bolt. Disengage timing belt from pulleys. See Figs. 1, 2 and 3. Installation (1980-95): 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-
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ing mark aligns with pointer on lower timing belt cover. See Figs. 5, 6, 7, 8 or 9. Adjust timing belt tension. See TIMING BELT ADJUSTMENT. Before installing valve cover gasket, apply non-hardening sealant to rounded surfaces of front and rear camshaft caps. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
TIMING BELT ADJUSTMENT

Remove cylinder head cover. Remove upper timing belt cover. Rotate crankshaft counterclockwise until No. 1 cylinder is at TDC of compression stroke. Loosen but do not remove, timing belt adjuster bolt. See Fig. 4. Rotate crankshaft 3 teeth counterclockwise on camshaft sprocket to create tension on timing belt. Tighten adjuster bolt to specification. Retighten crankshaft pulley bolt to specification if it loosened during crankshaft rotation. See TORQUE SPECIFICATIONS.
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TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Sprocket Bolt SOHC 1975-79 ................................................................. 22 (30) 1980-95 ................................................................. 28 (33) Crankshaft Pulley Bolt 1 SOHC ................................................................... 134 (185) Power Steering Pump Bracket Bolt ............................. 33 (45) Timing Belt Adjuster Bolt ............................................. 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 89 (10) Valve Cover Nut .......................................................... 89 (10) Water Pump Bolt ...................................................... 108 (12)
1
- Lubricate bolt threads. Do not lubricate washer or washer mating surface of bolt.
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Fig. 7: Aligning Timing Marks (1988-91: Dual Point Injection)
Fig. 8: Aligning Timing Marks (1988-91 Civic Si & 4WD Civic Wagon; Multipoint Injection)
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HONDA *1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. DOHC Civic Del Sol 1994-97 ................ 1 2.0 Hours ................. 250227 1 - With Air Cond. add .4 hours. With Cruise Control add .3 hours.
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For 1994 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles. For 1995-96 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service and 60,000 miles for severe service. For 1997 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).
Installation: Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 2. Set intake and exhaust camshaft pulleys to TDC. The TDC marks should align with each other with UP marks pointing up. See Fig. 2. Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, intake camshaft pulley, and exhaust camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulleys remained aligned with TDC marks. Loosen and retighten adjusting bolt to tension timing belt. Install lower and middle covers. Install crankshaft pulley. Tighten pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt seats on pulleys.

TIMING BELT
Removal: If the radio has a theft protection circuit, be sure to get the customers code before disconnecting battery. Disconnect negative battery cable. Remove engine lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Remove power steering pump and hang out of way, leaving hoses connected. Rotate crankshaft counterclockwise 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.
To adjust timing belt tension, set No. 1 piston at TDC (White TDC mark on crankshaft pulley aligned with pointer on cover). See Fig. 1. Loosen adjusting bolt 180 degrees. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque crankshaft pulley bolt. Ensure crankshaft and camshaft pulleys are still aligned at TDC. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. When installing valve cover gasket, apply liquid gasket to 8 corners where gasket meets camshafts. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 1: Setting Crankshaft Pulley To TDC
Fig. 2: Aligning Crankshaft & Camshaft TDC Marks
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HONDA *1.6L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt ........................ 33 (44) Alternator Mount Bolt ................................................... 33 (45) Camshaft Pulley Center Bolt .......................................... 41 (56) Crankshaft Pulley Bolt 1 ............................................ 130 (177) Engine Mount Bracket Nuts ............................................ 54 (74) Engine Mount Bracket-To-Engine Bolts .......................... 40 (54) Power Steering Pump Bracket Bolt ............................ 33 (44) Power Steering Pump-To-Bracket Bolts ......................... 17 (24) Timing Belt Adjusting Bolt ............................................. 40 (54) Water Pump Bolt (10 x 1.25 mm) ................................... 33 (44) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 89 (10) Valve Cover Nuts 2 ..................................................................................................... 89 (10) Water Pump Bolt (6 x 1.0 mm) .................................. 106 (12)
1 2
- Lubricate bolt threads and bottom shoulder of bolt head. - Tighten nuts in 2-3 steps, starting from center outward.
HONDA *1.6L 4-Cylinder SOHC, 1976-95

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.6L 4-Cyl. Accord (Includes Canadian) 1976-78 ................. 2.0 Hours .................. 250041 1980-83 ................. 2.0 Hours .................. 250041 Civic & Civic del Sol 1988-91 ................. 2.1 Hours .................. 250145 1992 (Except Si) ......... 2.1 Hours .................. 250145 (Si) ...................... 2.0 Hours .................. 250224 1993-95 ................. 2.1 Hours .................. 250224 Civic CRX 1988-91 ................. 2.1 Hours .................. 250145 Prelude (Canadian) 1980-82 ................. 2.1 Hours .................. 250041 1 - With Air Cond. add .4 hours.
1
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Install timing belt onto crankshaft pulley, tension adjuster pulley, water pump pulley, and camshaft sprocket. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft timing marks are still aligned. Adjust timing belt tension. See TIMING BELT ADJUSTMENT. Before installing valve cover gasket, apply non-hardening sealant to rounded surfaces of front and rear camshaft caps. To complete installation,reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
TIMING BELT ADJUSTMENT


Although the manufacturer does not recommend a specific scheduled maintenance interval for 1975-89 models, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1990-94 models, normal replacement interval is at 90,000 miles. For 1995 models, recommended replacement interval is 90,000 for normal service and 60,000 for severe service.
Remove valve cover. Remove upper timing belt cover. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Loosen but do not remove, timing belt adjuster bolt. See Fig. 2. Rotate crankshaft 3 teeth counterclockwise on camshaft sprocket to create tension on timing belt. Tighten adjuster bolt. Retighten crankshaft pulley bolt to specification if it loosened during crankshaft rotation. See TORQUE SPECIFICATIONS.

TIMING BELT
Removal: Disconnect battery negative cable. Rotate crankshaft counterclockwise until No. 1 cylinder is at TDC of compression stroke. Remove wheelwell splash shield. Remove power steering pump, leaving hoses attached. Remove A/C belt idler pulley bracket, and belt. Remove alternator belt. Remove power steering pump bracket. Remove cruise control actuator (if equipped). Remove power steering reservoir bracket. Use jack to support 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. Remove crankshaft pulley. Remove crankshaft position sensor 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: Ensure No. 1 cylinder is at TDC of compression stroke. Crankshaft keyway will be at 12 oclock position, and sprocket groove or mark will align with pointer on oil pump housing.
Fig. 1: Exploded View Of Timing Belt Components (Accord & Prelude)
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HONDA *1.6L 4-Cylinder SOHC, 1976-95 (Cont.)
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks (Accord, 1976-82)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Sprocket Bolt DOHC ....................................................................... 38 (51) SOHC ....................................................................... 28 (38) Crankshaft Pulley Bolt 1 SOHC ................................................................... 130 (180) SOHC ................................................................... 134 (185) Power Steering Pump Bracket Bolt ............................ 33 (45) Timing Belt Adjuster Bolt DOHC ....................................................................... 41 (55) SOHC ....................................................................... 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 89 (10) Valve Cover Nut .......................................................... 89 (10) Water Pump Bolt ...................................................... 108 (12) 1 - Lubricate bolt threads but do not lubricate washer or mat ing surface of bolt.
Fig. 3: Aligning Crankshaft & Camshaft Timing Marks (Prelude, 1980-82)
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Fig. 5: Exploded View Of Timing Belt Components (1992-95 Civic)
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Fig. 6: Aligning Timing Belt Marks (Civic, 1988-95)
HONDA *1.6L 4-Cylinder SOHC, 1996-2000

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC Civic 1996-00 ................ 1 2.0 Hours ................. 250224 Civic Del Sol 1996-97 ................ `1 2.0 Hours ................ 250224 1 - With Air Cond. add .4 hours. With Cruise Control add .3 hours.
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TIMING BELT
Removal: Disconnect negative battery cable. Remove engine lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 3. Remove engine oil dipstick. Remove power steering pump and set aside with hoses attached. Remove timing belt upper cover and A/C drive belt idler pulley bracket. Use jack to support engine. Working from front of engine, remove engine mount bracket nuts. Remove crankshaft pulley. Remove lower cover and dipstick tube. Remove Crankshaft Speed Fluctuation (CKF) sensor from oil pump. Loosen the timing belt tension adjusting bolt 180 degrees. Push tensioner to release belt tension. Retighten tension adjusting bolt. Mark rotation direction of timing belt if it is to be reused. Remove timing belt from pulleys. See Fig. 1.

For 1996 vehicles, manufacturer recommends replacing belt at 90,000 miles for normal service and 60,000 miles for severe service. For 1997-00 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
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Installation: Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 2. Set camshaft pulley to TDC. TDC marks should align with top surface of cylinder head. See Fig. 3. Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, and camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulley timing mark are aligned with TDC marks. Loosen and retighten adjusting bolt to tension timing belt. Install lower cover. Install crankshaft pulley. Tighten pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt seats on pulleys.
Fig. 2: Aligning Crankshaft TDC Mark & Oil Pump Mark NOTE: The following revised timing belt tensioner information is from Honda technical service bulletin 96-057; August 4, 1998.
Inspection: Inspect timing belt tensioner pulley for worn bearing. Replace as necessary. If there was a customer complaint of a whine or chirping noise from the front of the engine at idle, or just above idle, this may be caused by a timing belt that is tensioned too tight. A revised timing belt tensioner and spring are available for all 1996, 1997 and some 1998 engines. The timing belt tensioner kit is available under part number 14520-P2A-305.
To adjust timing belt tension, set No. 1 piston at TDC (White TDC mark on crankshaft pulley aligned with pointer on cover). Loosen adjusting bolt 180 degrees. See Fig. 5. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten adjusting bolt. If necessary, retorque crankshaft pulley bolt. Ensure crankshaft and camshaft pulleys are still aligned at TDC. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
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TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt ........................ 17 (24) Alternator Adjusting Bolt .................................................. 17 (24) Alternator Mount Bolt ................................................... 33 (45) Camshaft Pulley Center Bolt .......................................... 27 (37) Crankshaft Pulley Bolt 1 Step 1 ....................................................................... 14 (20) Step 2 ...................................... Plus 90 Degrees Clockwise Engine Mount Bracket Nuts ............................................ 54 (74) Power Steering Pump Bracket Bolt ............................ 17 (24) Power Steering Pump Lock Bolt ................................ 17 (24) Timing Belt Tensioner Adjusting Bolt ........................... 33 (45) INCH Lbs. (N.m) CKF Sensor Bolt ....................................................... 106 (12) Engine Lower Splash Shield .......................................... 89 (10) Timing Belt Cover Bolt ................................................ 89 (10) Water Pump Bolt ...................................................... 106 (12) 1 - Lubricate bolt threads and bolt head shoulder.
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HONDA 1.6L 4-Cylinder SOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC Civic 2001 ..................... 1 2.7 Hours ................. 250312 1 - With Air Cond. add .2 hours.
TIMING BELT
Removal: Disconnect negative battery cable. Remove engine lower splash shield. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 2. Remove front wheels. Remove splash shield. Remove power steering adjusting plate mounting bolt, then remove power steering pump belt and pump without disconnecting hoses. Remove alternator. Remove four (4) ignition coils, throttle cable clamps and harness holder from cylinder head cover. Remove cylinder head cover. See Fig. 1.

For 2001 vehicles, normal replacement interval is at 110,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
HONDA 1.7L 4-Cylinder SOHC (Cont.)
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Courtesy of American Honda Motor Co. , Inc. Courtesy of American Honda Motor Co. , Inc.
Fig. 5: Removing CKP Sensor From Oil Pump
Fig. 3: Removing Crankshaft Pulley
Fig. 6: Removing Tension From Timing Belt
Fig. 7: Aligning Crankshaft TDC Mark & Oil Pump Mark
Hold crankshaft pulley with Holder Handle (07JAB001020A), Holder Attachment (07JAA-001020A) and use a heavy duty 19 mm socket and breaker bar to remove pulley bolt. See Fig. 3. Support engine with a jack and wood block under oil pan. Remove upper engine bracket from timing belt end of engine. Remove grommet from upper timing belt cover and disconnect TDC sensor connector. Remove both upper and lower timing belt covers. See Fig. 4.
262
HONDA 1.7L 4-Cylinder SOHC, (Cont.)
Install timing belt in this sequence: timing belt drive pulley, tensioner pulley, water pump pulley, and camshaft pulley. See Fig. 9. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Ensure crankshaft and camshaft pulley timing marks are aligned with TDC marks. Install CKP sensor, side engine mount bracket, lower timing belt cover, and crankshaft pulley. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley.
Fig. 8: Aligning Camshaft TDC Marks
Turn crankshaft pulley so No. 1 piston is at TDC (White TDC mark on crankshaft pulley aligns with pointer on cover). See Fig. 2. Ensure camshaft pulley marks are aligned at TDC. See Fig. 8. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt ........................ 17 (24) Alternator Adjusting Bolt .................................................. 17 (24) Alternator Mount Bolt ................................................... 33 (45) Auto Tensioner Mounting Bolt ..................................... 33 (44) Camshaft Pulley Center Bolt .......................................... 27 (37) Crankshaft Pulley Bolt 1 Step 1 ....................................................................... 14 (20) Step 2 ...................................... Plus 90 Degrees Clockwise Engine Side Mount Bracket Nuts .................................... 33 (44) Engine Upper Bracket Nuts ............................................ 40 (54) Power Steering Pump Bracket Bolt ............................ 17 (24) Power Steering Pump Lock Bolt ................................ 17 (24) INCH Lbs. (N.m) CKP Sensor Bolt ...................................................... 106 (12) Engine Lower Splash Shield .......................................... 89 (10) Harness Holder & Cable Clamps .................................. 89 (10) Timing Belt Cover Bolt ................................................ 89 (10) Water Pump Bolt ...................................................... 106 (12) 1 - Lubricate bolt threads and bolt head shoulder.
Remove side engine mount bracket. Remove CKP sensor from oil pump without disconnecting connector. See Fig. 5. Move auto tensioner to remove tension from timing belt and remove timing belt. See Fig. 6. Installation: Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 7. Set camshaft pulley to TDC. TDC marks should align with top surface of cylinder head. See Fig. 8

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Accord 1979-83 .......... 12.0 Hrs. ............................ 250041 1984-85 .......... 12.0 Hrs. ..... 2521600 ........ 250094 Prelude 1979-82 .......... 12.0 Hrs. ............................ 250041 1983-85 .......... 12.0 Hrs. ..... 2521600 ........ 250094 1986-87 .......... 12.0 Hrs. ..... 2521600 ........ 250160 1 - With Air Cond. add .4 hours. Labor Time Component Kit No. Belt Part No.
263

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

TIMING BELT
Removal (1979-81): Disconnect negative battery cable. Remove engine support bolts and nuts. Remove side rubber mount. Remove side mount bracket. Remove cruise control actuator. Remove engine splash guard. Remove water pump drive belt, water pump pulley and crankshaft pulley. Remove alternator, 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. Remove upper timing belt cover from cylinder head and remove lower timing belt cover from engine block. Loosen, do not remove, timing belt adjusting and pivot bolts. If reusing belt, mark direction of belt rotation. Slide belt off pulleys. Installation (1979-81): To install, reverse removal procedure using care not to excessively bend or twist belt. If re-installing old belt, install belt so same direction of rotation will be maintained. Adjust drive belts to proper tension. Removal (1982-87): Disconnect negative battery cable. Remove engine support bolts and nuts. Remove side rubber mount. Remove side mount bracket. Remove cruise control actuator. Remove engine splash guard. Remove water pump drive belt, water pump pulley. Remove alternator, belt, A/C compressor and belt. Rotate crankshaft counterclockwise to position No. 1 cylinder to TDC of compression stroke. Remove all drive belts. Remove engine valve cover and upper timing belt cover. Ensure camshaft timing marks are aligned with valve cover surface and UP or ROUND mark is upward. See Fig. 2, Fig. 3 or Fig. 4.
Fig. 1: Exploded View Of Timing Belt & Components (Accord & Prelude, 1979-83)
264
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 (1982-87): Inspect timing belt for wear or rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear in drive belt area. Replace as necessary. Installation (1982-87): Ensure cylinder No. 1 is at TDC of compression stroke. Ensure camshaft timing marks are aligned with valve cover surface and UP or ROUND mark is upward. See Fig. 2, Fig. 3 or Fig. 4. Install timing belt. Use care not to excessively bend or twist belt. Ensure belt is installed in original direction of rotation. Belt tension must be adjusted. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on belt. Tighten tensioner adjustment bolt to specification.
CAUTION: Belt tension must be adjusted when engine temperature is cold.
Fig. 4: Aligning Crankshaft & Camshaft Timing Marks (Prelude, 1984-87)
Install washer on crankshaft bolt with flat side toward the pulley. Tighten retaining bolt to specification. Reverse removal procedure to complete installation. Tighten all bolts to specification. Apply non-hardening sealant to rounded surfaces of front and rear camshaft caps before installing valve cover gasket. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolts ................................... 35 (47) Alternator Adjustment Bolt ........................................... 17 (23) Alternator Bracket Bolt ................................................. 33 (45) Camshaft Pulley Bolt 1983-87 ..................................................................... 27 (37) 1979-82 ..................................................................... 22 (30) Crankshaft Pulley Bolt ............................................... 83 (112) Timing Belt Adjuster Bolt .............................................. 32 (44) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................... 84 (9) Valve Cover Bolt ......................................................... 108 (12) Valve Cover Nut ............................................................. 84 (9) Water Pump Bolt ....................................................... 108 (12)
265
Fig. 5: Exploded View Of Timing Belt & Components (Accord, 1984-85 & Prelude, 1984-87)
266
HONDA *2.0L 4-Cylinder CR-V

Installation: Ensure No. 1 cylinder is at TDC of compression stroke. Timing belt drive pulley TDC mark must align with pointer on oil pump housing. See Fig. 2. Set intake and exhaust camshaft pulleys to TDC. The TDC marks should align with cylinder head surface with UP marks pointing up. See Fig. 2. Install timing belt in this sequence: timing belt drive pulley, tension adjusting pulley, water pump pulley, exhaust camshaft pulley, and intake camshaft pulley. See Fig. 4. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Check that crankshaft and camshaft pulleys remained aligned with TDC marks. Loosen and retighten adjusting bolt to tension timing belt. Install lower and middle covers. Install crankshaft pulley. Tighten pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft pulley 5-6 turns counterclockwise so timing belt positions on pulley.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. CR-V 1997-01 .............. 1 3.0 Hours ................. 250184 1 - With Cruise Control add .3 hours.


TIMING BELT
Removal: Disconnect battery negative cable. Remove engine guard bar and lower splash shield. Remove power steering, alternator, and A/C compressor drive belts. Remove cruise control actuator and vacuum tank from left side fenderwell (if equipped) and hang out of way. Rotate crankshaft counterclockwise to TDC of compression stroke. See Fig. 1. 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.
To adjust timing belt tension, set No. 1 piston at TDC (White TDC mark on crankshaft pulley aligned with pointer on cover). See Fig. 1. Loosen adjusting bolt 180 degrees. Rotate crankshaft counterclockwise 3 teeth on camshaft
Fig. 1: Setting Crankshaft Pulley To TDC
Fig. 2: Aligning Crankshaft & Camshaft TDC Marks
HONDA *2.0L 4-Cylinder CR-V (Cont.)

pulley. Tighten adjusting bolt. If necessary, retorque crankshaft pulley bolt. Ensure crankshaft and camshaft pulleys are still aligned at TDC. If not, timing belt will need to be removed and repositioned. To complete installation, reverse removal procedure. When installing 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 TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
267
268
HONDA *2.0L 4-Cylinder CR-V (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Drive Belt Idler Pulley Bracket Bolt ........................ 33 (44) Alternator Adjusting Lock Nut ......................................... 17 (24) Alternator Mount Bolt ................................................... 33 (45) Camshaft Pulley Center Bolt .......................................... 27 (37) Crankshaft Pulley Bolt 1 ............................................ 130 (177) Engine Mount Bracket Nuts ............................................ 54 (74) Engine Underguard Bar Bolts ........................................ 17 (24) Power Steering Pump Bracket Bolt ............................ 33 (44) Power Steering Pump Lock Bolt ................................ 17 (24) Power Steering Pump-To-Bracket Bolts ......................... 17 (24) Timing Belt Adjusting Bolt ............................................. 40 (54) INCH Lbs. (N.m) Cylinder Head Cover Nuts 2 .......................................... 89 (10) Engine Lower Splash Shield .......................................... 89 (10) Timing Belt Cover Bolt ................................................ 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 *2.0L 4-Cylinder SOHC, Accord & Prelude

TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 2.0L 4-Cyl. SOHC Accord 1986-89 .......... 1 2.7 Hrs. .... 2521600 ........ 250160 Prelude 1985 ............... 1 2.7 Hrs. .... 2521600 ........ 250094 1986-87 .......... 1 2.7 Hrs. .... 2521600 ........ 250160 1988-90 .......... 1 2.7 Hrs. ........................... 250144 1 - With Air Cond. add .3 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
269

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.
Fig. 1: Exploded View Of Timing Belt Components (Except 1988-90 Prelude)

TIMING BELT
Removal (Except 1988-90 Prelude): Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Remove drive belts. Remove left engine mount bolts/ nuts, engine mount and bracket. Remove cruise control actuator (if equipped). 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 compressor (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 direction before removing. Loosen timing belt tensioner adjustment bolt. Push tensioner to release belt tension, retighten adjustment bolt. Remove timing belt. Inspection: Inspect timing belt for wear and for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear. Inspect water pump for excessive bearing play or coolant leakage. Replace as necessary. Installation (Except 1988-90 Prelude): Ensure cylinder No. 1 is still at TDC. Install timing belt on sprockets. DO NOT excessively bend or twist belt. Ensure arrow on used belt points in original rotation direction. Adjust timing belt tension by rotating crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Loosen, but do not remove timing belt adjustment bolt. Rotate crankshaft counterclockwise 3 teeth on cam-
Fig. 2: Timing Belt Installed Position (1988-90 Prelude)
shaft pulley to create tension on timing belt. Tighten adjustment bolt to specification. See TORQUE SPECIFICATIONS. Apply non-hardening sealant to rounded surfaces of front and rear camshaft caps before installing valve cover gasket. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. Removal (1988-90 Prelude): Turn crankshaft counterclockwise (as viewed from timing belt end of engine) so that No. 1 cylinder is at TDC of compression stroke. TDC mark (White paint) is at rear of engine on transaxle mating flange. See Fig. 3.
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 actuator (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 timing belt covers. Noting installed position for reassembly reference, remove timing belt guide plate from crankshaft. Loosen timing belt tensioner bolt and remove timing belt. Inspection: Inspect timing belt for wear and for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear. Inspect water pump for excessive bearing play or coolant leakage. Replace as necessary. Installation (1988-90 Prelude): 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 specification. See TORQUE SPECIFICATIONS. Loosen, but DO NOT remove, timing belt adjusting bolt through access hole in timing belt cover. See Fig. 4. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to tension timing belt. Tighten adjusting bolt to 31 ft. lbs. (43 N.m). Install upper timing belt cover. Install valve cover. Install generator, power steering pump and A/C compressor. Install accessory drive belts and adjust to proper tension. Install engine mount and cruise control actuator. TORQUE SPECIFICATIONS (EXCEPT 1988-90 PRELUDE) Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Bracket Adjustment Bolt .............................. 51 (69) Alternator Bracket Bolt ................................................ 18 (24) Camshaft Pulley Bolt .................................................. 27 (37) Crankshaft Pulley Bolt ............................................ 108 (146) Timing Belt Adjuster Bolt ............................................. 31 (42) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................. 84 (9) Valve Cover Nut ............................................................ 84 (9) Water Pump Bolt ...................................................... 106 (12) TORQUE SPECIFICATIONS (1988-90 PRELUDE) Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt .................................. 18 (25) Camshaft Pulley Bolt .................................................. 27 (37) Crankshaft Pulley Bolt ............................................ 108 (146) Engine Mount-To-Engine Nut ......................................... 47 (65) Generator Lower Mount Bolt ....................................... 33 (45) Generator Upper Mount Bolt ....................................... 20 (27) Power Steering Pump Upper Mount Bolt ........................ 20 (27) Timing Belt Adjuster Bolt ............................................. 31 (42) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 89 (10) Valve Cover Nut .......................................................... 89 (10) Water Pump Bolt ...................................................... 106 (12)
Fig. 3: Aligning Crankshaft & Camshaft Timing Marks (1985-87 Prelude, Others Similar)
Fig. 4: Adjusting Timing Belt Tension (1988-90 Prelude)
HONDA *2.0L & 2.1L 4-Cylinder DOHC, Prelude

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. DOHC Prelude 1988-91 ................ 1 3.3 Hours ................. 250142 2.1L 4-Cyl. DOHC Prelude 1990-91 ................ 1 3.3 Hours ................. 250142 1 - With Air Cond. add .5 hours.
271

Although the manufacturer does not recommend a specific scheduled maintenance interval for 1989 models, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1990-91 models, the manufacturer recommends belt be replaced every 90,000 miles.

TIMING BELT
Removal: Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Remove drive belts. Remove left engine mount bolts/ nuts, engine mount and bracket. Remove cruise control actuator (if equipped).
Remove engine splash shield. Remove power steering adjusting pulley. Remove power steering pump with hoses attached and set aside. Remove alternator. Remove A/C compressor (if equipped). Remove engine valve cover and upper timing belt cover. See Fig. 2. Ensure timing marks align, and UP marks on camshaft sprockets are positioned at the top. See Fig. 1. Remove crankshaft pulley. Remove lower timing belt cover. If reusing timing belt, mark belt rotation direction before removing. Loosen timing belt tensioner adjustment bolt and push tensioner to release belt tension. Tighten adjustment bolt and remove timing belt. Inspection: Inspect timing belt for wear and for signs of oil contamination. Replace belt if damaged or contaminated. Inspect all drive gears for wear in drive belt area. Inspect water pump for excessive bearing play or coolant leakage. Replace if necessary. Installation: Ensure cylinder No. 1 is still at TDC. Install timing belt on sprockets. DO NOT bend or twist belt excessively. Ensure arrow on used belt points in original rotation direction. Adjust timing belt tension by rotating crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. Loosen, but do not remove timing belt adjustment bolt. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on timing belt. Tighten adjustment bolt to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Apply non-hardening sealant to rounded surfaces of front and rear camshaft caps before installing valve cover gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Bracket Adjustment Bolt .............................. 20 (27) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Pulley Bolt .................................................. 27 (37) Crankshaft Pulley Bolt ............................................ 108 (146) Power Steering Adjustment Nut .................................. 31 (42) Power Steering Pump Bracket Bolt ............................. 33 (45) Timing Belt Adjustment Bolt ....................................... 31 (42) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 90 (10) Valve Cover Nut .......................................................... 90 (10) Water Pump Bolt ...................................................... 108 (12)
272
HONDA *2.0L & 2.1L 4-Cylinder DOHC, Prelude (Cont.)
HONDA *2.2L 4-Cylinder DOHC, Prelude

TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 2.2L 4-Cyl. DOHC, H22A Prelude 1993-01 ......... 1 3.3 Hrs. .... 2521860 ...... 2 250226 1993-01 .............................. 2521860 ...... 3 250186 1 - Balancer shaft belt included in camshaft belt labor time. With Air Cond. add .5 hours. 2 Camshaft timing belt. 3 Balancer shaft belt. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
273

For 1993-94 vehicle, the manufacturer recommends camshaft and balancer shaft belts be replaced at 90,000 miles. For 1995-96 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service or 60,000 miles for severe service. For 1997-01 vehicles, normal replacement interval is at 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).
Installation: Remove balancer belt drive pulley. Ensure crankshaft drive pulley TDC (White) mark is aligned with pointer on oil pump housing. See Fig. 3. Align camshaft pulleys at TDC position. See Fig. 1. Remove the auto-tensioner from front of engine. Place autotensioner in soft-jawed vise with maintenace bolt facing up. See Fig. 4. DO NOT grip housing. Remove maintenace bolt from top of auto-tensioner. Use a flat blade screwdriver to compress auto-tensioner to bottomed out position. Place stopper on auto-tensioner. Refill any oil that may have spilled out, and install maintenance bolt with new gasket. Install auto-tensioner on engine with stopper in place. Install timing belt around crankshaft drive pulley, adjusting pulley, water pump, exhaust camshaft pulley, then intake camshaft pulley. Ensure crankshaft and camshaft pulleys remain aligned at TDC. Remove the auto-tensioner stopper. Install balancer belt drive pulley. Temporarily install lower cover, crankshaft pulley, and crankshaft pulley bolt. Tighten bolt. Rotate crankshaft about 5-6 times counterclockwise so that timing belt positions on the pulleys. Place crankshaft and camshaft pulleys at TDC positions. If either crankshaft or camshaft pulley is not positioned at TDC, timing belt will have to be repositioned.

TIMING & BALANCER SHAFT BELTS
Removal: Disconnect the negative battery cable. Rotate crankshaft counterclockwise so that cylinder No. 1 is at TDC of compression stroke. Timing marks are viewed through window on transaxle-to-engine mating flange. See Fig. 1. Remove engine lower splash shield. Remove power steering pump and alternator drive belts. Remove alternator terminal and connector. If equippped, disconnect cruise control actuator electrical connector. Move cruise control actuator 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 pulley. Loosen belt tension adjusting nut. Push belt tensioner to release tension from balancer belt. Tighten adjusting nut. Remove balancer shaft and camshaft timing belts. Inspection: With belt or belt covers removed, inspect belts for wear, cracks, or oil soaking. Inspect belt teeth for wear. Replace belt if worn, oil soaked, or cracked. Inspect water pump for leaks.
Fig. 1: Identifying Camshaft & Crankshaft TDC Marks
274
HONDA *2.2L 4-Cylinder DOHC, Prelude (Cont.)
Remove crankshaft pulley and lower cover. Loosen belt tension adjusting nut about 1 turn. Verify balancer belt adjuster moves freely. Retighten tension adjusting nut. Remove sealing bolt from maintenance hole in side of engine block. See Fig. 5. Insert a 6x100 mm bolt into maintenance hole to lock rear balancer shaft in place. Ensure bolt inserts at least 2.9 (74 mm). Align groove on front balancer shaft with pointer on oil pump housing. See Fig. 6. Install balancer belt. Loosen adjusting nut to tension balancer belt. Remove 6 x 100 mm bolt from side of engine block. Install sealing bolt.
Install lower cover and crankshaft pulley. Lubricate crankshaft pulley bolt and underside of bolt shoulder. Install and tighten bolt to specification. Turn crankshaft pulley about 1 turn counterclockwise. Tighten belt tension adjusting nut. Install rubber seal around adjusting nut. Install accessory drive belts and adjust tension. Install middle cover. When installing cylinder head cover gasket, apply liquid gasket (Part No. 08718-001 or -0003) to 8 corners where gasket meets camshafts. Reverse removal procedure to complete installation.
HONDA *2.2L 4-Cylinder DOHC, Prelude (Cont.)
275
Fig. 3: Aligning Timing Belt Drive Pulley With TDC Mark
Fig. 5: Aligning & Locking Balancer Shaft
Fig. 4: Compressing Auto-Tensioner
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Mount Bolt ................................................... 33 (45) Auto-Tensioner Mount Bolts ........................................... 16 (22) Balance Shaft Pulley Bolt ............................................ 22 (30) Camshaft Pulley Bolt .................................................... 37 (51) Crankshaft Pulley Bolt ........................................... 1 181 (245) Maintenance Hole Sealing Bolt ...................................... 22 (29) Power Steering Pump Bolt/Lock Nut ........................... 16 (22) Timing Belt Tension Adjusting Nut .............................. 33 (45) INCH Lbs. (N.m) Auto-Tensioner Maintenance Bolt ..................................... 71 (8) Cylinder Head Cover Nut ............................................ 90 (10) Timing Belt Cover Bolt .............................................. 106 (12) Water Pump Bolt ...................................................... 106 (12) 1 - Lubricate bolt threads and underside of bolt shoulder.
Fig. 6: Aligning Balancer Shaft Pulley
276
HONDA *2.2L 4-Cylinder SOHC, Odyssey

Labor Time Belt Component Part Kit No. No.
TIMING BELT APPLICATION Application 2.2L 4-Cyl. RA1 Odyssey 1997-95 Balance Shaft ..................... 2521860 .... 250186 Camshaft ........ 1 2.7 Hrs. ... 2521860 ... 250187 1 - Balance shaft belt included in camshaft belt labor time. With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component 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. For 1997 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
96H14628
Fig. 1: Timing Belt, Balance Belt & Related Components

TIMING BELT
Removal: Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Use a jack, with cushion between oil pan and jack, to support engine. Remove side engine mount. Remove cylinder head cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. Loosen timing belt tensioner adjuster bolt 145-180 degrees. Push tensioner to release belt tension from timing belt and balancer belt. Retighten tensioner 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. Install timing belt in sequence shown. See Fig. 6. Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
96I14629
Fig. 2: Removing/Installing Timing Belt Covers
HONDA *2.2L 4-Cylinder SOHC, Odyssey (Cont.)
277
96D14632
Fig. 5: Aligning Camshaft Pulley TDC Marks
96B14630
Fig. 3: Loosening Tensioner Adjusting Nut
96E14633 96C14631 Courtesy of American Honda Motor Co., Inc.
Fig. 6: Timing Belt Installation Sequence Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Sprocket Bolt .............................................. 28 (38) Crankshaft Pulley Bolt ............................................ 181 (245) Power Steering Pump Mounting Nut ........................... 16 (22) Timing Belt Adjuster Bolt ............................................. 49 (67) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................. 86-104 (7.2-8.7) Valve Cover Nut ......................................................... 86 (9.8)
278
HONDA *2.2L & 2.3L 4-Cylinder DOHC & SOHC

Belt Component Part Kit No. No.
TIMING BELT APPLICATION Labor Application Time 2.2L 4-CYL. SOHC Accord 1990-93 Balance Shaft ..................... 2521860 ... 250186 Camshaft ........... 1 3.1 Hrs. .. 2521860 .... 250187 1994-95 EX Model Balance Shaft ....................................... 250186 Camshaft .......... 1 3.1 Hrs. ..................... 250244 Except EX Model Balance Shaft .................... 2521860 .... 250186 Camshaft .......... 1 3.1 Hrs. .. 2521860 .... 250187 1996-97 w/VTEC Balance Shaft ....................................... 250186 Camshaft .......... 1 3.1 Hrs. ..................... 250244 w/o VTEC Balance Shaft .................... 2521860 .... 250186 Camshaft .......... 1 3.1 Hrs. .. 2521860 .... 250187 Prelude 1992-96 Balance Shaft ..................... 2521860 .... 250186 Camshaft ........... 1 3.1 Hrs. .. 2521860 .... 250187 2.3L 4-Cyl. DOHC Prelude 1992-96 Balance Shaft ....................................... 250186 Camshaft ........... 1 3.3 Hrs. ..................... 250216 1 - Balance shaft belt included in camshaft belt labor time. With Air Cond. add .5 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
TIMING & BALANCE SHAFT BELTS

Removal: Disconnect negative battery cable. Position crankshaft with cylinder No. 1 at TDC of compression stroke. See Figs. 1, 2, or 3. Disconnect battery negative cable. Remove splash shield. Remove cruise control actuator, leaving cable connected. Remove power steering pump, leaving hoses connected. Disconnect alternator wiring. Remove wiring harness from valve cover. Remove alternator and A/C belts (if equipped). Remove valve cover and upper timing belt cover. Remove side engine mount. Remove engine oil dipstick and tube. Remove crankshaft pulley. Support engine. Remove 2 rear bolts from engine center support beam. Lower engine enough to permit removal of lower timing belt cover. Remove rubber seal from belt tension adjuster nut. Remove lower timing belt cover. Lock timing belt adjuster arm into position by installing one lower cover retaining bolt. Loosen belt tension adjuster bolt. Push belt tensioner to release tension from belt. Tighten adjuster bolt. Remove balance shaft and camshaft timing belts.

For 1990-94 vehicle, the manufacturer recommends camshaft and balance shaft belts be replaced at 90,000 miles. For 199596 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service or 60,000 miles for severe service. For 1997 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).
Fig. 1: Positioning Camshaft Sprocket For Valve Adjustment (Prelude 2.2L SOHC)
279 HONDA *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 alignment access hole. Align groove on front balance shaft pulley with pointer on oil pump body. Adjust timing belt tension by rotating crankshaft counterclockwise until No. 1 piston is at TDC of compression stroke. Loosen, but do not remove timing belt adjustment bolt. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley to create tension on timing belt. Tighten adjustment bolt to specification. See TORQUE SPECIFICATIONS. Reverse removal procedure to complete installation. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
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 *2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)
Fig. 4: Removing/Installing Timing & Balance Shaft Belts
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 37 (50) Alternator Bracket Adjuster Bolt ................................... 16 (22) Alternator Bracket Bolt ................................................ 33 (45) Balance Shaft Pulley Bolt ............................................ 22 (30) Camshaft Pulley Bolt 2.2L DOHC ............................................................... 37 (51) 2.2L SOHC & 2.3L .................................................... 27 (37) Crankshaft Pulley Bolt ............................................ 184 (250) Power Steering Belt Adjuster Nut ................................ 11 (15) Power Steering Pump Bracket Bolt ............................. 33 (45) Power Steering Pump Mounting Bolt .......................... 16 (22) Shift Cable Bracket Bolt .............................................. 16 (22) Timing Belt Tension Adjuster ...................................... 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................. 108 (12) Valve Cover Nut .......................................................... 90 (10) Water Pump Bolt ...................................................... 108 (12)
Fig. 5: Locating Timing Belt Adjuster Nut (Typical)
281 HONDA *2.2L & 2.3L 4-Cylinder DOHC & SOHC (Cont.)
Fig. 6: Installing Crankshaft Pulley (Typical)
Fig. 7: Aligning Balancer Belt Driven Pulley
282
HONDA *2.3L 4-Cylinder SOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L 4-Cyl. F23A, SOHC Accord 1998-01 Balance Shaft ....................................... 250186 Camshaft ........... 1 3.6 Hours ................ 250244 Odyssey 1998 Balance Shaft ....................................... 250186 Camshaft ........... 1 4.0 Hours ................ 250244 1 - Balance shaft belt included in camshaft belt labor time.

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

Removal: Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Raise and support vehicle. Remove engine lower splash shield. Remove accessory drive belts. Remove alternator terminal and connector. Remove alternator and alternator bracket. Use a jack, with cushion between oil pan and jack, to support engine. Remove side engine mount from front of engine. Remove dipstick tube from front of engine. Remove cylinder head cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1 and 2. Insert a 6 mm timing cover bolt through the hole in the end of the timing belt adjuster arm. This will temporarily lock the arm in place. Loosen belt tensioner adjusting nut about 1 turn. See Fig. 3. Push outer balancer shaft belt tensioner pulley up to take tension off of the balancer belt. Retighten belt tensioner adjusting nut. Remove balancer shaft belt. Loosen belt tensioner adjusting nut about 1 turn. See Fig. 3. Push camshaft timing belt tensioner pulley down to take tension off of camshaft timing belt. Retighten belt tensioner adjusting nut. Remove camshaft timing belt. Installation: Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by aligning dimple on timing belt drive pulley with pointer on oil pump housing. See Fig. 4. Ensure camshaft pulley TDC marks are aligned. See Fig. 5.
96H14628
Fig. 1: Timing Belt, Balancer Belt & Related Components
96I14629
HONDA *2.3L 4-Cylinder SOHC (Cont.)
283
96D14632
96B14630
Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
Install camshaft timing belt in sequence shown. See Fig. 6. Loosen and retighten tensioner adjusting nut to tension camshaft timing belt. Install balancer belt drive pulley and lower cover. Install crankshaft pulley. Install bolt. Rotate crankshaft pulley COUNTERCLOCKWISE about 56 turns so timing belt positions on pulley. Set No. 1 piston at TDC of compression stroke. Loosen belt tensioner adjusting nut about 1 turn. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt tensioner adjusting nut to specification. See TORQUE SPECIFICATIONS.
Rotate crankshaft so that crankshaft and camshaft pulleys are at TDC position. Ensure camshaft UP mark is facing up. If they are not, timing belt will have to be repositioned. Remove crankshaft pulley and lower cover. Set timing belt drive pulley to TDC position. Lock camshaft timing belt adjuster arm in place by installing a 6x10 mm timing cover bolt. Loosen belt tensioner adjusting nut about 1 turn. See Fig. 3. Verify balancer belt tensioner pulley moves freely. Push balancer belt tensioner up then retighten belt tensioner adjusting nut. Remove sealing bolt from maintenance hole on side of engine block. See Fig. 7. Scribe a line 2.9 (74 mm) from end of of 6x100 mm bolt. Install 6x100 mm bolt into sealing bolt hole to lock balancer shaft in place.
284
HONDA *2.3L 4-Cylinder SOHC (Cont.)
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 crankshaft 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 gasket or liquid gasket. Install rubber seal around belt tensioner adjusting nut. DO NOT loosen nut. Install crankshaft pulley. Lubricate crankshaft pulley bolt and underside of bolt shoulder. Install and tighten crankshaft pulley bolt to specification. Install dipstick tube with new O ring. When installing cylinder head cover gasket, apply liquid gasket (Part No. 087180001 or -0003) to 4 corners where gasket meets camshafts. 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Adjusting Lock Nut ......................................... 16 (22) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Sprocket Bolt .............................................. 43 (59) Crankshaft Pulley Bolt ............................................ 181 (245) Engine Block Sealing Bolt .............................................. 22 (29) Engine Bracket-To-Engine Side Mount Nut/Bolt Accord .......................................................................... 40 (54) Engine Side Mount Through-Bolt Odyssey ....................................................................... 47 (64) Engine Side Mount-To-Bracket Nut/Bolt Odyssey ....................................................................... 47 (64) Power Steering Pump Mounting Nut ........................... 16 (22) Timing Belt Tensioner Adjusting Nut .......................... 33 (44) INCH Lbs. (N.m) Cylinder Head Cover Nut ........................................... 86 (9.8) Dipstick Tube Bolt ........................................................ 106 (12) Engine Lower Splash Shield .......................................... 89 (10) Timing Belt Cover Bolt .............................................. 106 (12) Water Pump Bolts ........................................................ 106 (12)
Fig. 8: Aligning Balancer Belt Drive Pulley
Fig. 7: Locking Balancer Shaft In Place

TIMING BELT APPLICATION Part No. Application Labor Time1 2.6L 4-Cyl. Passport 1994-96 M/T .................... 1.6 Hours ................ 250147 A/T ..................... 1.9 Hours ................ 250147 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.
285
CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft or damage may result.

Inspection: Handle timing belt carefully. Avoid twisting or kinking belt. Do not allow belt to become contaminated by water, oil, dirt or other contaminates. Inspect belt for cracks or damage. Replace, if necessary. Measure tensioner pulley spring length and force. Spring length should not exceed 2.76" (70.2 mm) and spring force should not be less than 197-343 lbs. (27-48 kg). Replace tensioner pulley spring if not within specification. TIMING SPROCKET SPECIFICATIONS Application Standard Limit In. (mm) In. (mm) Camshaft ....................... 5.202 ................................ 5.198 (132.03) ......................... (131.93) Crankshaft ...................... 2.574 ................................ 2.570 (65.33) ............................. (65.23) Oil Pump ........................ 4.485 ................................ 4.481 (113.84) ......................... (113.74) Installation: Pull tensioner fully toward water pump side and temporarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC on compression stroke by rotating crankshaft until keyway aligns with mark on front crankshaft seal housing (12 oclock). Rotate camshaft until timing mark on cam gear (arrow) aligns with mark on upper camshaft cover (notch). See Fig. 1. Position timing belt over crankshaft sprocket, oil pump sprocket, camshaft sprocket and tensioner in that order. Ensure belt is positioned in sequence given and without slack between sprockets. Loosen tensioner pulley adjusting bolt allowing spring tension to tighten belt. Tighten adjusting bolt temporarily. Temporarily install crankshaft pulley bolt and rotate crankshaft 2 complete revolutions in opposite direction of engine rotation, until marks on crankshaft and front oil seal retainer are aligned again. See Fig. 1. Loosen tensioner lock bolt, allowing tensioner spring to fully adjust tension. Tighten tensioner lock bolt. Install timing belt covers. To complete installation, reverse removal procedures. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 43 (58) Crankshaft Pulley Bolt .............................................. 90 (122) Front Cover ................................................................. 14 (19) Tensioner Pulley Bolts ......................................................................... 18 (24) Nut ............................................................................ 10 (14) Water Pump Bolt .......................................................... 14 (19) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................. 53 (6)

TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction.
Removal: Disconnect negative battery cable. Remove all necessary air ducts. Position No. 1 cylinder at TDC of compression stroke. Align timing marks. See Fig. 3. Remove fan and fan shroud. Remove accessory drive belts. Remove water pump pulley. If necessary, remove radiator and splash guard. Prevent engine from rotating and remove crankshaft timing pulley. Remove upper and lower timing belt covers. See Fig. 2. Remove spring from tension pulley. Loosen adjusting bolt and move pulley toward water pump. Remove timing belt.
286
Fig 3: Installing Belt Guide
HONDA *2.7L V6
TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.7L V6 Accord 1996-97 .................. 4.0 Hours .................. 250263 1 - With Air Cond. add .3 hours.
1
287

1996 vehicles, the manufacturer recommends the belt be replaced at 90,000 miles for normal service or 60,000 miles for severe service. For 1997 vehicles, normal replacement interval is at 105,000 miles or 84 months. Replace at 60,000 miles if car is regularly driven in extreme temperatures (over 110 degrees F, or under -20 degrees F).

TIMING BELT
Removal: Disconnect negative battery cable. Remove front wheels and splash shield. Support engine with cushioned jack. Remove 3 bolts attaching side engine mount to engine, then loosen mount center bolt and pivot mount out of way. Remove A/C, P/S and alternator belt. Remove dipstick and pipe. Remove crankshaft pulley. Remove timing belt covers. See Fig. 2.
If timing belt is being reused, mark direction of belt rotation before removing. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. See Fig. 1. Loosen timing belt adjusting bolt 180 degrees and push tensioner to remove tension from timing belt. Retighten adjusting bolt and remove timing belt. Inspect camshaft and crankshaft seals, replace if leaking. Inspection: Inspect timing belt for wear or rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Installation: Clean timing belt covers and ensure No. 1 piston is at TDC of compression stroke. Ensure crankshaft and camshaft pulleys are at TDC and install timing belt in sequence shown. See Fig. 1. To adjust timing belt, rotate crankshaft clockwise 5-6 revolutions to seat belt and then rotate crankshaft until No. 1 piston is at TDC of compression stroke. Loosen adjusting bolt 180 degrees then retighten adjusting bolt. See Fig. 1. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt 8 mm Bolts ............................................................... 16 (22) 10 mm Bolts ............................................................. 33 (44) A/C Idler Pulley Center Nut ......................................... 33 (44) Alternator Bracket Bolts 8 mm Bolts ............................................................... 16 (22) 10 mm Bolts ............................................................. 33 (44) Camshaft Pulley Bolts ................................................ 23 (31) Crankshaft Pulley Bolt ............................................ 181 (245) Engine Mount Bolts .................................................... 43 (59) Idler Pulley Center Nut ................................................ 33 (44) Timing Belt Adjuster Bolt ............................................. 31 (42) INCH Lbs. (N.m) Dipstick Bracket Bolts .................................................. 84 (9) Timing Belt Cover Bolts ................................................ 84 (9)
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

TIMING BELT
Removal: Disconnect negative battery cable. Turn crankshaft pulley so that No. 1 piston is at TDC on compression stroke. White mark on crankshaft pulley should align with pointer on front cover. Remove lower engine splash shield. Remove the generator and power steering pump drive belts. Remove dipstick tube from front of engine. Support engine with a jack, and remove engine side mount from front of engine. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1. If reusing timing belt, mark direction of belt rotation for installation reference. Remove one of the battery clamp bolts from battery tray. Grind threaded end of bolt to a partial point (about 45 degree chamfer). Thread battery bolt into rear cover to hold timing belt adjuster in installed position. Hand tighten ONLY. See Fig. 2.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 (J30A1) Accord 1998-01 ................. 4.7 Hours .................. 250286 3.5L V6 (J35A1) Odyssey 1999-01 .................. 4.0 Hours .................. 250286

*NOTE: The 3.0L is an interference engine. See page A-59 for interference engine cautions.
HONDA *3.0L & 3.5L V6 (Cont.)
289
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 camshaft 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 autotensioner with maintenance bolt pointing up. Remove maintenance bolt. See Fig. 4. Clamp auto-tensioner in soft-jawed vise. DO NOT grip auto-tensioner housing. Insert flat blade screwdriver into maintenance hole. Place stopper on autotensioner 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 autotensioner 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 pulley. 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. Rotate crankshaft about 5-6 turns clockwise to position timing belt on pulleys. Ensure crankshaft and camshaft pulleys are aligned at TDC. Crankshaft pulley White mark should be aligned with pointer on front cover. Remove rubber plugs from upper covers to check camshaft pulley positions. If either camshaft is not at TDC, remove timing belt and readjust position. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Center Bolt ...................................... 67 (90) Crankshaft Pulley Bolt ............................................ 181 (245) Engine Side Mount Bracket-To-Mount Through-Bolt Accord & Odyssey ......................................................... 40 (54) Engine Side Mount-To-Engine Bolts .............................. 33 (44) Idler Pulley Bolt .............................................................. 33 (44) Power Steering Pump Lock Nut ..................................... 17 (24) Power Steering Pump Mount Bolt ................................... 17 (24) INCH Lbs. (N.m) Auto-Tensioner Maintenance Bolt ..................................... 71 (8) Auto-Tensioner Mount Bolts ......................................... 106 (12) Lower Engine Splash Shield Bolts ............................... 106 (12) Timing Belt Cover Bolts ............................................ 106 (12) Water Pump Bolts .................................................... 106 (12)
Fig. 2: Installing Battery Clamp Bolt On Auto-Tensioner
290
HONDA *3.0L & 3.5L V6 (Cont.)
Fig. 4: Compressing Auto-Tensioner (Accord; 1999 Odyssey)
Fig. 5: Compressing Auto-Tensioner (2000-01 Odyssey)
HONDA 3.2L V6 DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.2L V6 Passport 1998-01 ................. 2.8 Hours .................. 250303
291

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: Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove serpentine drive belt. Remove cooling fan and drive pulley. Remove serpentine drive belt idler pulley assembly. Remove serpentine drive belt tensioner assembly. Remove power steering pump with hoses attached, and set aside. Remove crankshaft pulley bolt. Using Puller (J8614-01) or equivalent, remove crankshaft pulley. Remove timing belt covers. Rotate crankshaft to align timing marks. See Figs. 1 and 2. When timing marks are aligned, No. 2 piston will be at TDC. If reusing timing belt, mark belt with arrow to indicate original rotation direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove timing belt tensioner, and set aside with push rod facing up. Remove timing belt.
CAUTION: To prevent air from entering timing belt tensioner, tensioner rod must always face up.
Fig. 2: Aligning Crankshaft Timing Marks NOTE: For correct timing belt installation, lettering on belt must be able to be read as viewed from the front of the vehicle. Also, note arrow on belt which indicates direction of rotation.
Installation: 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) camshaft sprocket with alignment mark on valve cover. See Fig. 3. Install timing belt on right hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. If reusing old timing belt, align mating marks on belt and camshaft sprocket that were made during removal. Secure belt with spring clip. Align timing mark on left hand (driver side) camshaft sprocket with alignment mark on valve cover. See Fig. 4. Route timing belt around water pump pulley and install on other left hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. Install pinch clip to hold belt on sprocket. Ensure there is no slack in belt between camshaft pulleys. 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.

Holding tensioner upright, SLOWLY compress timing belt tensioner rod until hole in top of rod and holes in housing are aligned. Install a locking pin through the holes. See Fig. 5. Install tensioner on engine with locking pin in place. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove locking pin from timing belt tensioner. Remove clips from camshaft and crankshaft sprockets. Rotate crankshaft 2 turns clockwise. Ensure timing marks are still aligned. Remove crankshaft pulley and install timing belt covers. Ensure rubber sealing bushings are installed on timing belt cover bolts. See Fig. 6.
292
HONDA 3.2L V6 DOHC (Cont.)
Fig. 3: Installing Timing Belt On Right Hand Camshaft 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 specification. Install cooling fan pulley. Install power steering pump. Install cooling fan. Install serpentine drive belt idler pulley and tensioner assemblies. Install radiator fan shroud. Connect battery. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 72 (98) Cooling Fan Pulley Bolt .............................................. 16 (22) Crankshaft Pulley Bolt ............................................ 123 (167) Power Steering Pump Bolt M8 Bolt ......................................................................... 16 (22) M10 Bolt ...................................................................... 34 (46) Timing Belt Cover Bolt ................................................ 14 (19) Timing Belt Idler Pulley Bolt ........................................ 38 (52) Timing Belt Tensioner Bolt ......................................... 18 (25) Timing Belt Tensioner Pulley Pivot Bolt ...................... 31 (42) Water Pump Bolt ......................................................... 18 (25)
HYUNDAI *1.5L 4-Cylinder DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.5L 4-Cyl. Accent 1995-97 ................ 1 2.2 Hours ................. 250282 1 - With Air Cond. add .2 hours.
293

For 1995-96 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles. For 1997 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

TIMING BELT
Removal: Loosen, but do not remove water pump pulley bolts. Remove all accessory drive belts. Remove pulleys from crankshaft and water pump.
CAUTION: DO NOT rotate engine counterclockwise. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation before removal.
Remove timing belt covers and gaskets, noting bolt length and location. Rotate crankshaft clockwise to align timing marks on crankshaft and camshaft sprockets. See Fig. 1. If reusing old belt, place mark on belt to indicate direction of belt rotation. Loosen timing belt tensioner bolts, and move tensioner inward toward water pump. Temporarily tighten bolt in slotted side of tensioner. Remove timing belt. Inspection: Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulley for worn bearing. Installation: Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Move timing belt tensioner toward water pump and tighten bolt. Install crankshaft sprocket (if removed) with chamfer (flange) toward engine. Install timing belt on crankshaft and camshaft sprockets. Make sure there is no slack in belt. If reusing old belt, ensure belt is installed in original direction of rotation. Apply counterclockwise force on camshaft sprocket to apply tension on tension side of belt. Ensure all timing marks are aligned. See Fig. 1.
CAUTION: Slot-side timing belt tensioner bolt must be tightened before pivot-side to prevent belt tensioner from rotating, causing belt to be over tightened.
Loosen timing belt tensioner bolts to place tension on timing belt. See Fig. 2. Tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Smoothly rotate crankshaft clockwise for one full revolution. Realign crankshaft and camshaft timing marks. Loosen pivot-side bolt and then slot-side bolt. Tighten slotside 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 crankshaft 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ......................................... 59-74 (80-100) Crankshaft Pulley-To-Sprocket Bolt .......... 103-111 (140-150) Crankshaft Sprocket Center Bolt ............... 103-111 (140-150) Timing Belt Idler Pulley Bolt ................................. 32-41 (43-55) Timing Belt Tensioner Bolt ............................... 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 89-106 (10-12) Water Pump Pulley Bolt ...................................... 71-89 (8-10)
Courtesy of Hyundai Motor Co.
Fig. 1: Aligning Tlming Marks
Fig. 2: Checking Tlming Belt Tension
294
HYUNDAI *1.5L 4-Cylinder SOHC

Component Kit No. Belt Part No. TIMING BELT
Removal: Remove all accessory drive belts. Remove pulleys from crankshaft and water pump.
TIMING BELT APPLICATION Application 1.5L 4-Cyl. Accent 1995-01 .......... 1 2.2 Hrs. .... 2521910 ........ 250191 Excel 1986-89 .......... 1 2.2 Hrs. ........................... 250073 1990-94 .......... 1 2.2 Hrs. .... 2521280 ........ 250128 Scoupe 1991-93 .......... 1 2.2 Hrs. .... 2521280 ........ 250128 1994-95 .......... 1 2.2 Hrs. .... 2521910 ........ 250191 1 - With Air Cond. add .2 hours. Labor Time

For 1986-96 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles. For 1997-01 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.
Remove timing belt covers and gaskets, noting bolt length and location. Rotate crankshaft clockwise to align timing marks on crankshaft and camshaft sprockets. See Fig. 1. If reusing old belt, place mark on belt to indicate direction of belt rotation. Move tensioner inward toward water pump, and temporarily tighten bolt in slotted side of tensioner. Remove timing belt. Inspection: Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner for worn bearing. Installation: Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Move timing belt tensioner toward water pump and tighten bolt. Install timing belt on crankshaft and camshaft sprockets. Make sure there is no slack in belt. If reusing old belt, ensure belt is installed in original direction of rotation. Apply counterclockwise force on camshaft sprocket to apply tension on tension side of belt. Ensure all timing marks are aligned. See Fig. 1.
Fig. 3: Locating Camshaft & Crankshaft Sprocket Marks
HYUNDAI *1.5L 4-Cylinder SOHC (Cont.)

295
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ......................................... 59-74 (80-100) Crankshaft Pulley-To-Sprocket Bolt .................. 10-11 (14-15) Crankshaft Sprocket Center Bolt ............... 103-111 (140-150) Timing Belt Tensioner Bolt ............................... 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 89-106 (10-12) Water Pump Pulley Bolt ............................... 106-133 (12-15)
Loosen timing belt tensioner bolts to place tension on timing belt. See Fig. 2. Tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Smoothly rotate crankshaft clockwise for one full revolution. Realign crankshaft and camshaft timing marks. Loosen pivot-side bolt and then slot-side bolt. Tighten slot-side bolt, and then pivot-side bolt to specification. To check belt tension, hold belt tensioner and timing belt together and apply slight thumb pressure at center point of belt tensioner. This is about 11 lbs. (4.98 kg). See Fig. 2. Ensure belt cog will reach half the width of timing belt tensioner bolt on slot-side of belt tensioner. Install timing belt cover. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
296
HYUNDAI *1.6L 4-Cylinder DOHC
Remove timing belt covers and gaskets, noting bolt length and location. Rotate crankshaft clockwise to align timing marks on crankshaft and camshaft sprockets. See Fig. 1. If reusing old belt, place mark on belt to indicate direction of belt rotation. Loosen timing belt tensioner bolts, and move tensioner inward toward water pump. Temporarily tighten bolt in slotted side of tensioner. Remove timing belt. Inspection: Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulley for worn bearing. Installation: Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Move timing belt tensioner toward water pump and tighten bolt. Install crankshaft sprocket (if removed) with chamfer (flange) toward engine. Install timing belt on crankshaft and camshaft sprockets. Make sure there is no slack in belt. If reusing old belt, ensure belt is installed in original direction of rotation. Apply counterclockwise force on camshaft sprocket to apply tension on tension side of belt. Ensure all timing marks are aligned. See Fig. 1.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. Accent 2001 ..................... 1 2.0 Hours ................. 250282 1 - With Air Cond. add .2 hours. 1 - With Pwr. Strg. add .2 hours.

For 2001 vehicles, the manufacturer recommends the belt be inspected every 30,000 miles. Manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

TIMING BELT
Removal: Loosen, but do not remove water pump pulley bolts. Remove all accessory drive belts. Remove pulleys from crankshaft and water pump.
Loosen timing belt tensioner bolts to place tension on timing belt. See Fig. 2. Tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS. Smoothly rotate crankshaft clockwise for one full revolution. Realign crankshaft and camshaft timing marks. Loosen pivot-side bolt and then slot-side bolt. Tighten slotside 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 crankshaft 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ......................................... 59-74 (80-100) Crankshaft Pulley-To-Sprocket Bolt .......... 103-111 (140-150) Crankshaft Sprocket Center Bolt ............... 103-111 (140-150) Timing Belt Idler Pulley Bolt ................................. 32-41 (43-55) Timing Belt Tensioner Bolt ............................... 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 89-106 (10-12) Water Pump Pulley Bolt ...................................... 71-89 (8-10)
Fig. 1: Aligning Tlming Marks
Fig. 2: Checking Tlming Belt Tension
HYUNDAI *1.6L & 1.8L 4-Cylinder DOHC

TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time 2 1.6L 4-Cyl. DOHC Elantra 1992 ..................... 1 3.0 Hrs. ..................... 250165 1993-95 Balance Shaft ........................................ 250168 Camshaft ........... 1 3.0 Hrs. ..................... 250165 1.8L 4-Cyl. DOHC Elantra 1993-95 Balance Shaft ...................... 2521670 ... 250168 Camshaft ........... 1 3.0 Hrs. ... 2521670 ... 250167 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .3 hours. 2 - Balance shaft belt included in camshaft belt labor time. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
297
Remove plug at left side of cylinder block. See Fig. 6. Insert screwdriver to hold left balance shaft in place. Screwdriver should insert at least 2.4 (60 mm) into hole. If not, rotate oil pump sprocket one full turn and align timing mark. Ensure screwdriver inserts correct amount. Loosen balance belt tensioner bolt. Remove balance belt. Inspection: Check belt teeth for cracks, damage and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged. Check end of automatic tensioner rod for wear. Measure distance from end of automatic tensioner rod to top of automatic tensioner housing. Distance should be .47" (12 mm). If out of specification, replace automatic tensioner. Compressing Automatic Tensioner: Check if plug at bottom of tensioner protrudes past tensioner housing. If plug protrudes past housing, place a washer over plug to prevent plug from contacting vise when pushing rod into tensioner housing. Place tensioner assembly in a soft-faced vise. SLOWLY squeeze rod back into automatic tensioner. Replace tensioner if rod can be retracted easily into automatic tensioner. Align holes in rod and automatic tensioner body. See Fig. 3. Insert drill bit or pin through holes to retain rod in retracted position.
NOTE: If right (viewed from rear of engine) balance shaft sprocket was removed, ensure right balance shaft spacer is installed with chamfer toward engine. Before installation, apply light coat of engine oil to spacer.
MANUFACTURERS SUGGESTED SCHEDULED MAINTENANCE SCHEDULE


TIMING BELT
Removal: Remove cover from under engine (if equipped). Support engine weight with floor jack. Remove engine mount located near timing belt cover. Remove all accessory drive belts. Remove water pump pulley and crankshaft pulley. Remove timing belt covers and gaskets, noting bolt lengths and locations.
Installation (Balance Shaft Belt): Ensure crankshaft sprocket and right side balance shaft sprocket timing marks are aligned with marks on oil pump housing. See Fig. 1. Install balance shaft belt. If removed, install balance shaft tensioner pulley and center bolt. Install balance shaft belt (timing belt B). No slack should be present in belt. Lift tensioner toward belt so that large part of center eccentric is to the left and above the center bolt. See Fig. 2. While tightening balance shaft tensioner center bolt, ensure tensioner and sprockets DO NOT rotate. Ensure timing marks are still aligned. Check belt tension by applying finger pressure to side of belt opposite tensioner. See Fig. 2. Deflection should be .20-.28" (5-7 mm). If not, readjust belt tension. Install crankshaft flange and outer sprocket. Install flange in correct direction to prevent damage to timing belt. See Fig. 5.
Rotate engine clockwise to align all timing marks so No. 1 cylinder is at TDC of compression stroke. See Fig. 7. Remove 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
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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
299
Fig. 10: Exploded View Of Timing Belt & Components (Engines Without Balance Shaft)
Installation (Camshaft Timing Belt): If crankshaft sprocket was removed, ensure sprocket, spacer and flange are installed correctly. See Fig. 4. Remove automatic tensioner from vise, and install onto engine with wire in place. Install tensioner arm. Position tensioner pulley so that pin holes are left of center bolt. See Fig. 8. Temporarily tighten camshaft tension pulley center bolt.
CAUTION: The same camshaft sprocket is used on intake and exhaust camshafts. Each has two timing marks. Both camshaft sprockets are positioned correctly when the center dowel pin holes face up (12 oclock position).
Rotate camshaft sprockets so dowel pins face up and timing marks on sprockets align. See Fig. 7. Inner marks on sprockets should be aligned with cylinder head surface. When exhaust camshaft sprocket is released, camshaft will rotate one tooth in counterclockwise direction. When installing timing belt, compensate for rotation. Rotate crankshaft and align timing marks on crankshaft and oil pump sprockets. If installing old timing belt, ensure it is installed in original direction of rotation. Install timing belt on tensioner pulley and crankshaft sprocket. Hold belt in place using left hand. Pull belt around oil pump sprocket using right hand. Pull belt around idler pulley.
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Install timing belt around intake camshaft sprocket. Ensure 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 2325 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 engine support bracket until screw end contacts tensioner arm. See Fig. 9. Turn set screw further until wire can be removed from automatic tensioner. Remove set screw. Rotate crankshaft clockwise 2 complete revolutions, and leave in this position for approximately 15 minutes. After 15 minutes, measure distance between bottom of tensioner arm and top of automatic tensioner body (automatic tensioner rod extension). Distance should be .15-.18" (3.84.5 mm). See Fig. 13, Dimension A. Repeat timing belt tensioning procedure until correct distance is obtained. If correct distance can be measured, go to last step. If correct distance CANNOT be measured, go to next step. If engine is in vehicle or distance cannot be measured due to lack of clearance, an alternate method can be used. Install Set Screw (09244-28000) until it contacts tensioner arm. Turn set screw inward, counting number of turns until tensioner arm contacts automatic tensioner housing. Set screw should rotate 2 1/2 - 3 turns inward if belt tension is correct. Repeat timing belt tensioning procedure until correct 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. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .................................. 14-20 (19-27) Camshaft Sprocket Bolt .................................. 58-72 (80-100) Crankshaft Pulley-To-Sprocket Bolt .................. 14-22 (19-30) Crankshaft Sprocket Center Bolt ................... 80-94 (110-130) Front Cover Bolt 8 x 30 mm Bolt ................................................ 20-26 (27-35) Except 8 x 30 mm Bolt .................................... 14-20 (19-27) Idler Pulley Bolt ................................................. 22-30 (30-42) Tensioner Pulley Bracket Bolt ........................... 12-19 (17-26) Tensioner Pulley Center Bolt ............................ 31-40 (43-55) Timing Belt Cover Left Lower Rear .............................................. 22-30 (30-42) Except Left Lower Rear ...................................................... 1
1
Fig. 12: Adjusting Camshaft Belt Tension
Fig. 13: Measuring Timing Belt Tensioner Protrusion
- Tighten to 89-106 INCH lbs. (10-12 N.m).
HYUNDAI *1.8L & 2.0L 4-Cylinder Elantra & Tiburon

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cyl. DOHC Elantra 1996-98 ................ 1 2.4 Hours ................. 250278 Tiburon 1997 ..................... 1 2.4 Hours ................. 250278 2.0L 4-Cyl. DOHC Elantra 1999-01 ................ 1 2.4 Hours ................. 250284 Tiburon 1997-01 ................ 1 2.4 Hours ................. 250284 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .3 hours.
301
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................... 77-89 (100-120) Crankshaft Pulley Bolt .............................. 125-133 (170-180) Timing Belt Idler Bolt .......................................... 31-41 (43-55) Timing Belt Tensioner Bolt .................................. 32-41 (43-55) INCH Lbs. (N.m) Timing Belt Cover Bolt ............................................ 71-86 (8-10)

The manufacturer requires that the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

Removal: Remove all drive belts and drive pulleys from crankshaft and water pump. Remove crankshaft pulley and water pump pulleys. Remove timing belt covers and gaskets, noting bolt lengths and locations. DO NOT rotate engine counterclockwise, as viewed from timing belt side of engine. Rotate engine clockwise to align all timing marks so No. 1 cylinder is at TDC of compression stroke. See Fig. 1. Move timing belt tensioner out of way to relieve belt tension. If reusing belt, place mark on timing belt to indicate direction of belt rotation. Remove timing belt. Inspection: Check belt teeth for cracks, damage, and oil contamination. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and worn bearings. Replace components if damaged. Installation: Ensure camshaft and crankshaft timing marks are still aligned. Outer marks on sprockets should be aligned with rocker cover surface. Install timing belt. If reusing old belt, ensure belt is installed in original direction of rotation. Loosen timing belt tensioner bolt, allowing tensioner pulley to contact belt. Tighten timing belt tensioner pulley bolt. Rotate crankshaft one turn clockwise. Realign camshaft and crankshaft timing marks.
TIMING BELT
Adjust timing belt tension until .15-.24 (4-6 mm) deflection is present midway between idler pulley and camshaft sprocket, with a force of 4.4 lbs. (2 kg) applied to belt. Rotate engine clockwise 2 revolutions. Ensure timing marks are still aligned and proper belt tension still exists. Install timing belt covers. Install crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belt tension. See page A-60 for belt tension ranges.
TECHNICAL SERVICE BULLETIN

TIMING BELT NOISE: FRONT CASE
Description: Some 1999-00 Elantras and Tiburons produced before Sept. 22, 1999, may exhibit an unusual noise at the front of the engine. The noise may be caused by the timing belt rubbing against the front of the engine. Some timing belt idler pulley mounting surfaces were machined incorrectly. This can cause the timing belt to ride off of the timing belt sprockets and into the front cover. Service Procedure: If this condition exists, the forward edge of the timing belt will shredded and the inside of the upper timing belt cover will be worn. Replace the front case, idler pulley, timing belt and any other damaged components.
NOTE: This information is from the Hyundai technical service bulletin 00-20-002-1; May, 2000.
302
HYUNDAI *2.0L 4-Cylinder Sonata
Inspect automatic tensioner for leaks. Check rod end of automatic tensioner for wear. Measure distance from tensioner rod end to tensioner housing. Distance should be .47" (12 mm). If not, replace automatic tensioner.
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 2.0L 4-Cyl. DOHC Sonata 1992-98 Balance Shaft ................. 2521670 ........... T168 Camshaft ..... 1 3.8 Hrs. .... 2521670 ........... T167 1 - Balance shaft belt included in camshaft belt labor time. With Air Cond. add .4 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
NOTE: If plug at bottom of tensioner protrudes past tensioner housing, place a washer over plug to prevent contacting vise when pushing rod into tensioner housing.

The manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended, but not required at 60,000 miles.

TIMING BELT
Removal: Remove all drive belts. Remove crankshaft pulley and water pump pulley. Remove upper and lower timing belt covers, noting bolt lengths and locations. Turn crankshaft clockwise and align timing marks so No. 1 cylinder is at TDC. Timing marks on camshaft sprockets should be aligned at upper surface of cylinder head. See Fig. 2. Camshaft sprocket dowel pins should face upward.
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.
Retract rod into tensioner housing by placing automatic tensioner assembly in a soft-faced vise. Close vise SLOWLY to push rod back into tensioner. See Fig. 4. Replace automatic tensioner assembly if rod can be easily pushed into automatic tensioner. While automatic tensioner is in vise, align holes in end of tensioner rod and housing. Install pin through holes to lock tensioner in position. Installation: Align timing marks on balance shaft sprockets with timing marks on engine case. See Fig. 5. Install balance shaft timing belt and crankshaft flange. Install crankshaft flange in correct direction. See Fig. 6. Position balance shaft tensioner so that the center of the pulley is to the left and above the tensioner bolt. See Fig. 5. Hold tensioner tightly against belt. Tighten tensioner pulley bolt without letting tensioner rotate. To check balance shaft belt tension, depress belt with finger midway between sprockets (opposite tensioner pulley). Deflection should be between .20-.29 (57 mm). If not, readjust belt tension. Place crankshaft sprocket on crankshaft. Tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure screwdriver is still installed through left side of cylinder block to hold balance shaft in place. Install automatic tensioner on engine block with rod locked in place. Rotate camshaft sprockets so dowel pins face upward and timing marks on sprockets align. See Fig. 2. Outer marks on sprockets should be aligned with cylinder head surface.
NOTE: The same camshaft sprockets are installed on intake and exhaust camshafts. Timing marks are correctly aligned when dowel pin holes are facing straight up.
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 screwdriver can be inserted at least 2.36 (60 mm). If not, rotate oil pump sprocket so screwdriver can be inserted to correct depth. Loosen balance shaft belt tensioner bolt. Remove front crankshaft sprocket and flange. Remove balance shaft timing belt. Inspection: Check belt teeth for damage and oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is not cracked, separated or showing canvas fiber. Inspect all sprockets for damage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged.
Fig. 1: Exploded View Of Timing Belt & Related Components
HYUNDAI *2.0L 4-Cylinder Sonata (Cont.)
303
Fig. 5: Aligning Balance Shaft Timing Marks
Fig. 3: Locking Balance Shaft In Place
Fig. 6: Installing Crankshaft Flange
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 exhaust 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. Temporarily tighten center bolt. See Fig. 7. To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise, and then rotate clockwise until No. 1 cylinder is at TDC. Ensure all timing marks are aligned. Loosen center bolt on tensioner pulley. Note location of pin holes in tensioner pulley. Using INCH lb. torque wrench and Socket Wrench (0922428100), apply a torque of 22-24 INCH Ibs. (2.6-2.8 N.m) on tensioner pulley. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to specification. See Fig. 8. Install Set Screw (09244-28000) or equivalent, in left engine support bracket until set screw end contacts tensioner arm. Rotate set screw further until locking pin can be removed from automatic tensioner. See Fig. 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. Install Set Screw (09244-28000) until it contacts tensioner arm. Rotate set screw inward while counting number of turns until tensioner arm contacts automatic tensioner housing. Turn set screw 2 1/2 -3 turns to correctly tension belt. Remove set screw. Install rubber plug in rear timing belt cover. Install timing belt covers. Install timing belt cover bolts in correct locations. See Fig. 9. To complete installation, reverse removal procedure. Apply sealant to contact areas on semi-circular packing and rocker cover before installing. Ensure correct bolts are installed in proper location in timing belt covers. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 10: Measuring Automatic Tensioner Protrusion
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27) Automatic Tensioner Bolt .................................. 15-20 (20-27) Balance Shaft Sprocket Bolt ............................. 32-36 (43-49) Balance Shaft Tensioner Retaining Bolt .......... 11 -16 (15-22) Camshaft Sprocket Bolt .................................. 59-74 (80-100) Crankshaft Pulley-To-Sprocket Bolt .................. 15-22 (20-30) Crankshaft Sprocket Center Bolt ................... 81-96 (110-130) Front Tensioner Pulley Bolt ............................... 32-41 (43-55) Idler Pulley Bolt ................................................. 25-31 (34-42) Oil Pump Sprocket Nut ..................................... 37-44 (50-60) Water Pump Mounting Bolt ................................... 9-11 (12-15) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 89-106 (10-12) Water Pump Pulley Bolt ...................................... 71-89 (8-10)
Fig. 8: Adjusting Timing Belt Tensioner Pulley
HYUNDAI *2.4L 4-Cylinder

TIMING BELT APPLICATION Application 2.4L 4-Cyl. Sonata 1989-91 Balance Shaft .... 1 .............. 2521240 ..... 250159 Camshaft ............ 2.7 Hrs. .. 2521240 ..... 250124 1 - Balance Shaft Belt included in Camshaft Belt labor time. With Air Cond. add .4 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits. Labor Time Component Kit No. Belt Part No.
305

and align rear belt marks. See Fig. 5. Install crankshaft gear, camshaft timing belt, washer and bolt. Align timing marks. See Fig. 1. Install rear tensioner. Hold tensioner tight against belt while tightening bolts. Depress belt with finger to ensure deflection is between .20-30 (5-7 mm). Install camshaft and oil pump sprocket (if removed). Tighten camshaft sprocket retaining bolt to specification while holding hexagon area of camshaft. Install belt tensioner, tension spring and spacer. Ensure spring is properly engaged against front case. Rotate tensioner toward water pump and temporarily tighten retaining bolts. Ensure camshaft and crankshaft timing marks are aligned. See Fig. 1. Install timing belt on crankshaft. Apply pressure on tension side of belt while installing belt on camshaft sprocket. Loosen tensioner to allow spring pressure to timing belt. Rotate camshaft sprocket clockwise until timing mark is offset by 2 teeth to apply tension on belt. Ensure all timing marks are aligned. Tighten tensioner bolt. Tighten tensioner spacer. To check belt tension, apply slight thumb pressure to measure deflection between camshaft and oil pump sprocket. Belt deflection should be .55 (14 mm). To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt .................................. 14-20 (19-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley-To-Sprocket Bolt .................. 14-22 (19-30) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Idler Pulley Bolt ................................................. 25-30 (34-41) Tensioner Pulley Bracket Bolt ........................... 17-20 (23-27) Tensioner Pulley Center Bolt ............................ 31-40 (42-54) INCH Lbs. (N.m) Crank Angle Sensor Nut ................................... 84-108 (9-12) Timing Belt Cover Bolt Left Lower Rear Cover Bolt ................................. 44-61 (5-7) All Exc. Left Lower Rear Cover Bolt ................. 84-108 (9-12) Water Pump Pulley Bolt ........................................ 72-84 (8-9)

TIMING BELTS
Removal: Disconnect negative battery cable. Remove all drive belts and crankshaft pulley. Remove upper timing belt cover and gasket. Remove timing belt lower cover and gasket, noting bolt lengths and locations. Remove crankshaft sprocket bolt access cover. Remove crankshaft sprocket bolt and washer. Rotate engine clockwise to align timing mark on camshaft sprocket with mark on cylinder head. See Fig. 1. Loosen front timing belt tensioner adjustment bolt, and move tensioner toward water pump. Tighten bolt to secure tensioner. Remove front timing belt. Remove camshaft sprocket. Remove oil pump sprocket access plug from cylinder block. Insert 8 mm Phillips screwdriver 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 *2.4L 4-Cylinder (Cont.)
Fig. 3: Blocking Left Silent Shaft
Fig. 4: Positioning Timing Belt Crankshaft Flange
HYUNDAI *2.4L 4-Cylinder (Cont.)
307
Fig. 5: Aligning Rear Timing Belt Marks
308
HYUNDAI *3.0L V6

Ensure engine is on No. 1 cylinder compression stroke and timing marks are aligned. Remove crankshaft pulley and timing belt covers. Rotate crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 3. Loosen timing belt tensioner bolt and pivot tensioner counterclockwise. Lock tensioner in retracted position. If reusing timing belt, mark rotation direction on belt. Remove timing belt. Inspection Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner for worn bearing. Installation: Align camshaft and crankshaft timing marks. See Fig. 3. If tensioner spring has been removed, install spring on tensioner so hook faces away from engine block. Route timing belt on crankshaft sprocket and then onto rear camshaft sprocket. Run timing belt under water pump pulley, over front camshaft sprocket and then over tensioner pulley. Apply force counterclockwise to rear camshaft sprocket, applying tension to right side of belt. Ensure timing marks are aligned. Loosen tensioner bolt allowing tensioner to take up slack in left side of timing belt. Tighten tensioner bolt. Rotate crankshaft 2 turns clockwise. Realign timing marks. Measure timing belt tension using belt tension gauge midway between crankshaft and camshaft sprockets, on side opposite tensioner. For new belt, tension should be 57-84 lbs. (26-38 kg). Install flange on crankshaft sprocket with flat side facing timing belt. Install front timing belt cover. Install crankshaft pulley and tighten bolt to specification. Install engine support bolts and tighten in sequence. See Fig. 1. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................. 59-74 (80-100) Crankshaft Sprocket Bolt .......................... 111-118 (150-160) Timing Belt Tensioner Bolt ............................... 16-22 (22-30) Water Pump Bolt Headmark 4 Bolt ............................................... 9-11 (12-15) Headmark 7 Bolt ............................................. 15-20 (20-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 89-106 (10-12)
Application 3.0L V6 Sonata 1990-98 .......... 1 3.1 Hrs. .... 2521390 ........ 250139 1 - With Air Cond. add .4 hours.

The manufacturer requires the belt be replaced every 60,000 miles, except for 1998 California vehicles. For 1998 California vehicles, timing belt replacement is recommended, but not required at 60,000 miles.

TIMING BELT
Removal: Support engine oil pan with jack and block of wood. Remove all drive belts. Remove power steering pump with hoses connected and set aside. Remove engine mount on timing belt end of engine. Remove engine support bracket bolts in sequence. Slowly remove reamer bolt. See Fig. 1.
NOTE: Reamer bolt may sometimes become seized on engine support bracket. Remove reamer bolt carefully without damaging threads.
Fig. 1: Engine Support Bolt Loosening & Tightening Sequence
HYUNDAI *3.0L V6 (Cont.)
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INFINITI *3.0L V6 J30

Installation: Ensure crankshaft sprocket, camshaft sprockets, idler pulleys and timing belt are dry and clean. Ensure No. 1 cylinder is at TDC of compression stroke and all timing marks are still aligned. See Fig. 2. Remove all spark plugs. Install timing belt with White marks on timing belt aligned with timing mark on crankshaft sprocket and camshaft sprockets. Ensure arrow on timing belt points toward front of engine.
CAUTION: Timing belt must be installed so White marks on timing belt align with timing mark on crankshaft sprocket and camshaft sprockets. Arrow on timing belt must point toward front of engine. DO NOT bend or twist timing belt during installation. CAUTION: Ensure stopper bolt is removed before adjusting clearance on automatic tensioner or stopper bolt and automatic tensioner may be damaged.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 J30 1993 ....................... 4.4 Hours ................ 250180 1994-97 .................. 4.4 Hours ................ 250251


TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove lower engine cover. Drain radiator and cylinder block. Remove air intake ducts, radiator, drive belts, cooling fan assembly and starter. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove coolant inlet and outlets for access to timing belt cover. Remove upper and lower timing belt covers. See Fig. 3.
NOTE: Crankshaft position sensor is mounted on front of exhaust camshaft on driver side. Crankshaft position sensor removal may be required for timing belt cover removal. Mark location of crankshaft position sensor before removing to ensure proper installation during reassembly.
Install a 6x16 mm stopper bolt on automatic tensioner to prevent tensioner from pushing outward. See Fig. 1. Rotate engine so No. 1 cylinder is at TDC on compression stroke. No. 1 cylinder is front cylinder on right side when viewed from rear of engine. Ensure timing marks on camshaft sprockets and crankshaft sprocket are aligned. See Fig. 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 contamination. Inspect crankshaft sprocket and camshaft sprockets for damaged teeth. Inspect automatic tensioner for signs of oil leakage around the shaft that pushes the pulley outward. Check all idler pulleys for smooth rotation. Replace components if damaged.
Remove stopper bolt from automatic tensioner. Using vise, adjust tensioner arm on automatic tensioner so .16" (4.0 mm) clearance exists between pusher and tensioner arm. See Fig. 4. Once correct clearance is obtained, reinstall stopper bolt. Install automatic tensioner on cylinder block with bolts finger tight. Slightly push automatic tensioner inward against timing belt to prevent timing belt from slipping. DO NOT push to hard or timing belt will be adjusted too tight. Rotate crankshaft 10 degrees clockwise. Tighten automatic tensioner retaining nut and then the bolts to specification in sequence. See Fig. 4. See TORQUE SPECIFICATIONS. Rotate crankshaft 120 degrees counterclockwise. Loosen automatic tensioner retaining bolts and nut 1/2 turn. Rotate automatic tensioner back as far as possible. Rotate crankshaft clockwise until No. 1 cylinder is at TDC on compression stroke and all timing marks are aligned. See Fig. 5. Using Push-Pull Gauge (J-38387) or equivalent and Hook (KV10112000) or equivalent, push end of pusher on automatic tensioner inward against timing belt with a force of 13.2 lbs. (6 kg). See Fig. 6. Tighten automatic tensioner retaining nut and then the bolts to specification in sequence. See Fig. 4. See TORQUE SPECIFICATIONS.
Fig. 1: Installing Stopper Bolt On Automatic Tensioner Fig. 2: Aligning Timing Marks
INFINITI *3.0L V6 J30 (Cont.)
311
Courtesy of Nissan Motor Co., U.S.A.
Rotate crankshaft clockwise 120 degrees clockwise from No. 1 cylinder TDC position. Rotate crankshaft counterclockwise 120 degrees back to No. 1 cylinder TDC position. Fabricate belt tension plate to proper specification. See Fig. 7. Using belt tension plate and push-pull gauge, check timing belt deflection at mid-way distance between sprockets and idler pulleys using 11 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 SPECIFICATIONS. Remove stopper bolt from automatic tensioner.
Fig. 4: Adjusting Automatic Tensioner Clearance & Identifying Bolt/Nut Tightening Sequence
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INFINITI *3.0L V6 J30 (Cont.)
Fig. 6: Adjusting Automatic Timing Belt Tensioner
Fig. 5: Aligning Crankshaft & Camshaft Timing Marks 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.
Fig. 7: Fabricating Belt Tension Plate & Checking Timing Belt Deflection
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Automatic Tensioner Bolt/Nut ........................... 12-15 (16-20) Camshaft Sprocket Bolt Exhaust .......................................................... 11-14 (15-19) Intake ......................................................... 91-97 (123-132) Crankshaft Position Sensor Brackets .............. 12-15 (16-20) Crankshaft Pulley Bolt .............................. 159-174 (216-236) Engine Mount-To-Frame Nut ............................ 41-49 (56-66) Idler Pulley Nut ................................................. 32-43 (45-58) Water Pump Bolt .............................................. 12-15 (16-20) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt .................................. 44 (5) Timing Belt Cover Bolt Rear Cover Bolt .......................................................... 53 (6) Upper & Lower ........................................................... 27 (3) Valve Cover Bolt/Screw Exhaust Camshaft Cover ........................................... 71 (8) Intake Camshaft Cover ............................................... 27 (3)
After 5 minutes, ensure clearance between tensioner arm and pusher on automatic tensioner is .138-.205" (3.505.20 mm). Ensure timing belt will not slip at any point on camshaft sprockets and crankshaft sprocket. To install remaining components, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
INFINITI *3.0L V6 M30

TIMING BELT APPLICATION Application 3.0L V6 M30 1990-92 .......... 4.0 Hours ... 2521040 ........ 250104 Labor Labor Component Kit No. Belt Part No.
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Rotate timing belt tensioner fully outward (away from timing belt area) and temporarily tighten retaining nut. Align White marks on timing belt with timing marks on camshaft and crankshaft sprocket and install timing belt.
CAUTION: Install timing belt with arrow pointing toward timing belt cover. With timing belt installed, 40 teeth should be between timing marks on right and left camshafts and 43 teeth between timing mark on left camshaft sprocket and timing mark on crankshaft sprocket. See Fig. 1.


TIMING BELT
Removal: Disconnect negative battery cable. Remove lower engine covers. Drain cooling system. Remove radiator, cooling fan and accessory drive belts. Remove water pump pulley, spark plugs and distributor cover. Remove fresh air tube from rocker arm cover. Remove A/C drive belt idler bracket. Disconnect coolant inlet hose from thermostat housing. Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley. Remove front upper and lower timing belt covers. See Fig. 2. Temporarily install crankshaft pulley retaining bolt. Using crankshaft pulley retaining bolt, rotate crankshaft until No. 1 cylinder is at TDC on compression stroke and all timing marks are aligned See Fig. 1. Loosen timing belt tensioner retaining nut. Rotate timing belt tensioner to release timing belt tension. Remove timing belt.
NOTE: No. 1 cylinder is front cylinder on left when viewed from front of engine. CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed or engine damage may result.
Using an Allen wrench, hold tension on timing belt tensioner and loosen retaining nut. Rotate timing belt tensioner clockwise 70-80 degrees and tighten retaining nut. Rotate crankshaft clockwise 2 full revolutions and realign timing marks so No. 1 cylinder is at TDC on compression stroke. Apply 22 lbs (10 kg) of pressure on timing belt at midway point between timing belt tensioner and camshaft sprocket. See Fig. 2. Loosen timing belt tensioner retaining nut while maintaining pressure on timing belt tensioner using an Allen wrench. Insert a .0138" (.350 mm) thick and 1/2" wide feeler gauge between timing belt tensioner and timing belt. Perform first step of installation. See Fig. 3. Rotate crankshaft clockwise until feeler gauge is properly positioned between timing belt and timing belt tensioner. Perform second step of installation. See Fig. 3. Timing belt should move approximately 2 1/2 teeth. Maintain steady pressure on timing belt tenisoner. Tighten timing belt tensioner retaining nut to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise and remove feeler gauge. Rotate crankshaft clockwise 2 full revolutions and realign timing marks so No. 1 cylinder is at TDC on compression stroke. Timing belt deflection should be .51-.59" (13.0-15.0 mm) when applying 22 lbs. (10 kg) pressure on timing belt at midway poing between camshaft sprockets. To install remaining components, reverse removal procedure. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Inspection: Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure timing belt tensioner rotates smoothly. Inspect tensioner spring for damage. Replace components if damaged. Installation: 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
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INFINITI *3.0L V6 M30 (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Locating Plate Bolt ........................... 58-65 (79-88) Camshaft Sprocket Bolt .................................... 58-65 (79-88) Crankshaft Pulley Bolt ................................. 90-98 (122-133) Crossmember-To-Body Bolt ............................. 32-41 (43-56) Timing Belt Tensioner Nut ................................ 32-43 (43-58) Water Pump Bolt .............................................. 12-15 (16-20) INCH Lbs. (N.m) Rocker Arm Cover Bolt ............................................ 9-27 (1-3) Timing Belt Cover Bolt .......................................... 27-44 (3-5)
Fig. 3: Checking Timing Belt Clearance
ISUZU *1.6L & 1.8L 4-Cylinder

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. DOHC I-Mark 1989 ......................... 2.0 Hours ............... 250169 Impulse 1990-92 Non-Turbo . 2.0 Hours ............... 250169 1991-92 Turbo ....... 2.4 Hours ............... 250169 Stylus 1991 ......................... 2.0 Hours ............... 250169 1.6L 4-Cyl. SOHC Stylus 1991-93 .................... 3.0 Hours ............... 250177 1.8L 4-Cyl. SOHC Impulse 1992 ......................... 2.4 Hours ............... 250205 Stylus 1992-93 .................... 2.4 Hours ............... 250205 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.
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Installation (DOHC): Rotate camshafts so timing marks align with cylinder head surface. Install 6 mm bolts in lock bolt holes to secure camshafts. Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 3. Install timing belt in the following order: over crankshaft sprocket, water pump, idler pulley, exhaust camshaft, intake camshaft and belt tensioner. Ensure no slack exists in belt. Loosen bolt and allow tensioner pulley to apply tension on timing belt. Hold tensioner pulley and tighten tensioner pulley bolt.
CAUTION: On new timing belts, push tensioner pulley sightly inward to apply more pressure on timing belt. On used timing belts, allow only spring tension to be applied to timing belt.
Rotate crankshaft 2 revolutions in direction of engine rotation. Ensure all timing marks align. Rotate crankshaft 60 degrees. Measure timing belt deflection at midpoint between camshaft sprockets. Ensure timing belt defection is within specification. See TIMING BELT DEFLECTION SPECIFICATIONS. If belt deflection is not within specification, repeat the last two steps.

CAUTION: Ensure timing marks align after belt adjustment.
To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. TIMING BELT DEFLECTION SPECIFICATIONS Application In. (mm) DOHC New Belt ..................................................... .28-.33 (7.1-8.4) Used Belt ................................................. .35-.41 (8.9-10.4) SOHC New Or Used Belt ........................................ .63-.79 (16-20) Removal (SOHC): Disconnect negative battery cable. Support engine. Remove right side engine mount. Remove alternator and power steering pump drive belts. Ensure engine is supported. Remove engine mounting bracket located at timing belt cover. Remove crankshaft pulley bolts. Remove crankshaft pulley from crankshaft pulley hub. Remove timing belt cover. Rotate crankshaft and position No. 4 cylinder at TDC of compression stroke. Ensure timing mark on camshaft pulley aligns with cylinder head. See Fig. 4 . Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 4. Loosen tensioner pulley bolt. Rotate tensioner pulley to loosen timing belt tension. Mark timing belt direction of rotation if reusing belt. Remove timing belt. Inspection (SOHC): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure tensioner pulley rotates freely. Replace components if damaged. Installation (SOHC): Rotate camshaft so timing mark aligns with cylinder head surface. Ensure dowel pin on camshaft pulley is in the up position. See Fig. 4. Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 4. Install timing belt in the following order: over crankshaft sprocket, camshaft pulley, water pump and belt tensioner.
*NOTE: The 1991-93 1.6L (SOHC) engine used in the Stylus is an interference engine. See page A59 for interference engine cautions.

TIMING BELT
Removal (DOHC): Disconnect negative battery cable. Remove accessory drive belts. Remove upper timing belt cover. See Fig. 1. Support engine. Remove engine mounting bracket located at timing belt cover. Rotate crankshaft and position No. 1 cylinder at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 timing mark on timing belt cover. Ensure timing marks on camshaft sprockets are aligned with cylinder head surface. See Fig. 3. Disconnect front exhaust pipe. Remove bolts attaching torque rod bracket to cylinder block. Remove bolt attaching torque rod to vehicle frame. Remove torque rod and bracket as an assembly. Remove engine stiffener brace. See Fig. 2. Remove flywheel dust cover. Hold flywheel while removing crankshaft pulley bolt. Remove crankshaft pulley. Remove lower timing belt cover. Ensure timing mark (notch) on crankshaft sprocket aligns with timing mark on oil pump. See Fig. 3. Loosen tensioner pulley bolt 1/2 turn. Rotate tensioner pulley clockwise. Mark timing belt direction of rotation if reusing old belt. Remove timing belt. Inspection (DOHC): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure tensioner pulley and idler pulley rotate freely. Replace components if damaged.
316
ISUZU *1.6L & 1.8L 4-Cylinder (Cont.)
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 specification, repeat thisstep. To install remaining components, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
CAUTION: Ensure timing marks align after belt adjustment.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 43 (58) Crankshaft Pulley Bolt DOHC ................................................................... 109 (148) SOHC ....................................................................... 62 (84) Idler Pulley Bolt ........................................................... 31 (42) Left Engine Mount Bolt ................................................ 51 (69) Power Steering Pump Bolt .......................................... 11 (15) Right Engine Mount Bolt ........................................... 89 (121) Right Engine Mount Nut ............................................. 37 (50) Right Engine Mount Through-Bolt .............................. 51 (69) Tensioner Pulley Bolt DOHC ....................................................................... 31 (42) SOHC ....................................................................... 37 (50) Water Pump Bolt ........................................................ 17 (23) Wheel Lug Nut .......................................................... 87 (118) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 89 (10)
Fig. 2: Engine Stiffener Brace
Fig. 3: Aligning Timing Marks (DOHC)
Fig. 1: Routing Timing Belt (DOHC) Fig. 4: Aligning Timing Marks (SOHC)
ISUZU *1.6L & 1.8L 4-Cylinder (Cont.)
317
Fig. 5: Checking Timing Belt Tension (SOHC)
Fig. 7: Routing Timing Belt (SOHC)
Fig. 6: Tightening Sequence For Valve Cover Bolts (DOHC)
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ISUZU *1.8L 4-Cylinder Diesel

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TIMING BELT APPLICATION Labor Time Belt Part No. Application 1.8L 4-Cyl. Diesel I-Mark 1981-84 ................. 3.1 Hours .................. 250076 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.

Check that fixing plate fits smoothly into slot at rear of camshaft, then remove fixing plate. Loosen tensioner pulley pivot bolts and take up timing belt slack. Tighten tensioner pulley center bolt, then tighten pivot bolts. Using Tension Gauge (J-29771) or equivalent, check for 47-64 Ibs. (21-29 kg) tension between camshaft and injection pump sprockets. Remove crankshaft pulley and install timing belt holder. Ensure that timing belt holder does not rubagainst timing belt. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Camshaft Sprocket ........................................... Crankshaft Pulley ............................................. Injection Pump Timing Pulley ........................... Tensioner Pulley Center Bolt ...................................................... Pivot Bolt ......................................................... Ft. Lbs. (N.m) 43-50 (58-68) 11-18 (15-24) 42-52 (57-71) 47-64 (64-87) 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 crankshaft pulley. Remove lower timing belt cover. Remove timing belt holder. See Fig. 3. Remove tension spring located behind front plate. Loosen tensioner pulley and pivot bolts. Remove timing belt. Installation: Remove camshaft sprocket center bolt. Using Puller (J-29801) or equivalent, remove camshaft sprocket. Install sprocket on camshaft. Lightly tighten center bolt so that sprocket can be turned smoothly by hand. Starting at crankshaft sprocket and working in a counterclockwise direction, engage new timing belt over each sprocket and pulley. Check that belt is properly engaged on all sprockets and pulleys. See Fig. 4. Take up belt slack at tensioner pulley by depressing pulley and installing tension spring. Tighten tensioner pulley pivot bolts just enough to prevent pulley movement. See Fig. 5. DO NOT tighten pulley center bolt at this time. Tighten camshaft sprocket bolt. Remove bolt used to lock injection pump sprocket in place. Remove fixing plate used to lock camshaft in place. Install crankshaft pulley on hub. Check that No.1 piston is still at TDC. DO NOT turn crankshaft in an attempt to adjust timing mark on pulley. Ensure that timing marks on injection pump sprocket and front plate are still aligned.
Fig. 1: Aligning Injection Pump Timing Marks
Fig. 2: Camshaft Fixing Plate
ISUZU *1.8L 4-Cylinder Diesel (Cont.)
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Fig. 5: Location Of Tensioner Pulley Fig. 3: Location Of Timing Belt Holder
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ISUZU *2.0L, 2.3L & 2.6L 4-Cylinder

TIMING BELT
NOTE: Some procedures may differ slightly due to engine construction.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. Turbo Impulse 1985-89 A/T ..................... 1 3.6 Hours ................. 250121 M/T .................... 1 3.4 Hours ................. 250121 2.3L 4-Cyl. Amigo 1989-93 A/T ..................... 1 1.9 Hours ................. 250122 M/T .................... 1 1.6 Hours ................. 250122 Impulse 1988-89 A/T ..................... 1 3.6 Hours ................. 250122 M/T .................... 1 3.4 Hours ................. 250122 Pickup 1986-95 A/T ..................... 1 1.9 Hours ................. 250122 M/T .................... 1 1.6 Hours ................. 250122 Trooper II 1986-87 A/T ..................... 1 1.9 Hours ................. 250122 M/T .................... 1 1.6 Hours ................. 250122 2.6L 4-Cyl. Amigo 1989-94 A/T ..................... 1 1.9 Hours ................. 250147 M/T .................... 1 1.6 Hours ................. 250147 Pickup 1988-95 A/T ..................... 1 1.9 Hours ................. 250147 M/T .................... 1 1.6 Hours ................. 250147 Rodeo 1991-97 A/T ..................... 1 1.9 Hours ................. 250147 M/T .................... 1 1.6 Hours ................. 250147 Trooper 1990-91 A/T ..................... 1 1.9 Hours ................. 250147 M/T .................... 1 1.6 Hours ................. 250147 Trooper II 1988-89 A/T ..................... 1 1.9 Hours ................. 250147 M/T .................... 1 1.6 Hours ................. 250147 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.
Removal: Disconnect negative battery cable. Remove all necessary air ducts. Position No. 1 cylinder at TDC of compression stroke. Align timing marks. See Fig. 1. Remove fan and fan shroud. Remove accessory drive belts. Remove water pump pulley. If necessary, remove radiator and splash guard. Prevent engine from rotating and remove crankshaft timing pulley. Remove upper and lower timing belt covers. Remove spring from tension pulley. Loosen adjusting bolt and move pulley toward water pump. Remove timing belt.
CAUTION: Ensure No. 1 cylinder is at TDC when rotating camshaft or damage may result.
Inspection: Handle timing belt carefully. Avoid twisting or kinking belt. DO NOT allow belt to become contaminated by water, oil, dirt or other contaminates. Inspect belt for cracks or damage. Replace, if necessary. On 2.0L engines, measure outside diameter of crankshaft, camshaft and oil pump sprockets. If specifications are exceeded, replace sprocket(s). See TIMING SPROCKET SPECIFICATIONS table. On all engines, measure tension pulley spring length and force. On 2.3L and 2.6L engine, spring length should not exceed 2.76" (70.2 mm) and spring force should not be less than 60-106 lbs. (27-48 kg). On 2.0L, spring length should not exceed 3.11" (79 mm) and spring force should not be less than 53-57 lbs. (24-26 kg). On all engines, replace tension pulley spring if not within specification. TIMING SPROCKET SPECIFICATIONS Application Standard Limit In. (mm) In. (mm) Camshaft ....................... 5.202 ................................ 5.198 (132.03) ......................... (131.93) Crankshaft ...................... 2.574 ................................ 2.570 (65.33) ............................. (65.23) Oil Pump ........................ 4.485 ................................ 4.481 (113.84) ......................... (113.74) Installation: Pull tensioner fully toward water pump side and temporarily tighten retaining bolt. Ensure No. 1 cylinder is at TDC on compression stroke by rotating crankshaft until keyway aligns with mark on front crankshaft seal housing (12 oclock). Rotate camshaft until timing mark on cam gear (arrow) aligns with mark on upper camshaft cover (notch). See Fig. 3. Position timing belt over crankshaft sprocket, oil pump sprocket, camshaft sprocket and tensioner in that order. Ensure belt is positioned in sequence given and without slack between sprockets. Loosen tensioner pulley adjusting bolt allowing spring tension to tighten belt. Tighten adjusting bolt temporarily. Temporarily install crankshaft pulley bolt and rotate crankshaft 2 complete revolutions in opposite direction of engine rotation, until marks on crankshaft and front oil seal retainer are aligned again. See Fig. 3. Loosen tensioner lock bolt, allowing tensioner spring to fully adjust tension. Tighten tensioner lock bolt.

ISUZU *2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
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Install timing belt covers. To complete installation, reverse removal procedures. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 43 (58) Crankshaft Pulley Bolt .............................................. 90 (122) Front Cover ................................................................. 14 (19) Tensioner Pulley Bolts ......................................................................... 18 (24) Nut ............................................................................ 10 (14) Water Pump ............................................................... 14 (19) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................................. 53 (6)
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ISUZU *2.0L, 2.3L & 2.6L 4-Cylinder (Cont.)
Fig. 2: Installing Belt Guide
Fig. 3: Timing Alignment Marks
ISUZU *2.2L 4-Cylinder Diesel

TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.2L 4-Cyl. Diesel LUV (Chevrolet) 1981-82 ................. 2.7 Hours .................. 250075 Pickup (Isuzu) 1983-85 ................. 2.7 Hours .................. 250075 PUP 1981-87 ................. 2.7 Hours .................. 250075 S10 & S15 Pickup (Chevrolet/GMC) 1983-85 ................. 2.7 Hours .................. 250075 Trooper II 1984-87 ................. 2.7 Hours .................. 250075 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.
1
323
Install and tighten injection pump pulley flange. Ensure hole in flange lines up with triangular timing mark on pump sprocket. See Fig. 3. Turn crankshaft 2 more turns, bringing No. 1 cylinder to TDC on compression stroke. Check timing mark alignment. Check timing belt tension with Tension Gauge (J-29771) or equivalent. Tension should be 33-55 Ibs. (15-25 kg). Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................. 72-87 (98-118) Crankshaft Sprocket Bolt .......................... 124-151 (168-205) Injection Pump Timing Pulley Bolt .................... 42-52 (57-71) Tension Spring Nut ........................................... 22-36 (30-49) Timing Belt Tensioner Bolts ........................ 79-94 (107-127)


TIMING BELT
Removal: Disconnect negative battery cable. Remove lower engine cover. Drain cooling system. Remove battery. Remove fan, fan shroud, top radiator hose and drive belts. Remove 4 crankshaft pulley bolts and crankshaft pulley. Remove timing belt covers. See Fig. 1. Remove tension spring. See Fig. 2. Position No. 1 cylinder at TDC of compression stroke. Ensure injection pump and camshaft sprocket timing marks are aligned. See Fig. 3. Remove injection pump pulley flange bolts and remove flange. Remove tensioner spring without using excess force on spring. Remove tension pulley nut and tensioner assembly. Remove timing belt. 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, camshaft 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 2236 ft. Ibs. (30-49 N.m). Turn crankshaft 2 complete revolutions in normal direction of rotation, then turn crankshaft 90 degrees past TDC. Loosen tensioner nut completely and allow tensioner to take up slack. Tighten nut.
Fig. 2: Removing Tension Spring
324
ISUZU *2.2L 4-Cylinder Diesel (Cont.)
Fig. 5: Timing Belt Tensioner Installation
Fig. 3: Timing Belt Sprocket Alignment
Fig. 6: Injection Pump Timing Alignment Marks
ISUZU *2.2L 4-Cylinder DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 4-Cyl. DOHC Amigo 1998-00 Auto. Trans. ....... 1 1.9 Hours ................. 250305 Man. Trans. ....... 1 1.6 Hours ................. 250305 Rodeo 1998-01 Auto. Trans. ....... 1 1.9 Hours ................. 250305 Man. Trans. ....... 1 1.6 Hours ................. 250305 1 - With Air Cond. add .4 hours.
325

For 1998 vehicles, the manufacturer recommends the belt be replaced every 75,000 miles. For 1999-00 vehicles, the manufacturer recommends the belt be replaced every 100,000 miles for normal service, or 75,000 miles for severe service. For 2001 vehicles, the manufacturer recommends the belt be replaced every 75,000 miles for normal service, or 60,000 miles for severe service.
Remove timing belt cover. If reusing old belt, place mark on belt to indicate direction of belt rotation. Rotate crankshaft so camshaft and crankshaft timing marks are aligned. See Fig. 1. Loosen timing belt tensioner pulley bolt, and move tensioner away from timing belt. Remove timing belt. Inspection: Check timing belt for cracks, cracked or missing teeth, and separating canvas. Inspect timing belt tensioner and idler pulley for worn bearings. Installation: Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 1. Place Camshaft Locking Tool (J-43037) between camshafts to prevent movement. Install timing belt on engine. If reusing old belt, install belt in original position. Ensure there is no slack in belt. Loosen tensioner pulley center bolt. Move timing belt tensioner toward belt.
NOTE: Adjust timing belt tension with engine cold.

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.
To tension timing belt, align timing belt tensioner arrow in correct position for new or used belt. See Fig. 2. Tighten timing belt tensioner to specification. See TORQUE SPECIFICATIONS. Remove camshaft locking tool. Turn crankshaft 2 turns in normal direction of rotation until No. 1 cylinder is at TDC. Check alignment of timing belt tensioner pointer. If marks do NOT align, repeat timing belt tensioning procedure. Install timing belt cover. Install engine harness cover. Connect engine harness electrical connectors. Continue installation in reverse of removal procedure.
326
ISUZU *2.2L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 1 Step 1 ........................................................................... 36 (50) Step 2 ................................................................ + 60 Degrees Step 3 (1998-00 Engines Only) ......................... +15 Degrees Crankshaft Pulley-To-Sprocket Bolt ............................ 14 (20) Crankshaft Sprocket Center Bolt 1 Step 1 ......................................................................... 94 (130) Step 2 ................................................................ + 45 Degrees Timing Belt Idler Pulley Bolt ........................................... 18 (25) Timing Belt Tensioner Bolt ......................................... 18 (25) Water Pump Bolt ........................................................... 18 (25) INCH Lbs. (N.m) Engine Harness Cover-To-Engine .................................. 53 (6) Timing Belt Cover Bolt .................................................. 53 (6) 1 Replace bolt if loosened or removed.
ISUZU *2.2L 4-Cylinder Oasis

TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 2.2L 4-Cyl. RA1 Oasis 1996-97 Balancer Shaft .................. 2521860 ..... 250186 Camshaft ....... 1, 2 2.7 Hrs. .. 2521860 ...... 250187 1 - Balancer shaft belt included in camshaft belt labor time. 2 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
327

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).
96H14628

TIMING BELT
Removal: Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Remove accessory drive belts. Remove alternator terminal and connector. Raise and support vehicle. Remove wheelwell splash shield. Using a jack with block of wood to support engine, remove side engine mount. Remove cylinder head cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. Loosen timing belt tension adjuster bolt 145-180 degrees. Push tensioner to release belt tension from timing belt and balancer 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. Install timing belt in sequence shown. See Fig. 6. Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
96I14629
328
ISUZU *2.2L 4-Cylinder Oasis (Cont.)
96D14632
96B14630
Fig. 6: Timing Belt Installation Sequence Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Sprocket Bolt .............................................. 28 (38) Crankshaft Pulley Bolt ............................................ 181 (245) Power Steering Pump Mounting Nut ........................... 16 (22) Timing Belt Adjuster Bolt ............................................. 49 (67) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................. 86-104 (7.2-8.7) Valve Cover Nut ......................................................... 86 (9.8)
ISUZU *2.3L 4-Cylinder Oasis

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L 4-Cyl. F23A, SOHC Oasis 1998-99 Balancer Shaft .. 1 4.0 Hours ................ 250186 Camshaft ........... 1 4.0 Hours ................ 250244 1 - Balance shaft belt included in camshaft belt labor time.
329

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


Removal: Disconnect negative battery cable. Rotate crankshaft counterclockwise until cylinder No. 1 is at TDC of compression stroke. While rotating crankshaft, check water pump for signs of seal leakage. Raise and support vehicle. Remove engine lower splash shield. Remove accessory drive belts. Remove alternator terminal and connector. Remove alternator and alternator bracket. Using a jack with a block of wood to support engine, remove side engine mount from front of engine. Remove dipstick tube from front of engine. Remove cylinder head cover. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1. 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 adjusting nut. Remove balancer shaft belt. Loosen belt tension adjusting nut about 1 turn. See Fig. 3. Push camshaft timing belt tensioner pulley down to take tension off of camshaft timing belt. Retighten belt tension adjusting nut. Remove camshaft timing belt. Installation: Clean tensioner pulleys. Ensure cylinder No. 1 is at TDC by aligning dimple on timing belt drive pulley with pointer on oil pump housing. See Fig. 4. Ensure camshaft pulley TDC marks are aligned. See Fig. 5. Install camshaft timing belt in sequence shown. See Fig. 6. Loosen and retighten tensioner adjusting nut to tension camshaft timing belt. Install balancer belt drive pulley and lower cover. Install crankshaft pulley. Install bolt.
96H14628
96I14629
330
96D14632
96B14630
Fig. 4: Aligning Timing Belt Drive Pulley Key & TDC Mark
Rotate crankshaft pulley COUNTERCLOCKWISE about 56 turns so timing belt positions on pulley. Set No. 1 piston at TDC of compression stroke. Loosen belt tensioner adjusting nut about 1 turn. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley. Tighten belt tensioner adjusting nut to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft so that crankshaft and camshaft pulleys are at TDC position. Ensure camshaft UP mark is facing up. If they are not, timing belt will have to be repositioned.
Remove crankshaft pulley and lower cover. Set timing belt drive pulley to TDC position. Lock camshaft timing belt adjuster arm in place by installing a 6x10 mm timing cover bolt. Loosen belt tension adjusting nut about 1 turn. See Fig. 3. Verify balancer belt tensioner pulley moves freely. Push balancer belt tensioner up then retighten belt tensioner adjusting nut. Remove sealing bolt from maintenance hole on sideof engine block. See Fig. 7. Scribe a line 2.9 (74 mm) from end of of 6x100 mm bolt. Install 6x100 mm bolt into maintenance hole to lock balancer shaft in place. Align front balancer shaft pulley groove with pointer on oil pump housing. See Fig. 8. Install balancer belt. Loosen tensioner adjusting nut about 1 turn to tension balancer shaft belt. Remove 6x100 mm bolt from rear of balancer shaft. Install sealing bolt with new washer.

Temporarily install crankshaft pulley and bolt. Turn crankshaft 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 gasket or liquid gasket. Install rubber seal around belt tensioner adjusting nut. DO NOT loosen nut. Install crankshaft pulley. Lubricate crankshaft pulley bolt and underside of bolt shoulder. Install and tighten crankshaft pulley bolt to specification. Install dipstick tube with new O ring. When installing cylinder head cover gasket, apply liquid gasket (Part No. 087180001 or -0003) to 4 corners where gasket meets camshafts. 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.
331
Fig. 8: Aligning Balancer Belt Drive Pulley
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt .................................... 33 (45) Alternator Adjusting Locknut ........................................... 16 (22) Alternator Bracket Bolt ................................................ 33 (45) Camshaft Sprocket Bolt .............................................. 43 (59) Crankshaft Pulley Bolt ............................................ 181 (245) Engine Block Sealing Bolt .............................................. 22 (29) Engine Bracket-To-Engine Side Mount Nut/Bolt Oasis ........................................................................... 40 (54) Engine Side Mount Through-Bolt Oasis ........................................................................... 47 (64) Engine Side Mount-To-Bracket Nut/Bolt Oasis ........................................................................... 47 (64) Power Steering Pump Mounting Nut ........................... 16 (22) Timing Belt Tensioner Adjusting Nut .......................... 33 (44) INCH Lbs. (N.m) Cylinder Head Cover Nut ........................................... 86 (9.8) Dipstick Tube Bolt ........................................................ 106 (12) Engine Lower Splash Shield ......................................... 89 (10) Timing Belt Cover Bolt .............................................. 106 (12) Water Pump Bolts ........................................................ 106 (12)
Fig. 7: Locking Balancer Belt Shaft In Place
332
ISUZU 3.2L V6 1993-97

SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .................................................. 41 (56) Camshaft Sprocket Bolt .............................................. 41 (56) Crankshaft Pulley Bolt ............................................ 123 (167) Fan Pulley Bolt ............................................................ 16 (22) Front Plate Bolt ........................................................... 14 (19) Idler Arm Retaining Bolt .............................................. 33 (44) Power Steering Pump Bolt .......................................... 34 (46) Timing Belt Cover Bolt ................................................ 13 (18) Timing Belt Tensioner Pulley Bolt ............................... 32 (43) Timing Belt Tensioner Pusher Bolt ............................. 14 (19) Upper Intake Manifold Bolt .......................................... 18 (24) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt ........................................ 87 (10) Cooling Fan Assembly Nut ........................................... 69 (8)
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.2L V6 DOHC Trooper 1992-95 ................ 1 2.6. Hours ................ 250220 3.2L V6 SOHC Rodeo 1993-97 ................ 1 2.8 Hours ................. 250221 Trooper 1992-97 ................ 1 2.8 Hours ................. 250221 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.


Removal: Disconnect negative battery cable. Remove air cleaner assembly. 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 crankshaft pulley pulley. Remove oil cooler hose from timing cover. Remove timing belt cover. Align all timing marks prior to belt removal. See Figs. 1, 2 and 3. Remove belt tensioner pusher and timing belt. Installation: Ensuring all timing marks are aligned. Install belt over one pulley at a time staring at crankshaft sprocket working counterclockwise. 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.
TIMING BELT
Fig. 1: Aligning Timing Marks (DOHC)
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 specification. Remove pin from timing belt tensioner pusher. Remove pinch clips from timing belt, (if used). Install crankshaft pulley, tightening center bolt finger tight. Rotate crankshaft 2 turns clockwise. Ensure timing belt tensioner pusher rod protrudes proper amount. See Fig. 5. If timing belt tensioner pusher rod protrusion is not within specification, remove pusher, loosen tensioner pulley bolt and readjust. Reset timing belt tensioner pusher rod and repeat step 3). Remove crankshaft pulley and install timing belt cover. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE
Fig. 2: Aligning Camshaft Timing Marks (SOHC)
ISUZU 3.2L V6 1993-97 (Cont.)
333
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
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.2L V6 Amigo 1998-99 ................ 1 2.8 Hours ................. 250303 Rodeo 1998-01 ................ 1 2.8 Hours ................. 250303 3.5L V6 Trooper 1998-01 ................ 1 2.4 Hours ................. 250303 VehiCROSS 1999-01 ................ 1 2.0 Hours ................. 250303 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .3 hours.

TIMING BELT
Removal: Disconnect negative battery cable. Remove air cleaner assembly. Remove upper fan shroud. Remove serpentine drive belt. Remove cooling fan and drive pulley. Remove serpentine drive belt idler pulley assembly. Remove serpentine drive belt tensioner assembly. Remove power steering pump with hoses attached, and set aside. Remove crankshaft pulley bolt. Using Puller (J8614-01) or equivalent, remove crankshaft pulley. Remove timing belt covers. Rotate crankshaft to align timing marks. See Figs. 1 and 2 . When timing marks are aligned, No. 2 piston will be at TDC. If reusing timing belt, mark belt with arrow to indicate original rotation direction. Also place mating marks on timing belt and camshaft sprockets for reassembly reference. Remove timing belt tensioner, and set aside with push rod facing up. Remove timing belt.
CAUTION: To prevent air from entering timing belt tensioner, tensioner rod must always face up. NOTE: For correct timing belt installation, lettering on belt must be able to be read as viewed from the front of the vehicle. Also, note arrow on belt which indicates direction of rotation.

TIMING BELT REPLACEMENT INTERVALS Application Miles 3.2L V6 Amigo 1998 ...................................................................... 75,000 1999 Normal Service .................................................... 100,000 Severe Service ....................................................... 75,000 Rodeo 1998 ...................................................................... 75,000 1999-01 Normal Service .................................................... 100,000 Severe Service ....................................................... 75,000 3.5L V6 Trooper 1998 ...................................................................... 75,000 1999-01 Normal Service .................................................... 100,000 Severe Service ....................................................... 75,000 VehiCROSS 1999-01 Normal Service .................................................... 100,000 Severe Service ...................................................... 75,000
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) camshaft sprocket with alignment mark on valve cover. See Fig. 3. Install timing belt on right hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. If reusing old timing belt, align mating marks on belt and camshaft sprocket that were made during removal. Secure belt with spring clip. Align timing mark on left hand (driver side) camshaft sprocket with alignment mark on valve cover. See Fig. 4. Route timing belt around water pump pulley and install on other left hand camshaft sprocket, aligning the White alignment mark on timing belt with camshaft sprocket mark. Install pinch clip to hold belt on sprocket. Ensure there is no slack in belt between camshaft pulleys.
ISUZU 3.2L & 3.5L V6 DOHC, 1998-01 (Cont.)
335
Fig. 5: Installing Locking Pin in Timing Belt Tensioner

Fig. 4: Installing Timing Belt on Left Hand Camshaft Sprocket
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.
Remove crankshaft pulley and install timing belt covers. Ensure rubber sealing bushings are installed on timing belt cover bolts. See Fig. 6. Install crankshaft pulley. Tighten center bolt to specification. Install cooling fan pulley. Install power steering pump. Install cooling fan. Install serpentine drive belt idler pulley and tensioner assemblies. Install radiator fan shroud. Connect battery. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 72 (98) Cooling Fan Pulley Bolt .............................................. 16 (22) Crankshaft Pulley Bolt ............................................ 123 (167) Power Steering Pump Bolt M8 Bolt ......................................................................... 16 (22) M10 ............................................................................. 34 (46) Timing Belt Cover Bolt ................................................ 14 (19) Timing Belt Idler Pulley Bolt ........................................ 38 (52) Timing Belt Tensioner Bolt ......................................... 18 (25) Timing Belt Tensioner Pulley Pivot Bolt ...................... 31 (42) Water Pump Bolt ......................................................... 18 (25)
Holding tensioner upright, SLOWLY compress timing belt tensioner rod until hole in top of rod and holes in housing are aligned. Install a locking pin through the holes. See Fig. 5. Install tensioner on engine with locking pin in place. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove locking pin from timing belt tensioner. Remove clips from camshaft and crankshaft sprockets. Rotate crankshaft 2 turns clockwise. Ensure timing marks are still aligned.
336
KIA *1.6L & 1.8L 4-Cylinder DOHC

deflection should be .36-45" (9.0-10.7 mm). If timing belt deflection is not within specification, repeat timing belt tensioning procedure or replace tensioner spring. If timing belt deflection is within specification, reverse removal procedure to complete installation. Before installing valve cover, apply silicone sealer to areas next to front camshaft journals and rear distributor mounting cap. Also apply thin bead of silicone sealer around spark plug holes on underside of valve cover. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Center Bolt ................... 116-123 (157-167) Spark Plug ........................................................ 14-17 (19-23) Timing Belt Tensioner Bolt ............................... 28-38 (38-51) INCH Lbs. (N.m) Crankshaft Pulley Bolt ................................. 106-152 (12-17) Timing Belt Cover Bolt ..................................... 69-97 (7.8-11) Valve Cover Bolt .............................................. 44-78 (5.0-8.8) Water Pump Pulley Bolt ................................... 69-97 (7.8-11)
Application 1.6L 4-Cyl. Sephia 1996-97 .......... 1 2.4 Hrs. .... 2521790 ........ 250179 1.8L 4-Cyl. Sephia 1995-97 .......... 1 2.4 Hrs. .... 2521790 ........ 250179 1 - With Air Cond. add .2 hours. With Pwr. Strng. add . 2 hours.

California Models The manufacturer recommends inspecting the belt at 60,000 miles, 90,000 miles, and replacing belt at 105,000 miles. Except California Models The manufacturer recommends the belt be replaced every 60,000 miles.

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

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.6L 4-Cyl. Sephia 1994-95 ................. 2.0 Hours .................. 250185 1.8L 4-Cyl Sephia 1996-97 ................. 2.0 Hours .................. 250185 1 - With Air Cond. add .2 hours. With Pwr. Strng. add . 2 hours.
1
337
Rotate crankshaft clockwise 2 more turns, and check timing belt deflection. Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt, midway between camshaft and crankshaft pulleys, on side opposite tensioner. Timing belt deflection should be .43-51" (10.9-13.0 mm). If timing belt deflection is not within specification, repeat procedure or replace tensioner spring. If timing belt deflection is within specification, reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 37-44 (50-60) Crankshaft Pulley Lock Bolt ...................... 116-123 (157-167) Spark Plug ........................................................ 14-17 (19-23) Timing Belt Tensioner Bolt ............................... 14-18 (19-25) INCH Lbs. (N.m) Camshaft Thrust Plate Bolt .......................................... 71 (8) Crankshaft Pulley Bolt ................................. 106-152 (12-17) Timing Belt Cover Bolt ..................................... 69-97 (7.8-11) Water Pump Pulley Bolt ................................... 69-97 (7.8-11)

California Models The manufacturer recommends inspecting the belt at 60, 000 miles, 90,000 miles, and replacing belt at 105,000 miles. Except California Models The manufacturer recommends the belt be replaced every 60,000 miles.

TIMING BELT
Removal: Disconnect negative battery cable. Remove all accessory 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 clockwise 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. Remove timing belt. Inspection: Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary. Installation: Ensure camshaft and crankshaft timing marks are still 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 apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft clockwise 2 complete turns. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure.
Courtesy of Kia Motors America, Inc.
338
KIA *1.6L & 1.8L 4-Cylinder SOHC (Cont.)
KIA *1.8L 4-Cylinder DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cyl. Sephia 1998-01 ................ 1 2.4 Hours ................. 250302 Spectra 2000-01 ................ 1 2.4 Hours ................. 250302 1 - With Air Cond. add .2 hours. With Pwr. Strng. add . 2 hours.
339

TIMING BELT
Removal: Disconnect negative battery cable. Remove all accessory drive belts. Remove water pump pulley. Remove crankshaft pulley bolt, and remove pulley and timing belt guide plate. See Fig. 1. Remove upper and lower timing belt covers. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Ensure camshaft sprockets and crankshaft sprocket timing marks align. See Figs. 2 and 3. Camshaft sprocket I and E marks must face up and align with marks on rear timing belt cover. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt tensioner pulley. See Fig. 4. Remove timing belt. Inspection: Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner and idler pulley bearings for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary.
NOTE: Manufacturer recommends replacing timing belt tensioner spring whenever timing belt is replaced. See Fig. 5.

Fig. 1: Removing Timing Belt Guide Plate
Installation: Install tensioner pulley with NEW spring. Move tensioner away from timing belt and tighten center bolt. Ensure camshaft and crankshaft timing marks are still aligned. See Figs. 2 and 3. Install timing belt around crankshaft sprocket. If reusing old belt, ensure belt is installed in original direction of rotation. Keeping belt pulled tight on right side (facing engine), route belt around idler pulley, camshaft sprockets, and tensioner pulley. Loosen timing belt tensioner center bolt, and allow spring to apply tension on belt. Tighten tensioner center bolt. Rotate crankshaft clockwise 2 complete revolutions. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. Check timing belt deflection with 22 lbs. (10 kg) of downward pressure applied to belt, midway between camshaft sprockets. Timing belt deflection should be .36-.45 (9.011 mm).
340
KIA *1.8L 4-Cylinder DOHC (Cont.)
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 crankshaft and water pump pulleys. Continue installation in reverse of removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 36-45 (49-61) Timing Belt Tensioner Bolt ............................... 28-38 (38-51) INCH Lbs. (N.m) Crankshaft Pulley-To-Crankshaft Bolt .......... 106-152 (12-17) Timing Belt Cover Bolt ..................................... 69-97 (7.8-11) Water Pump Pulley Bolt ............................... 106-152 (12-17)
KIA *2.0L 4-Cylinder DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. Sportage 1995-01 ................ 1 3.2 Hours ................. 250281 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
341

Application Ft. Lbs. (N.m) Camshaft Pulley Center Bolt .............................. 35-48 (47-65) Cooling Fan Clutch-To-Pulley Nuts ............................ 24 (32) Crankshaft Center Bolt ........................................... 120 (162) Crankshaft Pulley-to-Crankshaft Bolts .................. 9-13 (12-17) Generator Mount Bolts Top Generator Bolt .................................................... 16 (22) Bottom Generator Bolt ................................................ 32 (45) Idler Pulley Bolt ................................................. 27-38 (37-52) Power Steering Pump Bolts ................................ 27-34 (37-46) Timing Belt Tensioner Bolt ............................... 27-38 (37-52) Water Pump Bolt ............................................................ 16 (22) INCH Lbs. (N.m) Cooling Fan Shroud Bolts ............................................ 74 (8) Fresh Air Duct Mounting Bolts ..................................... 84 (10) 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. Remove cooling fan clutch-to-pulley nuts. Remove accessory drive belts. Remove cooling fan and pulley. Remove lower engine splash guard. Remove crankshaft pulley from crankshaft. It is NOT necessary to remove center bolt. Remove upper and lower timing belt covers. See Fig. 1. 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 outward to remove tension from timing belt, then retighten tensioner lock bolt. See Fig. 2. Mark timing belt rotation direction if old belt is to be reinstalled. Remove timing belt. Installation: Ensure crankshaft and camshaft pulleys are still aligned. Install timing belt so that there is no looseness at tension side, and at camshaft pulleys. If reusing old belt, ensure belt is installed in original direction of rotation. Loosen tensioner pulley bolt. Turn crankshaft 2 revolutions in normal direction of rotation. 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 pulley 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 between two camshaft pulleys. Install timing belt guide plate with flat side toward belt. Install timing belt covers. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
96D14491
Fig. 1: Timing Belt & Related Components
96E14492
Fig. 2: Loosening Tensioner
342
KIA *2.0L 4-Cylinder DOHC (Cont.)
96F14493
Fig. 3: Aligning Crankshaft Pulley Timing Marks
96G14494
Fig. 4: Aligning Camshaft Pulley Mating Marks
KIA *2.0L 4-Cylinder SOHC

TIMING BELT APPLICATION Appication Labor Time Belt Part No. 2.0L 4-Cyl. SOHC Sportage 1995 ..................... 1 2.3 Hours ................. 250264 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
343

96A14498

TIMING BELT
Removal: Disconnect negative battery cable. Remove timing belt cover. Remove accessory drive belts. Turn crankshaft and align timing mark on front housing and arrow at 2 on camshaft pulley. See Fig. 1. Remove damper pulley. Remove timing belt guide plate from timing belt pulley. Loosen tensioner lock bolt. Pry tensioner outward as far as possible from timing belt. Temporarily tighten tensioner lock bolt. Mark timing belt rotation direction if old belt is to be reinstalled. Remove timing belt. Installation: Check that timing belt tensioner spring has a free length of 2.24" (56.5 mm). Replace if necessary. Ensure timing belt pulley mark is aligned with timing mark. Ensure that arrow at 2 on camshaft pulley is aligned with timing mark on front housing. Install timing belt so that there is minimal slack from timing belt pulley to water pump and from water pump to camshaft pulley. Loosen tensioner bolt to apply tension to timing belt. Turn crankshaft 2 turns clockwise and verify that timing marks are correctly aligned. If not, repeat installation procedure. Tighten belt tensioner lock bolt. Check that belt deflection is .43-.51" (11-13 mm) at 22 lbs. (10 kg) pressure on belt between camshaft pulley and crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Belt Lock Bolts .................................. 24-30 (32-42) Cooling Fan Assembly ............................................... 27 (37) Cooling Fan Nuts ....................................................... 16 (22) Crankshaft Damper Bolts ......................................... 132 (15) Timing Belt Tensioner Lock Bolt ....................... 27-38 (37-52) INCH Lbs. (N.m) Cooling Fan Shroud Bolts ............................................ 74 (8) Fresh Air Duct Mounting Bolts ..................................... 84 (10) Timing Belt Cover Bolts .............................................. 84 (10)
Fig. 1: Timing Belt & Related Components
96J14497
Fig. 2: Camshaft Pulley Mating Marks
96J14497
Fig. 3: Crankshaft Pulley Mating Marks
344
LANCIA *1.8L 4-Cylinder

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.8L 4-Cyl. Beta 1976-78 ................. 2.7 Hours .................. 250020 1 - With Air Cond. add .6 hours.
Application Ft. Lbs. (N. m) Camshaft Housing Nuts ............................................ 16 (22) Timing Belt Tensioner ................................................ 33 (45)


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 camshaft gear timing holes. Attach fixture to cylinder head. Remove 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 fixture. Turn the crankshaft a few times, partially release the belt stretcher and finally relock it properly. Install timing reference pointers bracket. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 1: Align Camshaft Timing Marks With Bearing Reference Marks When Installing Timing Belt
VALVE TIMING
To check valve timing, turn crankshaft until reference mark on sheave aligns with long mark on timing gear cover. See Fig. 2. Check that the holes in camshaft gears (one in each) are aligned with reference marks on front camshaft bearings. See Fig. 2. If adjustment is necessary, use locking fixture (88013039) or equivalent, as instructed under TIMING BELT.
Fig. 2: Valve Timing Reference Marks
LEXUS 2.5L & 3.0L V6 1990-98

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L V6 ES250 1990-91 ................. 3.8 Hours .................. 250157 3.0L V6 ES300 1992-93 ................. 3.0 Hours .................. 250200 1994-98 ................. 3.0 Hours .................. 250257 TIMING BELT
345

Although the manufacturer does not recommend a specific scheduled maintenance interval for normal operating conditions, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. The manufacturer recommends the belt be replaced at 60,000 miles or 96 months for severe operating conditions.
Removal (2.5L & 1992-93 3.0L V6): Disconnect negative battery cable. Remove cruise control actuator and vacuum pump. Remove power steering reservoir with hoses attached, and secure them aside. Raise and support vehicle. Remove right front wheel. Remove right lower engine cover. Remove all drive belts. Remove top braces on right engine mount at timing belt cover. Slightly raise engine to remove weight from right engine mount. Remove retaining bolts/nuts and right engine mount assembly. Remove spark plugs. Remove retaining bolts, No. 2 timing belt cover, gasket and right engine mount bracket. See Fig. 1. Note bolt length and location of No. 2 timing belt cover bolts for reassembly reference.
CAUTION: If timing belt is to be reused, mark direction of timing belt rotation and location on camshaft sprockets for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover.

WARNING: To prevent air bag deployment, disconnect negative battery cable at least 90 seconds before working on vehicle.
Rotate crankshaft clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Ensure timing marks on camshaft sprockets are aligned with timing marks on No. 3 timing belt cover. See Fig. 2. Remove retaining bolts and timing belt tensioner.
346
LEXUS 2.5L & 3.0L V6 1990-98 (Cont.)

Installation (2.5L & 1992-93 3.0L V6): Install No. 1 idler pulley (if removed). Apply Loctite 242 on threads of No. 1 idler pulley retaining bolt. Install and tighten retaining bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates smoothly. Install timing belt on crankshaft sprocket with installation mark on timing belt aligned with timing mark on crankshaft sprocket. See Fig. 2. Install timing belt guide with cupped side away from crankshaft sprocket. Install No. 1 timing belt cover and gasket. Align crankshaft key with key groove of crankshaft pulley and install crankshaft pulley. Tighten retaining bolt to specification.
CAUTION: If reusing timing belt, ensure timing mark on crankshaft sprocket is aligned with reference mark placed on timing belt, and timing belt is installed in original direction of rotation.
Install Camshaft Sprocket Holder (SST 09278-54012) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets. Using Pulley Holder (SST 09213-54014) or equivalent, and Handle (SST 0933000021), hold crankshaft pulley, and remove retaining bolt. If timing belt is to be reused, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley is aligned with 0 mark on No.1 timing belt cover. Using puller, remove crankshaft pulley. DO NOT allow crankshaft to rotate. Remove No. 1 timing belt cover and gasket. If timing belt is to be reused, mark direction of belt rotation, and place reference marks on timing belt and crankshaft sprocket for reassembly reference. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide and timing belt. Remove idler pulleys (if necessary). Removal (1994-98 3.0L V6): Disconnect negative battery cable. Remove coolant reservoir. Raise and support vehicle. Remove right side front wheel. Remove right lower engine cover. Remove accessory drive belts. Remove engine stabilizer rod, engine mounting bracket and right engine mount brace, located near timing belt cover. Remove the alternator bracket for access to timing belt covers. Remove No. 2 timing belt cover. See Fig. 1. Use Pulley Holder (SST 09213-54015) or equivalent, and Handle (SST 0933000021) or equivalent, to hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 timing belt cover. See Fig. 1. Remove engine mounting bracket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). Remove retaining bolts, timing belt tensioner and dust boot. Remove crankshaft pulley bolt from crankshaft. Install camshaft sprocket holder (SST 09278-54012) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets. Inspection (2.5L & 3.0L V6): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body. Press rod against solid surface. Replace timing belt tensioner if rod moves. 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" (10.0110.49 mm).
Install No. 2 idler pulley. Tighten retaining bolt to specification. Ensure idler pulley rotates smoothly. Rotate crankshaft pulley so timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Rotate left camshaft so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. Rotate right camshaft so knock pin hole in camshaft aligns with timing mark on No. 3 timing belt cover. See Fig. 2. If reusing timing belt, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover. Using camshaft sprocket holder, slightly rotate left camshaft sprocket clockwise, and install timing belt on camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket.
Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)
LEXUS 2.5L & 3.0L V6 1990-98 (Cont.)

Using camshaft sprocket holder, slightly rotate left camshaft sprocket, and align timing mark on camshaft sprocket with timing mark on No. 3 timing belt cover. Ensure tension exists on timing belt between crankshaft sprocket and left camshaft reference mark on timing belt with timing mark on right camshaft sprocket. Install right camshaft sprocket on camshaft with flange side toward cylinder head. Ensure timing mark on right camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. Using camshaft sprocket holder, slightly rotate right camshaft sprocket so knock pin hole in camshaft sprocket aligns with knock pin hole in camshaft. Install knock pin in right camshaft. Install right camshaft sprocket retaining bolt, and tighten it to specification. See TORQUE SPECIFICATIONS.
347
Place washer on bottom side of timing belt tensioner. Using press, apply pressure on rod of timing belt tension until rod is retracted, and holes in rod and housing are aligned. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press, and install dust boot on timing belt tensioner. Install timing belt tensioner. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS. Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. Ensure timing marks on camshaft sprockets align with those on No. 3 timing belt cover. See Fig. 2.
CAUTION: Crankshaft must always be rotated clockwise. DO NOT rotate crankshaft counterclockwise.
To install remaining components, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Installation (1994-98 3.0L V6): Install timing belt plate. Install and tighten bolt to specification. Install No. 1 and No. 2 idler pulleys (if removed). Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Using camshaft sprocket holder, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3. Align reference marks on timing belt with dot on crankshaft sprocket and timing marks on camshaft sprocket. Ensure front mark is pointing toward timing belt end of engine.
CAUTION: Ensure reference marks on timing belt align with timing mark on camshaft sprockets and dot on crankshaft sprocket when installing timing belt. Front mark must face toward timing belt end of engine.
Fig. 3: Aligning Timing Marks (1994-98 3.0L)
Fig. 4: Identifying Timing Belt Reference Marks (1994-98 3.0L)
Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then on No. 1 idler pulley. Using press, apply pressure on rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification. Using new gaskets, install No. 1 and No. 2 timing belt covers. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS.
348
LEXUS 2.5L & 3.0L V6 1990-98 (Cont.)

TORQUE SPECIFICATIONS (2.5L V6) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 80 (109) Crankshaft Pulley Bolt ............................................ 181 (245) Engine Crossmember-To-Body Bolt .......................... 29 (39) Engine Mount Through-Bolt ........................................ 64 (87) Engine Mount-To-Engine Crossmember Bolt .................................................. 54 (73) Idler Pulley Bolt No. 1 Idler Pulley ....................................................... 25 (34) No. 2 Idler Pulley ....................................................... 29 (39) Idler Pulley Support Bolt ............................................. 13 (18) Right (Timing Belt Side) Engine Mount Bolt ........................................................................... 47 (64) Nut Bracket Side .......................................................... 38 (52) Body Side .............................................................. 65 (88) Timing Belt Tensioner Bolt ......................................... 20 (27) Water Pump Bolt ........................................................ 14 (19) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt ......................................... 65 (7) Valve Cover Nut ............................................................ 52 (6) TORQUE SPECIFICATIONS (3.0L V6) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 94 (127) Crankshaft Pulley Bolt ............................................ 159 (215) Front Engine Mount-To-Crossmember Bolt Toyota Motor Corporation Bolt .................................. 59 (80) Toyota Motor Manufacturing Bolt ............................... 49 (66) Front Engine Mount-To-Cylinder Block Bolt .................................................................. 47 (64) Power Steering Pump Bolt .......................................... 31 (42) Power Steering Pump Bracket To-Cylinder Head Bolt .............................................. 32 (43) Pulsation Damper ...................................................... 24 (33) Right Engine Mount Brace Bolt ................................... 23 (31) Stabilizer Bar Link-To Lower Control Arm Nut ............................................. 29 (39) Timing Belt Idler Pulleys No. 1 Idler Pulley Bolt ............................................... 25 (34) No. 2 Idler Pulley Bolt ............................................... 32 (43) Timing Belt Tensioner Bolt ......................................... 20 (27) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) No. 1 & 2 Timing Belt Cover Bolt ................................ 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)
Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 5: Measuring Timing Belt Tensioner Rod Protrusion
Fig. 6: Retracting Timing Belt Tensioner Rod
LEXUS 3.0L V6 1999-01

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 1MZFE ES300 1999-01 ................. 3.0 Hours .................. 250257 RX300 1999-01 ................. 4.4 Hours .................. 250257
349
Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing upward. Press rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 4. Replace timing belt tensioner if distance is not .394.425" (10.01-10.8 mm).

NOTE: Engine should be cold when installing timing belt.

TIMING BELT
Removal (ES300): Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. Remove engine stabilizer rod, engine mounting bracket and right engine mount brace, located near timing belt cover. Remove generator-to-engine bracket for access to timing belt covers. Using Pulley Holder (SST 09213-54015) or equivalent, and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and No. 2 timing belt covers and gaskets. See Fig. 1. Remove engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide.
NOTE: Always turn crankshaft clockwise, as viewed from timing belt side of engine.
Installation (ES300): Install No. 1 and No. 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket (front of vehicle side), No. 2 idler pulley, right camshaft sprocket (firewall side), and then on No. 1 idler pulley. If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. Using press, SLOWLY apply about 200-2200 lbs. of pressure on push rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 5. Align holes in housing and push rod to hold rod in retracted position. Install hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner.
Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 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 direction of rotation. 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): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Check water pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with push rod facing downward.
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. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install generator bracket. Install engine mount brace and stabilizer rod. Install fender apron seal and right front wheel. To install remaining components, reverse removal procedure. Tighten fasteners to specification. Connect engine ground strap. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (RX300): Remove the outer cowl top panel along with ventilation louvers and windshield wiper arm assembly. See Fig. 6. Remove shock tower suspension brace. Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Remove cruise control actuator from right side engine compartment. Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. Remove engine stabilizer rod and engine mounting bracket, located near timing belt cover. Remove generator-to-engine bracket for access to timing belt covers. Using Pulley Holder (SST 09213-54015) or equivalent, and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. Remove engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide.

Fig. 3: Identifying Timing Belt Reference Marks & Front Mark
Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. 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 direction of rotation.
Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS. 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 reinstall. Remove crankshaft pulley bolt. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification.
LEXUS 3.0L V6 1999-01 (Cont.)
351
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): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Inspect water pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with push rod facing downward.
Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with push rod facing upward. Press rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of timing belt tensioner housing. See Fig. 4. Replace timing belt tensioner if distance is not .394.425" (10.01-10.8 mm). Installation (RX300): Install No. 1 and No. 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 2. Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2.
Fig. 6: Exploded View Of Outer Cowl Top Panel (RX300)
Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket (front of vehicle side), No. 2 idler pulley, right camshaft sprocket (firewall side), and then on No. 1 idler pulley. If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. Using press, SLOWLY apply about 200-2200 lbs. of pressure on push rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 5. Align holes in housing and push rod. Install hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS.
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 reinstall. Remove crankshaft pulley bolt. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Using new gaskets, install No. 1 and No. 2 timing belt covers. Ensure there are no gaps in gasket. Cut off excess gasket. Install and tighten bolts to specification. Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install generator bracket. Connect engine ground strap. Install engine mount brace and stabilizer rod. Install cruise control actuator (if equipped). Install right hand fender apron seal. Install front wheel. Install shock tower suspension brace. Install outer cowl top panel. To install remaining components, reverse removal procedure. Tighten fasteners to specification. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
352
LEXUS 3.0L V6 1999-01 (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt Left Hand (Front End of Vehicle Side) ......................... 94 (125) Right Hand (Firewall Side of Vehicle) ........................... 65 (88) Crankshaft Pulley Bolt ............................................ 159 (215) Engine Mount Bracket-To-Engine Bolts .......................... 21 (28) Engine Stabilizer Rod Bolts ............................................ 47 (64) Generator Adjusting Lock Bolt ........................................ 13 (18) Generator Pivot Bolt ........................................................ 41 (56) Power Steering Pump Bolt .......................................... 32 (43) Power Steering Pump Bracket To-Cylinder Head Bolt .............................................. 32 (43) 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) No. 2 Idler Pulley Bolt ............................................... 32 (43) Timing Belt Tensioner Bolt ......................................... 20 (27) Wheel Lug Nut .......................................................... 76 (103) Wiper Arm Nuts .............................................................. 18 (24) INCH Lbs. (N.m) 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) Water Pump Bolt/Nut ........................................................ 71 (8) 1 - Apply Loctite 242 or equivalent to bolt threads.
LEXUS 3.0L 6-Cylinder 1993-97

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L 6-Cyl. GS300 1993-97 ................. 3.4 Hours .................. 250215 SC300 1993-97 ................. 3.4 Hours .................. 250215
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Inspection: Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3 . Replace timing belt tensioner if distance is not .315-.343" (8.00-8.80 mm).
NOTE: Tlming belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner

Removal: Disconnect battery cables and remove battery. Drain cooling system. Place reference mark on fan clutch and water pump for reassembly reference. Remove drive belt, cooling fan, fan clutch and water pump pulley. Remove radiator and lower engine cover. Remove oil filler cap, No. 2 and No. 3 timing belt covers, gaskets and drive belt tensioner. See Fig. 1. Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Timing marks on camshaft sprockets must align with timing marks on No. 4 timing belt cover. See Fig. 2. If conditions are not as described, rotate crankshaft clockwise one complete revolution clockwise.
CAUTION: If reusing timing belt, place arrow on timing belt to indicate direction of rotation. Place reference mark on timing belt and each camshaft sprocket for reassembly reference.
Installation: Install idler pulley and plate washer (if removed). Apply Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 2. Install timing belt on crankshaft sprocket.
CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft sprocket align and timing belt is installed in original direction of rotation.
Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner and dust boot. See Fig. 1. Remove timing belt from camshaft sprockets. Using Handle (SST 09330-00021) or equivalent, and Pulley Holder (SST 0921370010), or equivalent, hold crankshaft pulley and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide.
Install timing belt guide with cupped side away from crankshaft sprocket and flat side against timing belt. Install gaskets and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. If installing camshaft sprocket, align hole in camshaft sprocket with dowel pin in camshaft. Install camshaft sprocket. Hold camshaft sprocket with sprocket holder, and tighten bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Using sprocket holder, rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 2. Install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets.
CAUTION: If reusing timing belt, ensure reference marks on timing belt and camshaft sprockets align and timing belt is installed in original direction of rotation.
CAUTION: If reusing timing belt, place reference mark on timing belt and crankshaft sprocket tor reassembly reference.
Remove timing belt. Remove bolt, idler pulley and plate washer (if necessary).
Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 3. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 4. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.
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LEXUS 3.0L 6-Cylinder 1993-97 (Cont.)
CAUTION: Always rotate crankshaft clockwise. DO NOT rotate crankshaft counterclockwise.
Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate crankshaft counterclockwise. Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................... 36 (49) Nut ............................................................................ 22 (30) Air Intake Chamber Bolt/Nut ....................................... 13 (18) Camshaft Sprocket Bolt ............................................ 80 (109) Crankshaft Pulley Bolt ............................................ 181 (245) Distributor Housing Bolt ............................................. 13 (18) Drive Belt Idler Pulley Bolt ........................................... 27 (37) Drive Belt Tensioner Bolt/Nut ...................................... 12 (16) Power Steering Pump Bolt ........................................................................... 29 (39) Nut ............................................................................ 32 (43) Power Steering Pump Pulley Nut ................................ 32 (43) Pulsation Damper ...................................................... 29 (39) Spark Plug .................................................................. 13 (18) Timing Belt Tensioner Bolt ......................................... 20 (27) Water Pump Bolt/Nut .................................................. 13 (18) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt ............................... 57 (6.4) Valve Cover Bolt ......................................................... 52 (5.9)
Courtesy of Toyota Motor Sales, U.S.A, Inc.
LEXUS 3.0L 6-Cylinder 1998-2001

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L 6-Cyl. 2JZ-GE GS300 1998-01 ................. 3.4 Hours .................. 250215 SC300 1998-00 ................. 3.4 Hours .................. 250215
355
Timing marks on camshaft timing pulleys must align with timing marks on timing belt cover. See Fig. 1. If not, rotate crankshaft clockwise one complete revolution (360 degrees).
CAUTION: Crankshaft must be correctly positioned by aligning sub-timing mark with 0 mark on timing belt cover to prevent valves from contacting pistons.

Rotate crankshaft pulley 60 degrees counterclockwise. Align sub-timing mark with 0 mark on timing belt cover. See Fig. 3, STEP 1. Ensure the dot marks of camshaft timing pulleys are aligned with the timing marks of No. 4 timing belt cover. See Fig. 3, STEP 2.

Removal: Raise and support vehicle. Remove engine undercover. Drain cooling system. On GS300, remove air cleaner inlet, air cleaner, and MAF assembly. Remove radiator and electric cooling fan assembly. On 1999-98 models, rotate serpentine drive belt tensioner counterclockwise and remove belt. Tensioner bolt is left-hand threaded. On 2001-00 models, rotate tensioner clockwise to remove serpentine belt. On SC300, remove battery and battery tray. Drain coolant. Remove lower fan shroud. Remove radiator. Loosen 4 nuts holding fan clutch to water pump. Rotate serpentine drive belt tensioner bolt clockwise, and remove drive belt. Remove cooling fan, fan clutch, and water pump pulley. On all models, remove power steering pump front bracket. Remove pump with hoses attached, and hang out of way. Remove No. 2 and No. 3 timing belt covers and gaskets. See Fig. 2. Remove serpentine drive belt tensioner. Using Handle (SST 09330-00021) and Pulley Holder (SST 09213-70010) or equivalent to hold crankshaft pulley, loosen crankshaft pulley bolt. Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. See Figs. 1 and 3.
CAUTION: It reusing timing belt, place arrow on timing belt to indicate direction of rotation. Place reference mark on timing belt and each camshaft timing pulley for reassembly reference.
DO NOT allow the crankshaft pulley to rotate, and remove crankshaft pulley bolt. Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner, and dust boot. See Fig. 2. Remove timing belt from camshaft sprockets. Remove crankshaft pulley using gear puller. Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference (flat side toward timing belt). See Fig. 2. Remove timing belt guide. If reusing timing belt, place mating reference marks on timing belt and crankshaft sprocket. Remove timing belt. Inspection: Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner pulley for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.
NOTE: Timing belt tensioner may have a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner.
Hold timing belt tensioner body, and press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .315-.346" (8.008.80 mm). Installation: Install idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft timing pulley with timing mark on oil pump body. See Fig. 3, STEP 3. Clean oil or water off of crankshaft timing pulley, and install timing belt on crankshaft timing pulley and around idler pulley.
CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft timing pulley align, and timing belt is installed in original direction of rotation.
Install timing belt guide with cupped side away from crankshaft 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.
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Fig. 2: Exploded View Of Typical Timing Belt & Components
Ensure sub-timing mark (60 degrees BTDC) of crankshaft pulley is aligned with 0 timing mark of No. 1 timing belt cover. See Fig. 3, STEP 4. Temporarily install crankshaft pulley bolt.
CAUTION: If reusing timing belt, ensure reference marks on timing belt and camshaft timing pulleys align and timing belt is installed in original direction of rotation.
If necessary, use spanner wrench to rotate camshaft timing pulleys so timing marks on camshaft timing pulleys align with timing marks on No. 4 timing belt cover. See Fig. 1. Install timing belt on camshaft timing pulleys. Ensure tension exists on timing belt between camshaft timing pulleys. Using press, SLOWLY apply pressure on push rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 5.
357
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 tensioner. Alternately tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.
Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. Ensure timing marks on camshaft timing pulleys align with timing marks on timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. If timing marks are not aligned, remove timing belt and reinstall. 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 SPECIFICATIONS. Fill and bleed air from cooling system. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Timing Pulley Bolt ...................................... 60 (81) Crankshaft Pulley Bolt ............................................ 243 (330) 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) Timing Belt Tensioner Bolt ......................................... 20 (27) 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 - Apply Loctite 242 or equivalent to bolt threads.
Fig. 3: Aligning Sub-Timing Marks
358
LEXUS 4.0L V8 1990-97
Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on left side when viewed from rear of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. See Fig. 1. Timing marks on camshaft sprockets must align with timing marks on timing belt rear plates. See Fig. 1. If timing marks are not aligned, rotate crankshaft clockwise one complete revolution. Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner and dust boot. See Fig. 3. Using Sprocket Holder (SST 09278-54012) or equivalent, slightly rotate right camshaft sprocket clockwise to release tension on timing belt. Remove timing belt from camshaft sprockets. Using Pulley Holder (SST 09213-70010) or equivalent and Handle (SST 0933000021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. On LS400, remove bolts/nuts and fan bracket. On SC400, remove bolts/nuts and hydraulic pump. On all models, remove No. 1 timing belt cover, gaskets, timing belt cover spacer and gasket. See Fig. 3. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. Remove timing belt. Remove bolt, idler pulleys and plate washer (if necessary).
TIMING BELT APPLICATION Application Labor Time Belt Part No. 4.0L V8 LS400 1990-97 ................. 4.5 Hours .................. 250190 SC400 1992-97 ................. 4.8 Hours .................. 250190

For 1990-94 model years, although the manufacturer does not recommend a specific scheduled maintenance interval for normal operating conditions, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. The manufacturer recommends the belt be replaced at 60,000 miles or 96 months or severe operating conditions. For 1995-97 model years, the manufacturer recommends the belt be replaced at 90,000 miles for normal service and 60,000 miles for severe service.

CAUTION: If reusing timing belt, ensure installation mark exists at crankshaft sprocket. If installation mark does not exist, place installation mark on timing belt and crankshaft sprocket.
Removal: Remove battery. Remove lower engine cover Drain cooling system. On LS400, remove air duct located above top of radiator and air cleaner cover. Remove air cleaner assembly. Remove V-bank cover. Remove drive belt, fan clutch assembly and fan pulley. On SC400, rotate drive belt tensioner counterclockwise. Remove drive belt. Remove coolant reservoir. On all models, remove radiator. Remove A/C compressor with hoses attached and secure aside. Remove air intake pipe between air cleaner hose and throttle body. Remove upper spark plug wiring cover. Remove engine wiring covers located near valve covers. Remove No. 3 (upper) timing belt covers. Remove spark plug wire clamps. Disconnect spark plug wires from distributor caps. Disconnect high-tension wire from ignition coils. Remove spark plug wires and clamps. See Fig. 2. Remove bolt, plate and drive belt idler pulley. Remove left (drivers side) ignition coil. Disconnect cam position sensor electrical connector from clamp on No. 2 timing belt cover. Remove bolts, No. 2 timing belt covers and gaskets. See Fig. 3. It may be necessary to remove coolant pipe to access No. 2 timing belt covers. Remove bolts, distributor caps and rotors. Mark component location for reassembly reference. Disconnect electrical 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).
Inspection: Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation. Replace idler pulleys if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.
NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner.
Hold timing belt tensioner body and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .413-.453" (10.50-11.50 mm).
Fig. 1: Checking Camshaft Timing Mark Alignment
LEXUS 4.0L V8 1990-97 (Cont.)

Installation: Install No.1 idler pulley and plate washer (if removed). Apply Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Install No. 2 idler pulley and bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Ensure idler pulley bracket moves freely. Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. Install timing belt on crankshaft sprocket so CR installation mark on timing belt aligns with dot on crankshaft sprocket. See Fig. 5. Install timing belt on No.1 and then No. 2 idler pulley. Install timing belt guide with cupped side away from crankshaft sprocket. Flat side should be against timing belt. Install gasket and timing belt cover spacer. Install gaskets and No. 1 timing belt cover. On LS400, install fan bracket. Install and tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS. On SC400, install hydraulic pump. Install and tighten bolts/ nuts to specification. See TORQUE SPECIFICATIONS. On all models, align crankshaft key with key groove of crankshaft pulley. Using hammer and Pulley Installer (SST 0922346011) or equivalent, install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS.
CAUTION: Ensure camshaft sprocket is installed with identification mark facing forward, toward timing belt end of engine. Identification mark is located on camshaft sprocket, below timing belt area. Right camshaft sprocket contains an R identification mark, and left camshaft sprocket contains an L identification mark.
359
Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten bolts to specification. See TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft clockwise as viewed from front of engine. DO NOT rotate crankshaft counterclockwise.
Remove hexagon wrench from timing belt tensioner. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets align with timing marks on timing belt rear plate. See Fig. 1. If timing marks are not aligned, remove timing belt and reinstall. To install remaining components, reverse removal procedure. Ensure distributor housings are installed in correct location according to identification mark on front of distributor housing. Right distributor housing (viewed from rear of engine) contains an R identification mark. Left distributor housing contains an L identification mark. Install rotors so rotor protrusion aligns with camshaft sprocket groove. See Fig. 7. Ensure spark plug wires are properly positioned and installed in retainers. See Fig. 2. Tighten all bolts/nuts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Using sprocket holder, rotate camshaft sprockets and align timing marks on camshaft sprockets with timing marks on timing belt rear plate. See Fig. 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 timing mark on timing belt rear plate. See Fig. 1. Align installation 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 camshaft sprocket still aligns with timing mark on timing belt rear plate. Ensure tension exists on timing belt between right and left camshaft sprockets. Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing arealigned. See Fig. 6.
Fig. 2: Removing/Installing Spark Plug Wires & Retainers
360
LEXUS 4.0L V8 1990-97 (Cont.)
LEXUS 4.0L V8 1990-97 (Cont.)
361
Fig. 7: Installing Rotors
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................... 36 (49) Nut ............................................................................ 22 (30) Air Intake Chamber Bolt/Nut ....................................... 13 (18) Camshaft Sprocket Bolt ............................................ 80 (109) Crankshaft Pulley Bolt ............................................ 181 (245) Distributor Housing Bolt ............................................. 13 (18) Drive Belt Idler Pulley Bolt ........................................... 27 (37) Drive Belt Tensioner Bolt/Nut ...................................... 12 (16) Power Steering Pump Bolt ........................................................................... 29 (39) Nut ............................................................................ 32 (43) Pulsation Damper ...................................................... 29 (39) Power Steering Pump Pulley Nut ................................ 32 (43) Spark Plug .................................................................. 13 (18) Timing Belt Tensioner Bolt ......................................... 20 (27) Water Pump Bolt/Nut .................................................. 13 (18) INCH Lbs. (N.m) Crankshaft Position Sensor Bolt ............................... 57 (6.4) Valve Cover Bolt ......................................................... 52 (5.9)
Fig. 5: Identifying Timing Belt Installation Marks
362
LEXUS *4.0L V8 1998-00

Using Pulley Holder (SST 09213-70010) or equivalent and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley. Loosen, but do not remove crankshaft pulley bolt. Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on left side when viewed from rear of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. See Fig. 1. Timing marks on camshaft sprockets must align with timing marks on timing belt rear plates. See Fig. 1. If timing marks are not aligned, rotate crankshaft CLOCKWISE one complete revolution. Rotate crankshaft clockwise about 50 degrees clockwise. Place timing mark on crankshaft pulley in line with centers of crankshaft pulley bolt and No. 2 timing belt idler pulley bolt. See Fig. 3.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 4.0L V8 GS400 1998-00 ................. 4.5 Hours .................. 250298 LS400 1998-00 ................. 4.5 Hours .................. 250298 SC400 1998-00 ................. 4.8 Hours .................. 250298

The manufacturer recommends the belt be replaced at 90,000 miles or 72 months.
CAUTION: If timing belt is disengaged, having crankshaft at incorrect angle can cause piston to contact valves while removing crankshaft pulley.

Removal: Disconnect negative battery cable. Remove lower engine cover. Drain cooling system. Remove air cleaner inlet. Remove V bank cover from top of engine. Remove air cleaner assembly and intake air connector pipe. On all models, drain engine coolant. Remove upper radiator hose. On GS400 and LS400, remove serpentine drive belt by turning drive belt tensioner pulley bolt counterclockwise. Tensioner pulley bolt is LEFT HAND threaded. On SC400, turn serpentine drive belt tensioner bolt CLOCKWISE to relieve tension. On LS400, remove fan and fan clutch and fan pulley. On GS400, remove electric cooling fan assembly. On SC400, disconnect hydraulic fan motor pressure and return pipes from fan. Disconnect cooling fan inlet pipe and reservoir tank from fan shroud. On all models, remove the radiator assembly. Remove No. 2 drive belt idler pulley. See Fig. 2. Disconnect camshaft position sensor wiring connector from No. 3 left side belt cover. Move engine wiring harness out of way and remove No. 3 left side (driver side) belt cover. See Fig. 2. On GS400 and LS400, disconnect power steering air hose from clamp on No. 3 right side belt cover. On LS400, disconnect coolant reservoir-to-engine pipe from in front of No. 3 right side belt cover. On all models, remove No. 3 right side (passenger side) belt cover. See Fig. 2. Remove A/C compressor from engine mount with hoses attached. Move A/C compressor out of way. On GS400, remove No. 1 drive belt idler pulley and mount from engine. See Fig. 2. On LS400, remove fan bracket from front of engine. On SC400, remove fan hydraulic pump from front of engine. See Fig. 7.
CAUTION: If reusing timing belt, check that there are 3 mating marks on belt to show installed position on crankshaft and camshaft timing pulleys. If marks are missing, place installation mating marks on timing belt and camshaft and crankshaft pulleys. Also, mark belt with arrow to indicate original direction of rotation.
Fig. 1: Crankshaft & Camshaft Timing Mark Alignment
Without moving crankshaft pulley, remove pulley bolt. Alternately loosen 2 bolts, and remove timing belt tensioner. DO NOT hold timing belt tensioner with push rod facing downward. See Fig. 2. Using spanner wrench, slightly rotate right side camshaft pulley clockwise to relieve tension on timing belt. Remove timing belt from camshaft pulleys. On GS400, remove power steering pump pulley bolt and pulley. On all models, remove generator. Remove serpentine drive belt tensioner. Using gear puller, remove crankshaft pulley without rotating crankshaft. Remove No. 1 timing belt cover. See Fig. 4. Noting installed direction for reassembly reference, remove timing belt guide from end of crankshaft. Remove timing belt cover spacer.
LEXUS *4.0L V8 1998-00 (Cont.)
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Fig. 2: Exploded View Of Timing Belt Covers (GS400 Shown; Others Similiar)
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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: Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation and oil seal leakage. Replace idler pulleys if defective.
CAUTION: Never hold timing belt tensioner facing downward. NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner.
Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if there are excessive oil leaks. Hold timing belt tensioner body with push rod facing UPWARD. Press push rod against solid surface. Replace timing belt tensioner if push rod moves. Measure timing belt tensioner push rod protrusion from end of rod to edge of housing. See Fig. 5. Replace timing belt tensioner if distance is not .413-.453" (10.50-11.50 mm). Inspect water pump for leaks or worn bearing. Installation: Install No.1 idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley pivot bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. If removed, install No. 2 idler pulley and bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Ensure idler pulley bracket moves freely.
Fig. 4: Exploded View Of Timing Belt & Idler Pulleys
Clean any oil or water off of crankshaft timing pulley. DO NOT use solvent. Temporarily Install timing belt on crankshaft timing pulley, No. 1 idler pulley, and No. 2 idler pulley. If reusing old belt, ensure mating mark on timing belt aligns with mark on crankshaft timing pulley. Install timing belt guide in original direction on end of crankshaft. Install gasket and timing belt cover spacer. Install gaskets and No. 1 timing belt cover. Without rotating crankshaft, align crankshaft key with key groove of crankshaft pulley. Using hammer and Pulley Installer (SST 09223-46011) or equivalent, install crankshaft pulley. Install serpentine drive belt tensioner. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install generator. On GS400, install power steering pump pulley. On all models, ensure crankshaft is still at 50 degrees ATDC position. See Fig. 3.
Ensure camshaft timing pulleys are still aligned with mating marks on rear plate. See Fig. 1. Clean camshaft timing pulleys (do not use solvent). Install timing belt on left side (drivers side) camshaft pulley. If reusing old timing belt, ensure mating mark on belt aligns with mark on left side camshaft pulley. Using spanner wrench, turn left side camshaft pulley until there is tension on timing belt between crankshaft timing pulley and left side camshaft pulley. Install timing belt on right side camshaft pulley. If reusing old belt, ensure mating mark on belt aligns with mark on right side camshaft pulley. Ensure there is tension on timing belt between left side and right side camshaft pulleys. Using press, SLOWLY apply about 200-2205 lbs. of pressure on push rod of timing belt tensioner until rod is retracted. Ensure timing belt tensioner is held with push rod facing upward. Holes in push rod and housing must be aligned. See Fig. 6. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten bolts to specification. See TORQUE SPECIFICATIONS.
CAUTION: Always rotate crankshaft clockwise as viewed from front of engine. DO NOT rotate crankshaft counterclockwise.
Remove hexagon wrench from timing belt tensioner. Temporarily install crankshaft pulley bolt. Slowly rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure
LEXUS *4.0L V8 1998-00 (Cont.)
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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. Tighten crankshaft pulley bolt to specification. On GS400, install No. 1 drive belt idler pulley. On LS400, install fan bracket. On SC400, install fan hydraulic pump and attach lines. On all models, install A/C compressor. Install No. 2 timing belt cover. Install No. 3 timing belt covers. Connect camshaft position sensor electrical connectors. Install serpentine 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 until engine is warm. Stop engine. When engine is cool, refill coolant reservoir. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ........................................................................... 36 (49) Nut ............................................................................ 22 (30) Crankshaft Pulley Bolt ............................................ 181 (245) Drive Belt Idler Pulley Bolt ........................................... 27 (37) Drive Belt Tensioner Bolt/Nut ...................................... 12 (16) Fan Bracket-To-Engine Bolts (LS400) 12 mm Head ................................................................ 12 (16) 14 mm Head ................................................................ 24 (32) Generator Pivot & Lock Bolt ............................................ 29 (39) Hydraulic Pump-To-Engine Bolts (SC400) 12 mm Head ................................................................ 12 (16) 14 mm Head ................................................................ 24 (32) No. 1 Drive Belt Idler Pulley Mount-To-Engine Bolts (GS400) 12 mm Head ................................................................ 12 (16) 14 mm Head ................................................................ 24 (32) No. 2 Timing Belt Cover Bolt .......................................... 12 (16) No. 1 Timing Belt Idler Pulley Pivot Bolt ........................ 1 25 (35) No. 2 Timing Belt Idler Pulley Bolt .................................. 25 (35) Power Steering Pump Bolt ........................................................................... 29 (39) Nut ............................................................................ 32 (43) Power Steering Pump Pulley Center Nut GS400 .......................................................................... 32 (43) Spark Plug .................................................................. 13 (18) Timing Belt Tensioner Bolt ......................................... 19 (26) 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.
Courtesy ofToyota Motor Sales, U.S.A., Inc.
Fig. 7: Timing Belt Components (LS400 & SC400)
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LEXUS & TOYOTA *4.7L V8
TIMING BELT APPLICATION Application Labor Time Belt Part No. 4.7L V8 Land Cruiser 1998-01 ................. 4.5 Hours .................. 250298 LX470 1998-01 ................. 4.5 Hours .................. 250298 Tundra 2000-01 ................. 4.5 Hours .................. 250298

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

Removal (Land Cruiser & LX470): Raise and support vehicle. Remove lower engine cover. Drain cooling system. Remove intake manifold cover located 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.
CAUTION: If reusing timing belt, ensure installation mark exists at crankshaft and camshaft sprockets. If installation mark does not exist, place mating marks on timing belt and crankshaft sprocket. See Fig. 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 timing belt rear plates. See Fig. 2. If timing marks are not aligned, rotate crankshaft clockwise one full revolution. Realign crankshaft pulley groove with 0 timing mark on No. 1 (lower) timing belt cover.
CAUTION: Crankshaft must be properly positioned BEFORE removing timing belt to prevent pistons from hitting valves. DO NOT allow engine to rotate when removing crankshaft pulley bolt.
LEXUS & TOYOTA *4.7L V8 (Cont.)
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Remove serpentine drive belt tensioner. See Fig. 1. Remove generator. Without letting crankshaft rotate, use puller to remove crankshaft pulley. Remove No. 1 timing belt cover. Noting direction of timing belt guide for installation reference, remove timing belt guide 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): Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation. Replace idler pulleys if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.
NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. NEVER hold timing belt tensioner with push rod facing DOWNWARD.
Fig. 2: Locating Timing Belt Alignment Marks
Using crankshaft pulley bolt, rotate crankshaft clockwise (viewed from front of engine) about 50 degrees ATDC. This will align crankshaft pulley groove with centerline of crankshaft pulley bolt and No. 2 idler pulley bolt. See Fig. 3. This prevents valves from contacting pistons. Remove crankshaft pulley bolt. Alternately loosen bolts and remove timing belt tensioner and dust boot. Using spanner wrench in holes in camshaft sprocket, slightly rotate passengers side camshaft sprocket clockwise to release timing belt tension. Remove timing belt from camshaft sprockets.
DO NOT allow tensioner push rod to face downward. Hold timing belt tensioner body and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .413-.453" (10.50-11.50 mm). Inspect water pump for leaks or bearing failure.
NOTE: Install timing belt with engine cold.
Fig. 3: Positioning Crankshaft Pulley
Installation (Land Cruiser & LX470): If No. 1 idler pulley was removed, apply Loctite 242 or equivalent to bolt threads. Ensure pulley bracket moves freely. Install timing belt on crankshaft sprocket. If reusing old belt, ensure match marks made on removal are properly aligned. Place timing belt around No. 1 and No. 2 idler pulleys. Install gasket and timing belt cover spacer. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install No. 1 timing belt cover. Align groove of crankshaft pulley with key in crankshaft. Tap crankshaft pulley until seated on crankshaft. Install serpentine drive belt tensioner. Install generator. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. 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 matching marks are aligned. Rotate drivers side camshaft sprocket counterclockwise until tension exists on timing belt between crankshaft sprocket and drivers side camshaft sprocket.
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Ensure passengers side camshaft sprocket timing mark is still aligned. Install timing belt on passengers side camshaft sprocket. If reusing old belt, ensure matching marks are aligned. See Fig. 6. Using press, SLOWLY apply about 220-2200 lbs. of pressure 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 alternately tighten bolts to specification.
CAUTION: When checking valve timing, only rotate crankshaft clockwise as viewed from front of engine. DO NOT rotate crankshaft counterclockwise.
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 sprockets align with timing marks on rear plates. If installing old belt, ensure belt matching marks are aligned with camshaft sprockets. If timing marks are not aligned, timing belt will have to be removed and repositioned. Tighten crankshaft pulley bolt to specification. Install fan bracket. Install A/C compressor to engine mount bracket. Install No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install radiator. Install cooling fan assembly. To install remaining components, reverse removal procedure. Tighten all fasteners to specification. Fill and bleed air from cooling system. Cooling System Bleeding: Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary. Removal (Tundra): Raise and support vehicle. Remove lower engine cover. Drain cooling system. Remove radiator assembly. Remove throttle body cover. Remove intake air connector assembly. Loosen 4 bolts holding fluid coupling to cooling fan bracket. See Fig. 1. Remove serpentine drive belt, cooling fan fluid coupling assembly, and fan pulley. Remove power steering pump from engine with hoses attached and secure out of way. Remove serpentine drive belt idler pulley. Remove No. 3 timing belt cover from front of passengers side camshaft.
Fig. 6: Installing Timing Belt On Camshaft Sprocket
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.
CAUTION: If reusing timing belt, ensure installation mark exists 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.

Ensure timing marks on camshaft sprockets align with marks on the timing belt rear plates. See Fig. 2. If timing marks are not aligned, rotate crankshaft clockwise one full revolution. Realign crankshaft pulley groove with 0 timing mark on No. 1 (lower) timing belt cover). Alternately loosen bolts and remove timing belt tensioner and dust boot. Using spanner wrench in holes in camshaft sprocket, slightly rotate passengers side camshaft sprocket clockwise to release timing belt tension. Remove timing belt from camshaft sprockets. Remove serpentine drive belt tensioner. See Fig. 1. Without letting crankshaft rotate, use puller to remove crankshaft pulley. Remove No. 1 timing belt cover. Noting direction of timing belt guide for installation reference, remove timing belt guide and timing belt cover spacer. Remove timing belt.
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Using press, SLOWLY apply about 220-2200 lbs. of pressure 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 alternately tighten bolts to specification.
CAUTION: When checking valve timing, only rotate crankshaft clockwise as viewed from front of engine. DO NOT rotate crankshaft counterclockwise.
CAUTION: DO NOT use solvent to clean crankshaft or camshaft sprockets. Wipe clean only.
Inspection (Tundra): Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulleys for smooth rotation. Replace idler pulleys if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.
NOTE: Timing belt tensioner may weep a small amount of oil on rod seal under normal conditions. If excessive amount of oil exists, replace timing belt tensioner. NEVER hold timing belt tensioner with push rod facing DOWNWARD.
DO NOT allow tensioner push rod to face downward. Hold timing belt tensioner body and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 4. Replace timing belt tensioner if distance is not .413-.453" (10.50-11.50 mm). Inspect water pump for leaks or bearing failure.
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 sprockets align with timing marks on rear plates. If installing old belt, ensure belt matching marks are aligned with camshaft sprockets. If timing marks are not aligned, timing belt will have to be removed and repositioned. Tighten crankshaft pulley bolt to specification. Install fan bracket. Install A/C compressor to engine mount bracket. Install No. 2 and No. 3 timing belt covers. Install drive belt idler pulley. Install radiator. Install cooling fan assembly. To install remaining components, reverse removal procedure. Tighten all fasteners to specification. Fill and bleed air from cooling system. Cooling System Bleeding: Fill cooling system. Install radiator cap. Move heater control to warmest position. Start engine. Maintain engine speed at 2000-2500 RPM until engine is at normal operating temperature. Shut engine off. Allow engine to cool. Recheck coolant level. Fill coolant level to FULL line on coolant reservoir if necessary. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Tensioner Bolt ............................... 12 (16) A/C Compressor-To-Mount Bolt ................................. 36 (49) Air Intake Chamber Bolt/Nut ....................................... 13 (18) Camshaft Sprocket Bolt ............................................ 80 (109) Cooling Fan Bracket 12 mm Head ................................................................ 12 (16) 14 mm Head ................................................................ 24 (32) Cooling Fan Fluid Coupling-To-Cooling Fan Bracket .................................................................. 16 (21) Crankshaft Pulley Bolt ............................................ 181 (245) Drive Belt Idler Pulley Bolt ........................................... 27 (37) Drive Belt Tensioner Bolt/Nut ...................................... 12 (16) Generator Bolt/Nut .......................................................... 12 (16) No. 1 & No. 2 Idler Pulley Bolts ..................................... 1 25 (35) No. 2 Timing Belt Cover Bolt .......................................... 12 (16) Radiator Bracket-To-Body Bolts ...................................... 12 (18) Spark Plug .................................................................. 13 (18) Timing Belt Tensioner Bolt ......................................... 19 (26) Water Pump Stud Bolt & Nut ........................................................... 13 (18) Bolt ............................................................................... 15 (21) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolts .................................... 66 (7.5) 1 - Apply Loctite 242 or equivalent to No. idler pulley bolt threads.
NOTE: Install timing belt with engine cold.
Installation (Tundra): If No. 1 idler pulley was removed, apply Loctite 242 or equivalent to bolt threads. Ensure pulley bracket moves freely. Install timing belt on crankshaft sprocket. If reusing old belt, ensure match marks made on removal are properly aligned. Place timing belt around No. 1 and No. 2 idler pulleys. Install gasket and timing belt cover spacer. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install No. 1 timing belt cover. Align groove of crankshaft pulley with key in crankshaft. Tap crankshaft pulley until seated on crankshaft. Install serpentine drive belt tensioner. Install generator. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Ensure the crankshaft pulley groove aligns with 0 timing mark on No. 1 timing belt cover. See Fig. 7. Ensure timing mark on drivers side camshaft sprocket is correctly aligned. See Fig. 6. Install timing belt on drivers side camshaft sprocket. If reusing old belt, ensure matching marks are aligned. Rotate drivers side camshaft sprocket counterclockwise until tension exists on timing belt between crankshaft sprocket and drivers side camshaft sprocket. Ensure passengers side camshaft sprocket timing mark is still aligned. Install timing belt on passengers side camshaft sprocket. If reusing old belt, ensure matching marks are aligned. See Fig. 6.
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MAZDA 1.5L 4-Cylinder
Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 3. Ensure timing belt deflection is .28-.35 (7.0-9.0mm). Ensure grooves on valve cover are free of oil, water, and dirt. Using new valve cover gasket, install valve cover. Tighten valve cover bolts in sequence. See Fig. 1. Complete installation in reverse of removal procedure. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 36-45 (49-61) Crankshaft Pulley-to-Pulley Boss Bolt ............... 9-13 (12-18) Crankshaft Pulley Boss Bolt ..................... 116-123 (157-167) Timing Belt Tensioner Bolt ............................... 27-38 (37-51) Wheel Lug Nuts ....................................................... 80 (110) INCH Lbs. (N.m) Timing Chain Adjuster Bolt ................................. 71-97 (8-11) Timing Cover Bolt ................................................... 71-97 (8-11) Valve Cover Bolt ...................................................... 62-97 (7-11)
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.5L 4-Cyl. Protege 1995-97 ................. 2.4 Hours ................. 250266 1998 Up To Engine No. 194742 ............... 2.4 Hours ................. 250266 From Engine No. 194743 ............... 2.4 Hours ................. 250308

The manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. 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 crankshaft pulley hub bolt and hub. Remove spark plug wires. Remove valve cover bolts in reverse order of tightening sequence. See Fig. 1. Remove valve cover. Remove dipstick tube. Remove upper timing belt cover. Support engine with jack. Remove engine mount bracket from timing belt end of engine. If timing belt is to be reused, mark timing belt rotation direction. Ensure timing marks on camshaft and crankshaft sprockets are aligned. See Fig. 2. Remove lower and middle timing belt covers. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully expanded. Remove timing belt. Inspection: Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring free length. Specified length is 2.80 (71mm). Replace parts as necessary. Installation: Position notch on crankshaft sprocket to 12 oclock position (aligned with mark on oil pump). Align timing marks on camshaft sprocket and crankshaft. See Fig. 2. Ensure crankshaft timing mark is at TDC of compression stroke. Install belt around crankshaft sprocket. Working in a counterclockwise direction, route belt around pulleys and camshaft sprocket. Loosen timing belt tensioner lock bolt and allow spring to apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete turns in direction of normal engine rotation. Ensure timing marks align. Letter Z on camshaft pulley and pin on crankshaft pulley boss should face upward. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure.
Courtesy of Mazda Motors Corp.
Fig. 1: Valve Cover Bolt Tightening Sequence
MAZDA 1.6L 4-Cylinder DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. DOHC Protege 1999-01 ................ 1 2.7 Hours ................. 250308 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
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For 1999-00 vehicles, the manufacturer recommends belt replacement interval at 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001 vehicles, the replacement interval is 105,000 miles, UNLESS the vehicle is operated in outside temperatures under 0F (-18C). Under this condition, replace timing belt at 60,000 miles.

TIMING BELT
Removal: Disconnect negative battery cable. Remove camshaft position 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. Remove timing belt. Inspection: Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Tensioner spring free length should be 2.43 (61.8 mm). Replace parts as necessary. Installation: Install tensioner spring with damper rubber closing face on side away from tensioner. See Fig. 3. Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 2. Temporarily secure tensioner with spring fully extended. Install belt around crankshaft sprocket, idler pulley, exhaust camshaft, intake camshaft, then tensioner.
Temporarily install crankshaft pulley boss and bolt. Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Rotate crankshaft clockwise almost 2 complete turns. Remove the crankshaft pulley boss bolt and pulley boss. Ensure the crankshaft timing belt pulley mark is aligned with tensioner set mark. See Fig. 4. If not, rotate crankshaft to align. While holding timing belt tensioner, tighten lock bolt to specification. See TORQUE SPECIFICATIONS. Install crankshaft boss and tighten bolt to specification. Turn crankshaft clockwise 2 revolutions. Face pin on crankshaft pulley boss straight up. Ensure camshaft sprocket timing marks are correctly aligned. See Fig. 2. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. Check timing belt deflection with 22 lbs. (10 kg) of downward pressure applied to belt, midway between camshaft sprockets. Timing belt deflection should be 0.24-0.29 (6.07.5 mm). If not, readjust timing belt tension. To complete installation, reverse removal procedure. When installing valve cover, tighten valve cover bolts in correct sequence. See Fig. 5. Adjust air gap between crankshaft plate and Crankshaft Position (CKP) sensor. With a plate tooth directly centered over CKP sensor, air gap should be 0.020-0.059 (0.5-1.54 mm). Adjust accessory drive belts to proper tension. See page A-60 for belt tension ranges.
372
MAZDA 1.6L 4-Cylinder DOHC (Cont.)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 37-44 (50-60) Crankshaft Pulley Boss Bolt ....................... 116-123 (157-167) Engine Mount Nut/Bolt ......................................... 44-59 (59-80) Engine Mount-To-Engine Bolt .............................. 50-68 (67-93) Idler Pulley Bolt ................................................... 28-38 (38-52) Timing Belt Tensioner Bolt .................................. 28-38 (38-52) INCH Lbs. (N.m) Camshaft Position Sensor Bolt ............................. 69-95 (8-11) Crankshaft Position Sensor Bolt ........................ 69-95 (8-11) Crankshaft Pulley-To-Pulley Boss Bolt ....... 109-151 (12.3-17.1) Timing Belt Cover Bolt ............................................ 69-95 (8-11) Water Pump Pulley Bolt .......................................... 69-95 (8-11)
Fig. 3: Installing Timing Belt Tensioner Spring
Fig. 4: Aligning Timing Belt At Tensioner Set Mark
MAZDA 1.6L & 1.8L 4-Cylinder 1988-95

TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 1.6L 4-Cyl. DOHC MX-3 1994-95 .......... 1 2.9 Hrs. .... 2521790 ........ 250179 MX-5 Miata 1990-93 ......... 1 3.0 Hrs. .... 2521790 ........ 250179 323 1988-89 .......... 1 2.8 Hrs. ........................... 250149 1.6L 4-Cyl. SOHC MX-3 1992-93 .......... 1 2.0 Hrs. ........................... 250185 323 1986 ............... 1 2.0 Hrs. ........................... 250123 1987-89 .......... 1 2.0 Hrs. .... 2521410 ........ 250141 1990-94 .......... 1 2.0 Hrs. ........................... 250185 1.8L 4-Cyl. DOHC Protege 1990-95 .......... 1 2.8 Hrs. .... 2521790 ........ 250179 1.8L 4-Cyl. SOHC Protege 1990-94 .......... 1 2.0 Hrs. ........................... 250185 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
373

For 1992 and earlier model years, the manufacturer recommends the belt be replaced every 60,000 miles. For 1993-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.
Removal (MX-3, Protege & 323): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right splash panels. Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary, and remove crankshaft pulley bolts and pulley. Remove crankshaft pulley hub bolt and hub. Remove timing belt covers. If timing belt is to be reused, mark timing belt rotation direction. Align timing marks on camshaft sprocket(s). See Figs. 5 and 6. Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove timing belt. Inspection (All Models): Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary. Installation (All Models): Position notch on crankshaft sprocket to 12 oclock position (aligned with mark on oil pump). Align timing marks on camshaft sprocket(s). See Figs. 5 and 6. Ensure crankshaft timing mark is at TDC. Install belt around crankshaft sprocket then working in a counterclockwise direction, route belt around camshaft sprocket(s). Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock bolt. Rotate crankshaft 2 complete turns in direction of normal engine rotation. Ensure timing marks align. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure. On all engines, check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 7. Ensure timing belt deflection is within specification. See TIMING BELT DEFLECTION. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.

TIMING BELT
Removal (MX-5 Miata): Disconnect negative battery cable. Drain cooling system. Remove radiator hose and by-pass hoses from thermostat housing. Remove air cleaner intake duct assembly from throttle body to air cleaner filter housing. Remove splash shield. Remove drive belt(s) and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft pulley stationary. Remove crankshaft pulley bolts. Remove pulley. Remove crankshaft pulley hub bolt and hub. Remove cylinder head cover. Remove upper, center and lower timing belt cover. If timing belt is to be reused, mark timing belt rotation direction. Ensure timing marks on camshaft sprockets are aligned. See Fig. 5. Loosen timing belt tensioner lock bolt, and move tensioner away from belt with spring fully expanded. Remove timing belt.
Fig. 1: Exploded View Of Timing Belt Components (1989 SOHC)
374
MAZDA 1.6L & 1.8L 4-Cylinder 1988-95 (Cont.)
TIMING BELT DEFLECTION

1 Application 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.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket MX-5 Miata ...................................................... 11-16 (15-22) MX-3, Protege & 323 ....................................... 17-26 (23-35) Alternator Top Bolt ............................................ 27-38 (37-52) Camshaft Sprocket Bolt .................................... 36-45 (49-61) Crankshaft/Timing Belt Sprocket Bolt 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) Timing Belt Tensioner Bolt DOHC ............................................................. 27-38 (37-52) SOHC ............................................................. 14-19 (19-26) INCH Lbs. (N.m) Camshaft/Rocker Cover Bolt DOHC & SOHC (Top) ......................................... 43-78 (5-9) SOHC (Timing Belt Cover-To-Camshaft Cover) ........... 69-95 (8-11) Crankshaft Pulley Bolts ............................... 109-152 (12-17)
Fig. 3: Exploded View Of Timing Belt Components (DOHC)
Fig. 4: Exploded View Of Timing Belt Components (Miata)
Fig. 2: Exploded View Of Timing Belt Components (1990 & Later SOHC)
MAZDA 1.6L & 1.8L 4-Cylinder 1988-95 (Cont.)
375
Fig. 5: Aligning Camshaft Timing Marks (DOHC Engines)
Fig. 7: Measuring Timing Belt Deflection Fig. 6: Aligning Camshaft Timing Marks (SOHC Engines)
376
MAZDA 1.8L 4-Cylinder DOHC, BP Engine

pulley boss stationary, remove crankshaft pulley boss bolt. Remove pulley boss. Remove upper, middle, and lower timing belt covers. If timing belt is to be reused, mark timing belt with arrow to indicate rotation direction. Ensure timing marks on camshaft sprockets and crankshaft sprockets are aligned. See Fig. 4 . Loosen timing belt tensioner lock bolt. Move tensioner away from belt with spring fully expanded, and tighten lock bolt. Remove timing belt. Removal (Protege): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove right splash shield from wheelwell. Remove drive belts and water pump pulley. Align crankshaft pulley timing mark with cylinder No. 1 at TDC of compression stroke. Hold crankshaft stationary, and remove crankshaft pulley pulley from crankshaft pulley boss. See Fig. 2 and 3. Remove spark plug wires from spark plugs. Remove valve cover. Remove dipstick pipe. and stay. Remove upper timing belt cover. If timing belt is to be reused, mark timing belt rotation direction. Support engine from above and remove engine mount bracket from timing belt end of engine. Remove middle and lower timing belt covers. Holding crankshaft stationary, remove crankshaft pulley boss. Align timing marks on crankshaft and camshaft sprocket(s). See Fig. 4. Loosen timing belt tensioner lock bolt. Temporarily secure tensioner away from belt with spring fully expanded. Remove timing belt. Inspection (All Models): Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner and idler pulley bearing for looseness or roughness of rotation. Replace parts as necessary.
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 1.8L 4-Cyl. DOHC MX-5 Miata 1994-01 .......... 1 2.6 Hrs. .... 25211790 ...... 250179 Protege 1995-98 .......... 1 2.4 Hrs. .... 2521790 ........ 250179 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
NOTE: Engine identification code is on machined pad at left rear end of engine, at transmission mating flange.

For 1994-96 vehicles, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1997-98 vehicles, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1999-00 vehicles, the replacement interval is 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001 MX-5 Miata, the replacement interval is 60,000 miles.

TIMING BELT
Removal (MX-5 Miata): Disconnect negative battery cable. Drain cooling system. Remove radiator hose and by-pass hoses from thermostat 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. Remove plate with crankshaft pulley. Ensure crankshaft pulley boss locating pin faces straight up. Holding crankshaft
Fig. 1: Exploded View Of Timing Belt Components (Miata)
MAZDA 1.8L 4-Cylinder DOHC, BP Engine (Cont.)
377
Fig. 2: Exploded View Of Timing Belt Components (Protege)
Inspect tensioner spring for stretching. Replace tensioner spring if free length is not greater than 2.33 (59.2 mm). Free length is measured between inside edge to inside of hooked portion of spring. Installation (All Models): Position notch on crankshaft sprocket to 12 oclock position (aligned with mark on oil pump). See Fig. 4. Align timing marks on camshaft sprocket(s).
NOTE: Timing mark on intake camshaft sprocket is an I; timing mark on exhaust camshaft is an E.
Install timing belt tensioner spring with damper rubber closing face away from tensioner. See Fig. 5. Temporarily secure the timing belt tensioner with tensioner spring fully expanded. Install timing belt around crankshaft sprocket, then working in a counterclockwise direction, route belt around idler pulley, camshaft sprocket(s), and tensioner pulley. Ensure there is no slack in belt between crankshaft sprocket, idler pulley, and camshaft sprockets.
378
Fig. 3: Exploded View Of Timing Belt Components (Miata With Oil Control Valve - Protege Similar)
Temporarily install the crankshaft pulley boss and bolt. Rotate crankshaft about 2 turns in direction of normal engine rotation. Align timing belt pulley boss mark with tensioner set mark for correct timing belt tension adjustment. See Fig. 6. Holding crankshshaft stationary, remove the crankshaft pulley boss and bolt. Ensure the crankshaft and camshaft timing marks are still aligned. Loosen timing belt tensioner lock bolt to apply tension to timing belt. Without moving tensioner, tighten tensioner lock bolt to specification. See TORQUE SPECIFICATIONS. Install crankshaft pulley boss and final tighen bolt to specification. Rotate crankshaft 2 1/6 times. Camshaft timing marks should be aligned with marks on rear cover, and the crankshaft pulley boss locating pin should point straight up. If timing marks are not aligned, remove belt, realign all timing marks, and repeat installation procedure.
Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. See Fig. 7. Ensure timing belt deflection is within specification. See TIMING BELT DEFLECTION table. TIMING BELT DEFLECTION
1 Application Deflection in. (mm) DOHC, BP Engine ....................................... .35-.45 (8.5-11.5) 1 - Deflection measurement is with 22 lbs. (10 kg) of pressure applied to timing belt. See Fig. 6.
To install remaining components, reverse removal procedure. While installing valve cover gasket, apply light bead of silicone sealer to 6 corners where gasket meets ends of camshafts. Tighten all valve cover bolts in the correct sequence. See Fig. 8.
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 minutes. Recheck coolant level and fill as necessary. On Protege, check ignition timing. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 37-44 (50-60) 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) Timing Belt Cover Bolt ............................................ 71-97 (8-11) Valve Cover Bolt ...................................................... 43-78 (5-9)
Fig. 6: Aligning Timing Belt Tensioner Set Mark

Fig. 5: Installing Timing Belt Tensioner Spring
380
MAZDA 1.8L 4-Cylinder FP Engine

Installation: Install tensioner, and idler pulley (if removed). Temporarily tighten tensioner with spring fully retracted. Ensure camshaft and crankshaft timing marks are aligned. See Fig. 1. Install timing belt around crankshaft sprocket, water pump sprocket, idler pulley, and camshaft sprockets. Ensure slack does not exist on idler side of timing belt. Complete timing belt installation on slack (tensioner) side. Allow tensioner to ride against timing belt. Turn crankshaft 2 revolutions in normal direction of rotation. Ensure camshaft and crankshaft timing marks are still correctly aligned. If not, timing belt will have to be removed and repositioned. If all timing marks are okay, turn tensioner clockwise by using a hex wrench. Connect tensioner spring to pin on engine block. Turn crankshaft 2 revolutions. Ensure camshaft and crankshaft timing marks are still aligned. To install remaining components, reverse removal procedure. Tighten valve cover bolts in correct sequence. See Fig. 3. Install water pump pulley with stamped F mark away from engine. Adjust drive belts to proper tension. See page A-60 for belt tension 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .......................................... 37-44 (50-60) Crankshaft Pulley Bolt .............................. 116-123 (157-167) Timing Belt Idler Pulley Bolt .............................. 28-38 (38-52) Timing Belt Tensioner Bolt ............................... 28-38 (38-52) INCH Lbs. (N.m) CKP & CMP Sensor Bolts ...................................... 71-97 (8-11) Timing Belt Covers ............................................. 61-87 (7-10) Valve Cover Bolts .................................................. 62-89 (7-10) Water Pump Pulley Bolts ....................................... 71-97 (8-11)
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cyl. DOHC Protege 1999-00 ................ 1 2.4 Hours ................. 250316 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
NOTE: Engine code is stamped on machined pad on lower left end of engine, on transaxle mating flange.

The replacement is 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

TIMING BELT
Removal: Disconnect negative battery cable. Remove Crankshaft Position (CKP) and Camshaft Position (CMP) sensors from front of engine. Remove accessory drive belt. Remove the water pump pulley. See Fig. 2. Rotate crankshaft so No. 1 cylinder is on TDC of compression stroke.
CAUTION: Crankshaft position sensor rotor is on rear of crankshaft pulley. DO NOT damage rotor when removing crankshaft pulley.
Remove crankshaft 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 direction of rotation. Install crankshaft pulley bolt finger-tight to retain crankshaft sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 piston is at TDC of compression stroke and timing marks are aligned. See Fig. 1. Turn tensioner clockwise with a hex wrench to relieve spring tension, and then disconnect spring. Remove timing belt. Remove tensioner and idler pulley (if necessary). Inspection: Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Tensioner spring free length should be 1.44 (36.6 mm). Replace parts as necessary.
MAZDA 1.8L 4-Cylinder FP Engine (Cont.)
381
Loosening Sequence Fig. 3: Valve Cover Bolt Loosening & Tightening Sequence
Tightening Sequence
382
MAZDA *2.0L 4-Cylinder DOHC, Except Tribute

Belt Part No.
CAUTION: On models with a crankshaft position sensor, rotor is on rear of crankshaft pulley. DO NOT damage rotor when removing crankshaft pulley.
TIMING BELT APPLICATION Labor Component Application Time Kit No. 2.0L 4-Cyl. DOHC MX-6 1993-97 .......... 1 2.5 Hrs. .... TCK228 ....... 250228 Protege 2001 ............... 1 2.4 Hrs. .... TCK228 ....... 250228 626 1993-01 .......... 1 2.5 Hrs. .... TCK228 ....... 250228 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours

For 1993 model year, 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 at 105,000 miles. For 1997-98 model years, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1999-00 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001 models, the manufacturer recommends the belt be replaced at 105,000 miles, UNLESS the vehicle is operated in temperatures under 0F (-18C). Under this condition, replace belt at 60,000 miles.
Remove crankshaft pulley and guide plate (large washer). Loosen valve cover bolts in 2-3 steps. See Fig. 2. Remove valve cover and gasket. Remove dipstick tube. Remove upper and lower timing belt covers. Support engine from above. Remove engine mount at timing belt end of engine. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Install crankshaft pulley bolt finger-tight to retain crankshaft sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 piston is at TDC of compression stroke and timing marks are aligned. See Fig. 1. Turn tensioner clockwise with a hex wrench to relieve spring tension, and then disconnect spring. Remove timing belt. Remove crankshaft sprocket, tensioner and idler pulley (if necessary). Inspection: Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Tensioner spring free length should be 1.44 (36.6 mm). Measure spring free length from inside edge to inside edge of hooked portion of spring. Replace parts as necessary. Installation: Install crankshaft sprocket, tensioner, and idler pulley (if removed). Temporarily tighten tensioner. DO NOT install tensioner spring yet. Ensure all timing marks are aligned. See Fig. 1. Install timing belt around crankshaft sprocket, water pump sprocket, idler pulley, and camshaft sprockets. Ensure slack does not exist on idler pulley side of timing belt. Complete timing belt installation on slack (tensioner) side. With tensioner spring removed, allow tensioner to ride against timing belt. Turn crankshaft 2 revolutions in normal direction of rotation. Ensure camshaft and crankshaft timing marks are still correctly aligned. If not, timing belt will have to be removed and repositioned. If all timing marks are okay, turn tensioner clockwise using a hex wrench. Connect tensioner spring to pin on engine block. Turn crankshaft 2 revolutions. Ensure camshaft and crankshaft timing marks are still aligned.

TIMING BELT
Removal: Disconnect negative battery cable. Remove Crankshaft Position (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.
383 MAZDA *2.0L 4-Cylinder DOHC, Except Tribute (Cont.)
To install remaining components, reverse removal procedure. When installing valve cover gasket apply small amount of silicone sealer to 4 corners of gasket where the front of both camshafts go through cylinder head. Tighten valve cover bolts in correct sequence. See Fig. 2. Adjust drive belts to proper tension. See page A-60 for belt tension 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .......................................... 37-44 (50-60) Crankshaft Pulley Bolt .............................. 116-123 (157-167) Timing Belt Idler Pulley Bolt .............................. 28-38 (38-51) Timing Belt Tensioner Bolt ............................... 28-38 (38-51) INCH Lbs. (N.m) CKP & CMP Sensor Bolts ...................................... 71-97 (8-11) Timing Belt Covers ............................................. 61-87 (7-10) Valve Cover Bolts .................................................. 62-89 (7-10) Water Pump Pulley Bolts ....................................... 71-97 (8-11)
Loosening Sequence
Tightening Sequence
Fig. 2: Valve Cover Bolt Loosening & Tightening Sequences
384
MAZDA 2.0L 4-Cylinder DOHC, Tribute
Rotate crankshaft to just before No. 1 cylinder TDC. See Fig. 2. Remove stud and install Crankshaft TDC Timing Peg (303-574). See Fig. 3.
NOTE: Make sure second notch in pulley is indexed to lower cylinder block. See Fig. 2.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. VIN 3 Tribute 2001 ...................... 3.6 Hours .................. 250294


TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshafts with timing belt removed, damage to valves and pistons may result.
Rotate crankshaft clockwise against peg to bring it to TDC. Loosen water pump pulley bolts. Remove timing belt cover by removing crankshaft pulley, then remove lower timing belt cover bolts and lower timing belt cover. See Fig. 4. Install Engine Support Bar (303-F072). See Fig. 5. Remove ground strap and engine mount upper bracket and studs. See Fig. 6. Remove upper timing belt cover bolts and cover. See Fig. 7. Remove water pump pulley and accessory drive belt idler pulley. Install Camshaft Alignment Tool (303-465) and align camshafts. See Fig. 8.
Removal: Disconnect negative battery cable. Remove accessory drive belt. Remove air cleaner outlet pipe and ignition wires from spark plugs. Disconnect throttle cables and cruise control actuator cable. Disconnect accelerator cable. Remove valve cover. See Fig. 1. Remove spark plugs. Remove catalytic converter. Remove coolant tube bolt and nut. Position coolant tube to side.
NOTE: Installation of Camshaft Alignment Tool (303-465) into exhaust camshaft may require camshafts to be rotated slightly clockwise.
Raise and support vehicle. Remove engine mount lower bracket. See Fig. 9. Loosen timing belt tensioner pulley and allow it to slide down to bottom of its travel. Slide timing belt off of camshaft and crankshaft sprockets.
CAUTION: DO NOT reuse old timing belt. Replace with a NEW belt.
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 2.0L 4-Cylinder DOHC, Tribute (Cont.)
385
Fig. 5: Installing Engine Support Bar (303-F072)
Fig. 9: Removing Engine Mount Lower Bracket
Fig. 6: Removing Engine Mount Upper Bracket
Fig. 7: Removing Upper Timing Belt Cover
Installation: Slide crankshaft pulley onto crankshaft. Ensure crankshaft position is at No. 1 TDC by rotating it clockwise against Crankshaft TDC Timing Peg (303-574). Ensure second notch in pulley is indexed to lower cylinder block. See Fig. 2. Remove crankshaft pulley. Ensure timing belt tensioner is installed correctly with tab positioned in slot in inner timing cover. See Fig. 10. Install new timing belt onto timing belt sprockets and adjust 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 specification. See TORQUE SPECIFICATIONS. Install front engine mount lower bracket. Install accessory drive belt idler pulley. Install water pump pulley but hand tighten only. Install timing belt covers. Install crankshaft pulley. Tighten water pump pulley bolts to specification. See TORQUE SPECIFICATIONS. Remove Crankshaft TDC Timing Peg (303-574). Install stud. Install engine mount upper bracket and ground strap. Remove 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. Reconnect negative battery cable.
Fig. 8: Installing Camshaft Alignment Tool (303-465)
386
MAZDA 2.0L 4-Cylinder DOHC, Tribute (Cont.)

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Idler Pulley Bolt .......................... 35 (45) Coolant Tube Attachments ............................................. 15 (20) Crankshaft Pulley Bolt .................................. 81-89 (110-121) Engine Mount Lower Bracket Nuts ................................. 37 (50) Engine Mount Upper Bracket Nuts ................................. 61 (83) Engine Mount Upper Bracket Studs .............................. 25 (34) Exhaust Camshaft Center Plug ..................................... 27 (37) Ground Strap .................................................................. 25 (34) Spark Plugs ................................................................... 11 (15) Stud (For Crankshaft TDC Timing Peg) ......................... 18 (24) Timing Belt Tensioner Bolt ............................................ 18 (25) Water Pump Pulley Bolt ................................................. 18 (24) INCH Lbs. (N.m) Lower Timing Belt Cover Bolt ....................................... 62 (7) Upper Timing Belt Cover Bolt ....................................... 71 (8) Valve Cover ...................................................................... 80 (9)
MAZDA *2.0L & 2.2L 4-Cylinder SOHC

TIMING BELT APPLICATION Labor Component Kit No. Application Time1 2.0L 4-Cyl. SOHC B2000 1986 Thru: Chassis No. 568707 ......... 2.6 Hrs. ............................. 250113 From: Chassis No. 568708 ......... 2.6 Hrs. ............................. 250117 1987 ............... 1.6 Hrs. ............................. 250117 626 1983 ............... 1.6 Hrs. ............................. 250088 626 Coupe 1984-85 Thru: VIN JM1GC221E 1617 ............. 1.6 Hrs. ........................... 2 250088 From:VIN JM1GC221E 16176 ........... 1.6 Hrs. ........................... 3 250113 626 Hatchback 1984-85 Thru: VIN JM1GC 241E1 .......... 1.6 Hrs. ........................... 2 250088 From: VIN JM1GC 241E1 .......... 1.6 Hrs. ........................... 3 250113 626 Sedan 1984-85 Thru: VIN JM1GC221E163 5511 ............. 1.6 Hrs. ........................... 2 250088 From: VIN JM1GC221E163 5511 ............. 1.6 Hrs. ........................... 3 250113 1986-87 ........ 1.6 Hrs. ........................... 250117 2.2L 4-Cyl. Non-Turbo & Turbo B2200 1987-93 .......... 2.6 Hrs. ...... 2521340 ........ 250134 MX-6 1988-92 .......... 2.3 Hrs. ...... 2521340 ........ 250134 626 1988-92 .......... 1.6 Hrs. ...... 2521340 ........ 250134 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours 2 With square tooth sprocket. 3 With round tooth sprocket. Belt Part No.
387
*NOTE: These applications are interference engines. See page A-59 for interference engine cautions.

TIMING BELT
Removal: Disconnect negative battery cable. Drain cooling system. Remove cooling fan and shroud. Remove distributor from front housing. Remove cooling fan pulley and bracket. Remove secondary air pipe assembly (carbureted engines). Remove alternator drive belt and A/C and P/S drive belts (if equipped). Remove crankshaft pulley and baffle plate. Remove timing belt covers. Align camshaft pulley with front housing timing mark. See Fig. 1. Mark an arrow on timing belt to indicate direction of travel. Remove tensioner lock bolt, tensioner and spring. Remove timing belt. On 2.2L engines, measure free length of tensioner spring. Replace spring if free length is not 2.48 inch (63 mm). See Fig. 2.
NOTE: Never twist, turn inside out, or bend timing belt.
Installation: Align camshaft pulley with front housing timing mark. Align crankshaft pulley with pointer on oil pump body. See Fig. 1. Install tensioner, lock bolt and tensioner spring. Position timing belt tensioner to its limit of travel toward the intake manifold side and partially tighten lock bolt.

Fig. 1: Timing Belt Reference Marks & Deflection
388
MAZDA *2.0L & 2.2L 4-Cylinder SOHC (Cont.)

TORQUE SPECIFICATIONS (2.0L) Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .......................................... 35-48 (47-65) Crankshaft Pulley Bolt .............................. 116-123 (157-167) Timing Belt Tensioner Bolt ............................... 28-38 (38-52) Torque Stopper Bolts ........................................ 45-56 (61-76) INCH Lbs. (N.m) Timing Belt Covers ............................................. 61-87 (7-10) Valve Cover ........................................................... 26-35 (3-4) TORQUE SPECIFICATIONS (2.2L & 2.2L Turbo) Application Ft. Lbs. (N.m) Coolant Inlet Pipe Bolt ...................................... 14-19 (19-26) Crankshaft Sprocket Bolt .......................... 116-123 (157-167) Timing Belt Idler Pulley ..................................... 27-38 (37-52) Timing Belt Tensioner Lock Bolt ....................... 27-38 (37-52) Water Pump Bolt .............................................. 14-19 (19-26) INCH Lbs. (N.m) Crankshaft Pulley-To-Crankshaft Sprocket Bolt ................................................. 109-152 (13-7) Rocker Cover Bolt ................................................. 26-35 (3-4) Timing Belt Cover ............................................... 61-87 (7-10)
Fig. 2: Measuring Free Length Of Tensioner Spring
Install timing belt onto crankshaft pulley and then camshaft pulley. Install timing belt from tension side (right side, as viewed from engine front). If timing belt is being reused, ensure that arrow is pointing in direction of travel. Loosen tensioner lock bolt to apply tension. To apply equal tension to each side of timing belt, turn crankshaft 2 revolutions in direction of travel. Tighten tensioner lock bolt. Check for proper alignment of timing marks. Check for proper belt tension by measuring amount of deflection midway between crankshaft and camshaft pulleys when force of 22 lbs. (10 kg) is applied. See Fig. 1. Deflection should be .43-.51" (11-13 mm). If tension is incorrect, repeat timing belt tensioning procedure. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
MAZDA *2.0L 4-Cylinder Diesel

TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.0L 4-Cyl. Diesel 626 1984-85 Camshaft ........... 1.9 Hours ................. 250103 Injection Pump ... 1.0 Hours .................. 250102 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
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389

Remove torque bracket from right fender apron. If reusing timing belt, mark an arrow on timing to indicate direction of travel, then remove timing belt. Check belt for premature wear, missing teeth, or cracks. Check turning smoothness of belt tensioner. Installation: Ensure that timing mark on camshaft pulley is aligned with mark on front seal plate. Make sure that notch on crankshaft pulley is aligned with timing mark on oil pump housing. See Fig. 1. If tensioner was removed, install tensioner, lock bolt, and spring. Push tensioner as far left as it will go. Snug tensioner lock bolt. Install timing belt. Release tensioner lock bolt and allow tensioner to contact belt. Turn crankshaft in a clockwise direction (as viewed from front) for 2 complete revolutions. Tighten tensioner lock bolt. Check timing marks on front camshaft and crankshaft pulleys.

TIMING BELT (FRONT)
Removal: Disconnect negative battery cable. Remove right side splash shield (if equipped). Remove drive belts and crankshaft pulley. Remove timing belt covers and rubber seals. Turn crankshaft in a clockwise direction until mark on front camshaft pulley and front seal plate timing mark align. Loosen tensioner lock bolt, and push tensioner as far back as it will go. Snug tensioner lock bolt.
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 procedure 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, using a screwdriver, as far as it will go. Snug tensioner lock nut. If reusing timing belt, mark an arrow on timing belt to indicate direction of travel. Remove rear timing belt. Check belt for premature wear, missing teeth, or cracks. Check turning smoothness of belt tensioner. Installation: 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 *2.0L 4-Cylinder Diesel (Cont.)

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ........................................ 41-48 (56-65) Crankshaft Pulley Bolts .................................... 17-24 (23-33) Fuel Injection Pump Pulley Bolts ...................... 43-51 (58-69) Timing Belt (Front) Pulley Bolt .................. 116-123 (157-167) Timing Belt Tensioner Bolt Front ............................................................... 23-34 (31-46) Rear ............................................................... 15-20 (20-27) Water Pump Bolts ............................................ 23-34 (31-46) INCH Lbs. (N.m) Rear Cover Bolts .................................................. 60-84 (7-9)
If tensioner was removed, install tensioner lock nut, and spring in fully released position. Rotate belt tensioner clockwise, using a screwdriver, as far as it will go. Snug tensioner lock nut. Install rear timing belt on injection pump pulley, around tensioner, and then on camshaft pulley. Remove bolts securing injection pump pulley. Loosen tensioner lock nut until tension is applied on belt. Turn crankshaft in a clockwise direction for 2 complete revolutions. Check timing marks on rear camshaft and injection pump pulleys. See Fig. 2. Tighten tensioner lock nut. Check timing belt deflection using 22 lbs. (10 kg) of force between injection pump and camshaft pulleys. Deflection should be 0.375" (9.53 mm). Install rear timing belt cover. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L 4-Cyl. B2300 1994 ..................... 1 2.2 Hours ................. 250210 1995-97 ................ 1 2.2 Hours ................. 250276 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
391


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. Remove alternator. Loosen water pump pulley bolts. Remove accessory drive belt(s). Remove spark plugs to ensure belt does not jump time during rotation. Remove cooling fan and water pump pulley. Remove crankshaft pulley, hub and belt guide. Remove crankshaft position sensor. Remove dipstick and pipe. Remove timing belt cover retaining bolt. Release 8 cover interlocking tabs. Remove timing belt cover. Loosen timing belt tensioner pulley bolt. 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: Ensure crankshaft is set at TDC and camshaft sprocket timing mark is aligned with cover pointer. See Fig. 1. Install belt guide with flat side toward the camshaft sprocket. See Fig. 2. 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 removal procedure. Fill and bleed cooling system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 50-71 (68-96) Crankshaft Damper Bolt ........................... 103-133 (140-180) Water Pump Bolt 1 ............................................ 14-21 (19-29) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt .......................... 71-106 (8-12) Valve Cover Bolt .................................................. 62-97 (7-11)
1
- Apply sealant to bolt threads.
392
If reusing old timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt.
CAUTION: Always rotate engine in direction of normal rotation (clockwise as viewed from front of engine). Reverse rotation may cause timing belt to jump time, causing engine damage.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L 4-Cyl. B2500 1998-00 ................ 1 2.2 Hours ................. 250276 1 - With Air Cond. add 1.0 hours. With Pwr. Strng. add .5 hours.

The manufacturer recommends the belt be inspected at 120,000 miles and replaced if necessary.

TIMING BELT
Removal: Disconnect negative battery cable. Remove exhaust side spark plugs. Rotate crankshaft clockwise so No. 1 piston is at TDC of compression stroke. Remove fan shroud. Loosen fan clutch-to-pulley bolts. Remove accessory drive belt. Remove fan clutch and pulley. Remove crankshaft center bolt and remove crankshaft pulley. Using recycling equipment, recover refrigerant from air conditioning system (if equipped). Disconnect A/C clutch connector from A/C clutch. Remove A/C compressor from mounting bracket. Remove A/C compressor mounting bracket with hoses attached, and position out of way. Remove timing belt outer cover retaining bolt. Release 7 cover interlocking tabs. Remove timing belt cover. Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. Holding timing belt tensioner with Camshaft Belt Tension Adjuster (T74P-6254-A) or equivalent, loosen adjusting bolt and slowly release tension. See Fig. 2. Pry tensioner away from timing belt and tighten bolt to hold tensioner in place.
Installation: Ensure crankshaft is set at TDC and camshaft sprocket timing mark and oil pump sprocket timing mark are aligned with inner cover timing marks. See Fig. 1. Install timing belt on crankshaft sprocket. Working clockwise, install belt over oil pump sprocket, camshaft sprocket, and tensioner pulley. Loosen tensioner bolt and allow tensioner to adjust itself. Rotate crankshaft clockwise 2 complete revolutions to remove slack from belt. Recheck timing mark alignment. Readjust as necessary. Tighten timing belt tensioner bolts. Install timing belt cover. Install crankshaft pulley. Install A/C compressor bracket with power steering pump. Install A/C compressor and recharge system (if equipped). To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Mount Bolts M8 Bolt ......................................................................... 18 (25) M10 Bolt ....................................................................... 35 (48) A/C Compressor-To-Bracket Bolt ........................ 16-20 (21-28) Camshaft Sprocket Bolt .................................... 52-70 (70-95) Cooling Fan-To-Pulley Bolts ............................. 13-16 (17-23) Crankshaft Damper Bolt ............................ 92-122 (125-165) Oil Pump Sprocket Bolt ..................................... 29-41 (40-55) Timing Belt Tensioner Adjusting Bolt ................ 35-45 (26-33) Timing Belt Tensioner Pivot Bolt ....................... 29-41 (40-55) INCH Lbs. (N.m) Engine Timing Belt Cover Bolt .......................... 71-106 (8-12) Spark Plug ........................................................ 80-115 (9-13)
Fig. 1: Aligning Camshaft & Oil Pump Timing Marks
MAZDA 1.8L V6
393
Application Labor Time Belt Part No. TIMING BELT 1.8L V6 Removal: MX-3 Disconnect negative battery cable. Drain coolant. Raise and 1992-93 ............... 1 3.8 Hours ................ 250214 support vehicle and remove right front wheel. Remove lower engine covers. Remove accessory drive belts. Remove water MX-3 (Canadian) pump pulley. Remove drive belt idler pulley bracket. See 1995 .................... 1 3.8 Hours ................ 250214 Fig. 1. Disconnect necessary clamps and power steering 1 - With Air Cond. add .2 hours. pressure switch connector to remove power steering resWith Pwr. Strng. add .2 hours. ervoir. Remove retaining bolts and power steering reser-

For 1992 model year, the manufacturer recommends the belt be replaced every 60,000 miles. For 1993-95 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.
voir with hoses attached, and secure reservoir aside. Remove retaining nut and power steering pump pulley. Remove retaining bolts and power steering pump with hoses attached, and secure pump aside. Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley.
CAUTION: DO NOT damage crank angle sensor rotor on rear of crankshaft pulley during crankshaft pulley removal.
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 in original direction of rotation.
Unplug crank angle sensor and unclip wires from oil dipstick tube. Remove oil dipstick and oil dipstick tube. Remove crank angle sensor harness bracket. Remove engine wiring harness, located along top of timing belt cover. Support engine using hoist or floor jack. Remove right front wheel. Remove through-bolt, retaining nuts and right (timing belt side) engine mount. Remove retaining bolts, timing belt covers and gaskets. See Fig. 1. Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. Ensure grove on crankshaft sprocket aligns with indicator on oil pump body. See Fig. 2. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation. Hold timing belt tensioner and remove lower retaining bolt first, then remove upper bolt. Remove timing belt tensioner. Remove No. 2 timing belt pulley and timing belt. Remove No. 1 idler pulley and tensioner pulley (if necessary). Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulleys No. 1 and No. 2 and tensioner pulley rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Measure timing belt tensioner rod protrusion from end of rod to edge of the housing. See Fig. 3. Replace timing belt tensioner if distance is not .550-.630" (13.97-16.00 mm). Installation: Place timing belt tensioner in a press using a flat washer to prevent damage to timing belt tensioner. See Fig. 4. Compress tensioner rod until holes in rod and housing are aligned and install .06" (1.5 mm) diameter pin through holes in housing and rod to hold rod in retracted position. See Fig. 4. Install timing belt tensioner on cylinder block with the upper retaining bolt only, do not fully tighten upper bolt. Install No. 2 idler pulley and tighten to specification. See TORQUE
Push outward at bottom of timing belt tensioner and install lower retaining bolt in timing belt tensioner. Tighten both timing belt tensioner retaining bolts to specification. Remove pin from timing belt tensioner, allowing tension to be applied on timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets and crankshaft sprockets are properly aligned. See Fig. 2. If timing marks are not aligned, repeat entire timing belt installation procedure. Check timing belt deflection by applying 22 lbs (10 kg) of force at designated area on timing belt. Check timing belt deflection. See Fig. 6. Timing belt deflection should be .24.31" (6.0-8.0 mm). If timing belt deflection is not within specification, replace timing belt tensioner. Install timing belt covers using NEW gaskets. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS. Install dipstick tube with new O ring. To install remaining components, reverse removal procedure. Tighten fasteners to specification. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ....................................... 27-38 (37-52) Crankshaft Pulley Bolt .............................. 116-123 (157-166) No. 1 Idler Pulley Bolt ........................................ 28-38 (38-52) No. 2 Idler Pulley Bolt ........................................ 28-38 (38-52) Power Steering Pump Bracket Bolt ....................................... 1 Power Steering Pump Pulley Nut ...................... 49-69 (66-93) Right (Timing Belt Side) Engine Mount Nut ................................................................ 55-75 (74-102) Through-Bolt .................................................... 50-68 (67-92) Tensioner Pulley Bolt ........................................ 28-32 (38-44) Timing Belt Tensioner Bolt ............................... 14-19 (19-26) Water Pump Bolt .............................................. 14-19 (19-26) INCH Lbs. (N.m) Crank Angle Sensor Bracket Bolt ........................ 69-95 (8-11) Cylinder Block Valley Cover Bolt ......................... 69-95 (8-11) Timing Belt Cover Bolt ........................................ 69-95 (8-11) Valve Cover Bolt 2 .................................................. 43-78 (5-9) Water Pump Pulley Bolt ...................................... 69-95 (8-11) - Tighten 2 upper bolts on front of bracket to 23-34 ft. lbs. (31-46 N.m.). Tighten lower bolt on front of bracket to 14-19 ft. lbs. (19-26 N.m). Tighten rear bracket-to-cylinder block bolt to 24-33 ft. lbs. (32-45 N.m). 2 - Tighten bolts to specification in sequence. See Fig. 5.
1
395
396
MAZDA 2.3L V6
TIMING BELT
Removal: Disconnect negative battery cable. Drain coolant. Raise and support vehicle. Remove right front wheel. Remove lower engine covers. Remove accessory drive belts. Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley. Remove power steering pump pulley. Remove water pump pulley. Remove generator drive belt auto tensioner. See Fig. 1. Remove camshaft position sensor from right hand camshaft. Remove engine oil dipstick and pipe. Remove vacuum pipe. Remove upper radiator hose. Support engine using hoist. Remove No. 3 engine mount and brackets from timing belt end of engine. Remove retaining bolts, timing belt covers and gaskets. Remove power steering belt auto tensioner. See Fig. 1.
CAUTION: DO NOT damage crank angle sensor rotor on rear of crankshaft pulley during crankshaft pulley removal.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L V6 Millenia 1995-00 ................ 1 4.5 Hours ................ 250267 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.

For 1996-95 vehicles, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California. For vehicles sold in California, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1998-97 vehicles, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2000-99 vehicles, the replacement is 60,000 miles except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2001 vehicles, the replacement is 60,000 miles.
Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. The crankshaft and camshaft timing marks should align. See Fig. 2. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation. Hold timing belt tensioner and remove lower retaining bolt first, then remove upper bolt. Remove timing belt tensioner. Remove timing belt.
397
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 SPECIFICATIONS. Ensure all timing marks align. See Fig. 2.
Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Inspect timing belt auto tensioner for signs of oil leakage. Replace timing belt auto tensioner if oil leakage exists. Measure timing belt auto tensioner rod protrusion from end of rod to edge of the housing. See Fig. 3. Replace timing belt auto tensioner if distance is not .563.594" (14.3-15.1 mm).
NOTE: The following information on repairing the front engine oil leaks is from Mazda technical service bulletin MT0596-07; May, 1996.
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 thoroughly. Apply Loctite PST Pipe Sealant with Teflon (No. 565) to stud threads. Install stud on engine block.
398

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ....................................... 27-38 (37-52) Camshaft Position Sensor Bolt ........................... 14-18 (19-25) Crankshaft Pulley 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) Timing Belt Auto Tensioner Bolt ........................ 14-19 (19-26) Water Pump Bolt .............................................. 14-19 (19-26) Wheel Lug Nut ................................................. 66-94 (89-127) INCH Lbs. (N.m) Timing Belt Cover Bolt ........................................ 69-95 (8-11) Water Pump Pulley Bolt ...................................... 69-95 (8-11)
Fig. 6: Locating Engine Mount Bracket Stud
Remove pin from timing belt tensioner, allowing tension to be applied on timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets and crankshaft sprockets are properly aligned. See Fig. 2. If timing marks are not aligned, remove and repeat entire timing belt installation procedure. Install timing belt covers using NEW gaskets. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS. Install dipstick tube with new O ring. To install remaining components, reverse removal procedure. Tighten fasteners to specification. Check ignition timing. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
MAZDA 2.5L V6
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L V6 Millenia 1995-01 ............... 1 3.4 Hours ................ 250214 MX-6 1993-97 ............... 1 4.0 Hours ................ 250214 626 1993-01 ............... 1 4.0 Hours ................ 250214 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.
399

For 1993 model year, 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 at 105,000 miles. For 1997-98 model years, the manufacturer suggests the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusettes. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 1999 626 models and 1999-00 Millenia models, the manufacturer recommends the belt be replaced at 60,000 mile intervals except for vehicles registered in California, Connecticut, Delaware, Maine, Maryland, Massachusetts, New Hampshire, New Jersey, New York, Pennsylvania, Rhode Island, Vermont, Virginia and Washington D.C. For these states, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles. For 2000 626 models, the manufacturer recommends the belt be replaced at 60,000 mile intervals except for vehicles registered in California, Maine, 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 under 0F (-18C). In this case, replace timing belt at 105,000 miles.
Remove oil dipstick and oil dipstick tube. Remove crankshaft position sensor from front of engine. See Fig. 2. Support engine using hoist or floor jack. Remove right (timing belt side) engine mount. Remove retaining bolts, timing belt covers, and gaskets. See Fig. 2. Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. Ensure grove on crankshaft sprocket aligns with indicator on oil pump body. See Fig. 1. Ensure camshaft sprocket timing marks are aligned with marks on rear cover. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation. Loosen the 2 timing belt tensioner bolts. Hold timing belt tensioner and remove lower retaining bolt. Remove No. 1 idler pulley and timing belt. Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulleys No. 1 and No. 2, and tensioner pulley rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3. There are 2 types of tensioner used on this engine. See Fig. 4. Replace timing belt tensioner if rod protrusion distance is not as specified. See TIMING BELT TENSIONER ROD PROTRUSION table. TIMING BELT TENSIONER ROD PROTRUSION Application In. (mm) Type A (2001) ................................... 0.511-0.551 (13.0-14.0) Type A (1993-00) .............................. 0.473-0.511 (12.0-13.0) Type B ............................................ 0.563-0.594 (14.3-15.1) Installation: Place timing belt tensioner in a press using a flat washer to prevent damage to timing belt tensioner. See Fig. 5. Using no more than 2200 lbs. pressure, SLOWLY compress

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 water pump pulley. Remove drive belt idler pulley bracket. Remove retaining bolts and power steering pump with hoses attached, and secure pump out of way. Holding crankshaft stationary, remove the crankshaft pulley 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
Fig. 4: Identifying Timing Belt Tensioner Types
401
Rotate crankshaft 2 full revolutions clockwise (as viewed from timing belt end of engine) from TDC to TDC. Ensure timing marks on camshaft sprockets and crankshaft sprockets are properly aligned. See Fig. 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 specification. See TORQUE SPECIFICATIONS. Install dipstick tube with new O ring. To install remaining components, reverse removal procedure. Tighten fasteners to specification. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Check crankshaft position sensor air gap. Gap between center of sensor and outer edge of rotor tooth should be 0.020-0.059 (0.5-1.5 mm). If not, check for damaged components. Air gap is not adjustable. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt .............................. 116-123 (157-166) No. 1 & No. 2 Idler Pulley Bolt ........................... 28-38 (38-52) Power Steering Pump Bracket Bolt ....................................... 1 Power Steering Pump Pulley Nut ...................... 37-43 (50-58) Right (Timing Belt Side) Engine Mount Nut (Millenia & 626) ....................................... 55-75 (74-102) Through-Bolt 626 ............................................................ 63-86 (86-116) Tensioner Pulley Bolt ........................................ 28-32 (38-44) Timing Belt Tensioner Bolt ............................... 14-18 (19-25) Water Pump Bolt .............................................. 14-18 (19-25) Wheel Lug Nut Millenia ........................................................... 66-94 (89-127) INCH Lbs. (N.m) Crankshaft Position Sensor Bracket Bolt ........... 69-95 (8-11) Timing Belt Cover Bolt ........................................ 69-95 (8-11) Water Pump Pulley Bolt ...................................... 69-95 (8-11)
1
tensioner rod until holes in rod and housing are aligned. Install 0.055" (1.4 mm) diameter pin through holes in housing and rod to hold rod in retracted position. Install timing belt tensioner on cylinder block with the upper retaining bolt only, do not fully tighten upper bolt. Ensure crankshaft and camshaft timing marks align. See Fig. 1. Install timing belt on sprockets in order. See Fig. 6. Ensure tension exists on belt between crankshaft pulley and camshaft pulleys. See Fig. 6. While applying pressure on timing belt, install No. 1 idler pulley.
Push outward at bottom of timing belt tensioner and install lower retaining bolt in timing belt tensioner. Tighten both timing belt tensioner retaining bolts to specification. See TORQUE SPECIFICATIONS. Remove pin from timing belt tensioner, allowing tension to be applied on timing belt.
- 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

1
TIMING BELT APPLICATION Labor Time Belt Part No. Application 3.0L V6 DOHC 929 1990-95 ................. 3.9 Hours .................. 250183 Serenia (Canadian) 1992-95 ................. 3.9 Hours .................. 250183 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours.

The manufacturer recommends the belt be replaced every 60,000 miles for Federal vehicles, and 105,000 miles on California vehicles.
age sensor rotor. Remove coolant by-pass and upper radiator hoses. Remove distributor. Remove timing belt covers and gasket. See Fig. 1. Turn crankshaft to align pulley match marks. See Fig. 2. Remove timing belt upper idler pulley. If reusing timing belt, mark rotation direction. Remove timing belt and timing belt automatic tensioner. Inspection: Check automatic tensioner rod projection. Rod should project .47-.55" (12-14 mm) from tensioner body. Replace tensioner if projection is not within specification. Installation: Using flat washer to prevent damage to tensioner body plug, place automatic tensioner in vise or arbor press. Compress tensioner rod until a pin can be inserted into tensioner rod through hole in tensioner body. Install tensioner with pin installed.
CAUTION: DO NOT exceed 2200 lbs (1000 kg) pressure on tensioner rod.

TIMING BELT
Removal: Disconnect negative battery cable. Drain engine coolant. Remove spark plug cables and spark plugs. Remove air intake hose. Remove cooling fan and fan shroud. Remove drive belts. Remove A/C and P/S idler pulleys (if equipped). Remove crankshaft pulley, baffle plate (if equipped), and sensor rotor (if equipped). DO NOT dam-
Ensure match marks on pulleys align with marks on heads. See Fig. 2. With upper idler pulley removed, install timing belt on pulleys. Keep slack toward automatic tensioner side. Install upper idler pulley. Rotate crankshaft twice in direction of rotation, and ensure match marks still align. Remove automatic tensioner pin, and repeat steps to confirm match marks are still in alignment. Check timing belt deflection between right cam pulley and lower idler. Deflection should be .20-.28" (5-7 mm) at 22 lbs. (10 kg). If deflection is not correct, repeat installation procedure. If deflection is still not correct, check for faulty automatic tensioner or stretched timing belt.
MAZDA *3.0L V6 DOHC (Cont.)
403
To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor-To-Bracket Bolt ..................... 21-29 (29-39) Alternator-To-Bracket Bolt ................................. 27-38 (37-52) Camshaft Pulley Bolt Left Head ........................................................ 14-18 (19-25) Right Head ..................................................... 52-59 (71-80) Crankshaft Pulley Bolt .............................. 116-123 (157-167) Power Steering Idler Bolt ......................................................... 14-18 (19-25) Pulley Nut ....................................................... 29-43 (39-58) Pump Mount Bolt .............................................. 23-34 (31-46) Radiator Bolt ..................................................... 14-18 (19-25) Timing Belt Lower Idler Bolt ............................. 32-45 (43-61) Timing Belt Tensioner Bolt ............................... 14-18 (19-25) Timing Belt Upper Idler Bolt ............................. 27-38 (37-52) Water Pump Bolt/Nut ........................................ 14-18 (19-25) INCH Lbs. (N.m) Timing Belt Cover Bolt 1 ...................................... 71-97 (8-11) Valve Cover Bolt .............................................. 30-39 (3.4-4.4)
1
Fig. 2: Aligning Timing Belt Match Marks
- Exc. 3 top bolts on right side cover: 14-18 ft. Lbs. (19-25 N.m).
404
MAZDA *3.0L V6 SOHC
During the 60,000 mile inspection or timing belt replacement on MPV models, inspect tensioner pulley pivot bushing for a bronze color (wear) on the Teflon coating. If the bushing is worn, the tensioner pulley and spacer must be replaced with the timing belt. This is to prevent a torn or jumped timing belt. Installation: Install tensioner pulley and lower idler pulley (if removed). Install retaining bolts, and tighten to specification. See TORQUE SPECIFICATIONS. Ensure all pulleys are clean and rotate smoothly.
TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time 1 3.0L V6 SOHC 929 1988-91 .......... 3.1 Hrs. ...... 2521460 ........ 250146 MPV 1989-98 .......... 3.0 Hrs. ...... 2521460 ........ 250146 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
CAUTION: DO NOT apply more than 2200 lbs. (1000 kg) pressure on timing belt tensioner rod.

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 at 105,000 miles. For 1997-99 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for vehicles sold outside of California and Massachusetts. For vehicles sold in California and Massachusetts, inspect timing belt at 60,000 and 90,000 miles, and replace timing belt at 105,000 miles.

Removal: Disconnect negative battery cable. Drain cooling system. Remove spark plug wires and spark plugs. Remove air intake hose. Remove cooling fan and fan shroud. Remove drive belts. Remove A/C compressor drive belt idler pulley. Remove retaining bolt and crankshaft pulley. Remove coolant bypass and upper radiator hoses. Remove timing belt covers and gaskets. See Fig. 1. Rotate crankshaft and align all timing marks. See Fig. 2. 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: Measure timing belt tensioner rod protrusion from end of rod to edge of timing belt tensioner housing. Replace timing belt tensioner if distance is not .47-.55" (12.0-14.0 mm). Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys and tensioner pulley rotate freely. Inspect timing belt tensioner for signs of oil leakage. Replace worn components.
NOTE: The following information on tensioner pulley inspection is from Mazda technical service bulletin 002/00R; March 9,2000.
MAZDA *3.0L V6 SOHC (Cont.)

Place timing belt tensioner in press with flat washer to prevent damage to timing belt tensioner plug. Apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 3. Install pin through holes in housing and rod to hold rod in retracted position. Release press and remove timing belt tensioner. Install timing belt tensioner on cylinder block with pin installed. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS. Rotate camshafts and crankshaft to ensure all timing marks are aligned. See Fig. 2. With upper idler pulley removed, install timing belt on crankshaft sprocket, lower idler pulley, left camshaft sprocket, right camshaft sprocket and tensioner pulley in sequence.
405
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ....................................... 13-20 (18-27) A/C Compressor Bracket-To-Cylinder Block Bolt ........................................................ 27-38 (37-52) Camshaft Sprocket Bolt .................................... 52-59 (71-80) Crankshaft Pulley Bolt .............................. 116-123 (157-167) Lower Idler Pulley Bolt ...................................... 27-38 (37-52) Power Steering Pump Bolt ................................ 23-34 (31-46) Power Steering Pump Pulley Nut ...................... 29-43 (39-58) Tensioner Pulley Bolt ........................................ 17-22 (23-30) Timing Belt Cover Bolt 6 mm Bolt ........................................................................... 1 10 mm Bolt ..................................................... 27-38 (37-52) Timing Belt Tensioner Bolt ............................... 14-19 (19-26) Upper Idler Pulley Bolt ...................................... 27-38 (37-52) Water Pump Bolt/Nut ........................................ 14-19 (19-26) INCH Lbs. (N.m) Valve Cover Bolt .................................................... 30-39 (3-4)
1
Install upper idler pulley. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure all timing marks are aligned. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. Remove pin from timing belt tensioner, allowing pressure to be applied to timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure all timing marks are aligned. Check timing belt deflection by applying 22 lbs. (10 kg) of force at midpoint between right camshaft sprocket and tensioner pulley. Timing belt deflection should be .20-.28" (5.0-7.0 mm). If timing belt deflection is not within specification, repeat installation procedure. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
- Tighten to 69-95 INCH lbs. (8-11 N.m).
406
MITSUBISHI *1.5L 4-Cylinder SOHC

TIMING BELT APPLICATION Application 1.5L 4-Cyl. Mirage 1985-86 .......... 2.8 Hrs. ............................. 250073 1987-90 .......... 2.8 Hrs. ...... 2521280 ........ 250128 1991-96 .......... 2.4 Hrs. ...... 2521910 ........ 250191 1997-01 .......... 2.4 Hrs. ............................. 250289 Precis 1987-89 .......... 2.2 Hrs. ............................. 250073 1990-93 .......... 2.2 Hrs. ...... 2521280 ........ 250128 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .3 hours.

For 1985-93 models, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-00 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed. For 2001 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.
Fig. 2: Installing Timing Belt Tensioner (1985-96)

TIMING BELT
Removal (1985-96): Disconnect negative battery cable. Remove air cleaner assembly, then disconnect accelerator cable and oxygen lead sensor. Mark position of spark plug wires for installation, then remove wires from spark plugs. Support engine using a suitable engine support bar. Remove left engine mount bracket. Remove all accessory drive belts and pulleys.
Remove timing belt covers and gaskets, noting bolt lengths and locations as they are removed. Rotate engine clockwise to align timing mark on camshaft sprocket with mark on cylinder head. Ensure all timing marks are aligned. See Fig. 1. Loosen timing belt tensioner bolts. Move tensioner inward toward water pump. Temporarily tighten bolt in slot side of tensioner. Remove timing belt from camshaft sprocket. Remove crankshaft pulley, and timing belt. Inspection: Inspect belt teeth for cracks, damage, or oil contamination. Inspect all sprockets for damage. Examine belt tensioner for grease leakage and roughness when pulley is rotated. Replace components if defective. Installation (1985-96): Ensure crankshaft and camshaft timing marks are aligned. See Fig. 1. Install timing belt onto crankshaft and camshaft sprockets. Ensure tension side is tight and all timing marks are aligned when camshaft sprocket is rotated. Install crank-
MITSUBISHI *1.5L 4-Cylinder SOHC (Cont.)
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 crankshaft sprocket timing mark aligns with TDC position. Recheck belt tension. To check belt tension, hold belt tensioner and timing belt together. Apply slight thumb pressure at center point of belt tensioner. See Fig. 3. A tension gauge can also be used to check belt tension. See Fig. 4. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (1997-01): Disconnect negative battery cable. Remove all accessory drive belts. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Holding crankshaft stationary, remove crankshaft pulley.
Place jack under engine. Support engine so there is no weight on engine mount bracket (timing belt end of engine). On vehicles equipped with A/C, move A/C relay box and drier assembly (hoses attached) out of way to remove
engine mount bracket. On all vehicles, remove engine mount bracket-to-engine bolt and nut. Remove engine mount bracket-to-body through bolt. Remove engine mount bracket. Remove water pump pulley. Remove power steering pump and bracket with hoses attached and secure out of way. Remove oil dipstick tube. Remove timing belt upper and lower covers. Rotate crankshaft clockwise to align timing mark on camshaft sprocket with mark on cylinder head. Ensure crankshaft sprocket timing marks are aligned. See Fig. 6. Loosen timing belt tensioner adjusting bolt. Move tensioner toward water pump to relieve tension on timing belt. 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.
408
MITSUBISHI *1.5L 4-Cylinder SOHC (Cont.)
Installation (1997-01): Ensure crankshaft and camshaft timing marks are aligned. See Fig. 6. If timing belt tensioner and spring were removed, install with tensioner spring in correct position. See Fig. 7. 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 adjusting bolt. Ensure timing belt teeth are fully seated in camshaft sprocket. Install timing belt covers. Install crankshaft pulley. Tighten bolt to specification. See TORQUE SPECIFICATIONS table. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS (1985-96 MIRAGE) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt 1985-91 .......................................................... 47-54 (65-75) 1992-96 ........................................................ 52-74 (70-100) Crankshaft Pulley Bolt 1991-96 .......................................................... 10-11 (14-15) Crankshaft Sprocket Bolt 1985 ............................................................... 37-43 (50-58) 1986-96 ...................................................... 52-74 (70-100)) Front Cover Bolt 1985-88 ............................................................ 9-10 (12-14) Rocker Arm Adjuster Lock Nut 1989-96 .......................................................... 10-13 (14-18) Timing Belt Tensioner Bolt 1985-96 .......................................................... 14-20 (19-27) INCH Lbs. (N.m) Crankshaft Pulley Bolt ................................... 108-120 (12-14) Front Cover Bolt ................................................ 84-132 (9-15) Fuel Rail Bolt 1992-96 .......................................................... 84-108 (9-12) Rocker Cover Bolt ........................................... 13-17 (1.5-1.9) Timing Belt Cover Bolt ........................................ 84-108 (9-12) Water Pump Pulley Bolt 1988-85 ..................................................... 108-120 (12-14) 1996-89 .............................................................. 72-84 (8-9) TORQUE SPECIFICATIONS (1991-94 PRECIS) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 48-55 (65-75) Camshaft Thrust Case Bolt .............................. 14-20 (19-27) Crankshaft Sprocket Bolt ................................ 52-74 (70-100) Front Cover Bolt ................................................ 10-11 (14-15) Timing Belt Tensioner Bolt ............................... 15-20 (20-27) INCH Lbs. (N.m) Camshaft Rear Cover Bolts ................................. 70-86 (7-10) Rocker Cover Bolt ........................................... 13-18 (1.5-2.0) Timing Belt Cover Bolt .................................... 86-104 (10-12)
TORQUE SPECIFICATIONS (1997-01) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................................ 64 (88) Crankshaft Pulley Center Bolt ................................... 1 93 (125) Engine Mount Bracket-To-Engine ................................... 25 (35) Engine Mount Bracket-To-Engine Bracket Bolt/Nut ............................. 42 (57) Bracket-To-Body Through Bolt .................................... 2 72 (98) Power Steering Pump Bracket-To-Engine Bolt ................................................ 16 (22) Timing Belt Tensioner Adjusting Bolt .......................... 17 (24) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................... 89-106 (10-12) Water Pump Pulley Bolt ................................................ 80 (9)
1 2
Apply engine oil to bolt thread before installation. Final tighten with full weight of engine on bolt.
MITSUBISHI 1.6L 4-Cylinder SOHC

409
Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC Mirage 1985-88 .............. 1 2.8 Hours ................ 250093 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .3 hours.


TIMING BELT
Removal: Remove splash panel in left side wheel house. Remove air intake duct to air cleaner housing. Noting installed position for reassembly reference, remove spark plug cables from spark plugs. Remove all accessory drive belts. Place jack under engine. Support engine so there is no weight on engine mount bracket (timing belt end of engine). Remove left side engine mount. Remove power steering pump pulley (if equipped). Remove water pump pulley. See Fig. 1. Remove upper timing belt cover.
Loosen tensioner adjusting bolt and nut about 1 turn so that timing belt tensioner contacts timing belt. Turn crankshaft clockwise by 2 teeth of the camshaft sprocket. See Fig. 5. This is to give adequate tension to the timing belt. DO NOT turn crankshaft counterclockwise. Push timing belt tensioner to the right (as viewed from front of engine) so that belt engages completely with camshaft sprocket without any slack. Tighten tensioner bolt first, and then the tensioner nut. See TORQUE SPECIFICATIONS. Turn crankshaft one full revolution. Ensure camshaft and crankshaft timing marks are still aligned. To check timing belt final tension, hold timing belt between thumb and forefinger midway between camshaft sprocket and oil pump sprocket. See Fig. 6. Distance from back of timing belt to to edge of timing belt cover must be .23 (6 mm). Readjust belt tension, if necessary. Install timing belt covers. Ensure bolts are installed in correct position. See Fig. 7. Install crankshaft pulley. Tighten bolt to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 59-74 (80-100) Crankshaft Pulley Center Bolt ....................... 1 80-96 (110-130) Engine Mount To-Engine Bracket Bolt/Nut ............................... 37-50 (50-65) Bracket-To-Body Through Bolt ......................... 66-81 (90-110) Timing Belt Tensioner Adjusting Bolt/Nut ................... 17 (24) Vibration Damper-To-Adapter Bolts ..................... 11-13 (15-18) INCH Lbs. (N.m) Power Steering Pump Pulley Bolt ................................. 80 (9) Timing Belt Cover Bolt ................................... 89-106 (10-12) Water Pump Pulley Bolt ................................................ 80 (9) 1 Apply engine oil to bolt thread before installation.
Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Ensure camshaft sprocket timing mark aligns with mark on under upper cover. See Fig. 2. Holding crankshaft stationary, remove crankshaft pulley. Remove lower timing belt cover. Loosen timing belt tensioner adjusting bolt and nut. Move tensioner 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. Ensure crankshaft and camshaft timing marks are aligned. See Fig. 2. Install timing belt onto crankshaft sprocket, and keeping tension tight, install timing belt on camshaft sprocket. After installing timing belt, ensure timing belt is tensioned between crankshaft and camshaft sprockets. Check that all timing marks are still aligned.
410
MITSUBISHI 1.6L 4-Cylinder SOHC (Cont.)
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 1.8L & 2.0L 4-Cylinder

TIMING BELT APPLICATION Application 1.8L 4-Cyl. Cordia & Tredia 1983-84 Balance Shaft ... 1 .................................. 250090 Camshaft .......... 2 3.2 Hrs. .................... 250089 1985-86 Balance Shaft ... 1 .................................. 250159 Camshaft .......... 2 3.2 Hrs. .................... 250089 1987-88 Balance Shaft ... 1 .................................. 250159 Camshaft ............ 2 3.2 Hrs. . 2521580 .... 250158 2.0L 4-Cyl. Cordia & Tredia 1984, Balance Shaft ... 1 .................................. 250090 Camshaft .......... 2 3.2 Hrs. .................... 250089 1985-86 Balance Shaft ... 1 .................................. 250159 Camshaft .......... 2 3.2 Hrs. .................... 250089 1987-88, Balance Shaft ... 1 .................................. 250159 Camshaft .......... 2 3.2 Hrs. .................... 250158 Galant 1989-92 Balance Shaft ... 1 .................................. 250159 Camshaft .......... 2 2.4 Hrs. . 2521550 .... 250155 1993, Balance Shaft ... 1 .................................. 250168 Camshaft .......... 2 2.4 Hrs. . 2522320 .... 250232 Pickup 1983-86 Balance Shaft ... 1 .................................. 250090 Camshaft .......... 2 2.3 Hrs. .................... 250089 1987-89 Balance Shaft ... 1 .................................. 250159 Camshaft .......... 2 2.3 Hrs. . 2521581 .... 250158 1 - Balance Shaft Belt labor time included in Camshaft Belt labor time. 2 - With Air Cond. add .7 hours. With Pwr. Strng. add .3 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits. Labor Time Belt Component Part Kit No. No.
411

TIMING BELT
Removal (1983-88): Disconnect negative battery cable. On models equipped with A/C, remove upper radiator shroud and cooling fan/ clutch assembly. On models equipped with power steering, remove power steering pump and pulley. On all models, position No. 1 cylinder at TDC of compression stroke. Loosen pulley bolts. Remove drive belts. Remove crankshaft, water pump and power steering pulleys. Remove upper and lower front timing belt covers. Relieve camshaft timing belt tensioner pressure and secure tensioner toward water pump. If camshaft timing belt is to be reused, mark belt with an arrow indicating direction of rotation and remove belt. Remove camshaft and crankshaft sprocket bolts. Remove camshaft sprocket, crankshaft sprocket and crankshaft flange. Remove plug on left side of cylinder block. Insert a screwdriver to keep left silent shaft in position. See Fig. 3. Remove oil pump sprocket. Loosen right silent shaft sprocket mounting bolt until it can be turned by hand. Remove belt tensioner B and timing belt B. Inspection (1983-88): Inspect back of belt for hardness, non-elasticity and glossy surface. If no mark is produced when fingernail is forced into it, replace belt. Check for rounded sides on belt, flaking, peeling, cracking and separating rubber. Cracks are most evident at base of tooth. Installation (1983-88): Install timing belt B ensuring tension side has no slack. Install tensioner B so only light pressure is on belt. Ensure flange on tensioner is mounted away from engine and finger-tighten bolt. Lift tensioner with finger tip until slack is removed from tension side of belt. Tighten tensioner bolt, being careful to prevent turning shaft. Ensure timing marks are in alignment. Tighten right silent shaft bolt. Check belt tension by pressing center of tension side inward, using index finger and measuring belt deflection. Deflection should be .20-.30" (5.0-7.0 mm). Readjust if not within specification. Align camshaft timing belt sprockets with corresponding timing marks. See Fig. 1 or Fig. 2. To ensure oil pump sprocket is in correct alignment, insert screwdriver shaft in hole on left side of block. See Fig. 3. If screwdriver cannot be inserted at least 2.4" (60.0 mm), turn oil pump sprocket one revolution and realign marks. Insert screwdriver. Leave screwdriver inserted until timing belt installation is complete. With tensioner secured fully toward water pump, install timing belt in order of 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, tension bracket will turn and belt will be too tight. Ensure all timing marks are in correct alignment. Remove screwdriver and install plug in block. Turn crankshaft, clockwise only, one revolution. Loosen mounting nut and bolt to allow tensioner to readjust and tighten slot-side bolt, then tighten nut. Hold belt and seal line of undercover, between thumb and forefinger, at center of tension side. Measure clearance between belt and seal line. Clearance should be .55" (14.0 mm). Reverse removal procedure to complete reassembly. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.

412
Removal (1989-93): Disconnect negative battery cable. Remove A/C and power steering hose mounting bracket or oxygen sensor connector bracket from upper engine mount at timing belt cover. Support engine, and remove upper engine mount. Remove all drive belts and drive pulleys from crankshaft and water pump. Remove drive belt tensioner. Remove upper and lower timing belt covers. Note bolt lengths and locations. Longer (2) bolts are located above crankshaft seal. Remove crankshaft sprocket bolt access cover, crankshaft sprocket bolt and washer. If necessary, remove rocker arm cover for clearance.
MITSUBISHI 1.8L & 2.0L 4-Cylinder (Cont.)
sprocket. Belt deflection should be .55" (14 mm). To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS
Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 1 or Fig. 2. Loosen timing belt tensioner adjustment bolt, and move tensioner toward water pump. Tighten bolt to secure tensioner. Remove front timing belt and camshaft sprocket. If oil pump sprocket removal is necessary, remove left silent shaft access plug from cylinder block. Insert .31" (8.0 mm) diameter Phillips screwdriver to block left silent shaft. Remove oil pump sprocket nut and sprocket. Remove front crankshaft sprocket and flange. Note direction and order of installation. Remove rear timing belt tensioner assembly. Remove rear timing belt. Inspection (1989-93): Check belt teeth for cracks, damage and contamination. Inspect sprockets for damage. Check belt tensioner for leakage or roughness in rotation. Replace components as necessary. Installation (1989-93): If reusing rear timing belt, install in original direction of rotation. Ensure timing marks are aligned. See Fig. 4. Install rear timing belt tensioner. Hold tensioner tightly against belt while tightening bolts. Depress belt between sprockets to ensure deflection is .20-28" (5-7 mm). Adjust as necessary. Install crankshaft front sprocket. Install oil pump sprocket. Hold left silent shaft using a .31 (8.0 mm) diameter Phillips screwdriver through access hole. Ensure screwdriver can be inserted at least 2.36 (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36" (59.9 mm), and rotate oil pump sprocket one revolution. Align timing mark. Insert screwdriver, and ensure it can be inserted at least 2.36" (59.9 mm). DO NOT remove screwdriver until timing belt is installed. Install camshaft sprocket. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install front timing belt tensioner, tension spring and spacer(s). Ensure spring is properly engaged against water pump case. Rotate tensioner toward water pump, and temporarily tighten bolts. Ensure timing marks are aligned. See Fig. 1 or Fig. 2. If reused, install timing belt in original direction of rotation. Apply pressure on tension side of belt while installing belt on camshaft sprocket. Loosen timing belt tensioner to apply spring pressure to timing belt. Ensure timing marks are still aligned. To apply tension on belt, rotate crankshaft clockwise until camshaft sprocket timing mark is offset by 2 teeth. Tighten tensioner bolt. Tighten tensioner nut. To check belt tension, apply slight thumb pressure and measure deflection between camshaft and oil pump
Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27) Automatic Tensioner Bolt .................................. 14-20 (19-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt 1983-85 .......................................................... 11-15 (15-20) 1986-93 .......................................................... 15-21 (20-29) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Damper Pulley Bolt ........................................... 11-13 (15-18) Front Cover Bolts M8 X 30 Bolt .................................................... 20-26 (27-35) Except M8 X 30 Bolt ........................................ 14-20 (19-27) Idler Pulley Bolt ................................................. 25-30 (34-41) Rear Timing Belt Tensioner ............................. 11-16 (15-22) Silent Shaft Sprocket Bolt .08" (2.0 mm) Washer .................................... 25-29 (34-39) .10" (2.5 mm) Washer .................................... 31-35 (42-47) Tensioner Pulley Bracket Bolt ........................... 17-20 (23-27) Tensioner Pulley Center Bolt ............................ 31-40 (42-54) Timing Belt Cover Bolt Left Lower Rear Cover .................................... 22-30 (30-41) All Others ............................................................................ 1 Timing Belt Tensioner Nut 1983-85 .......................................................... 16-21 (22-28) 1986-93 .......................................................... 32-39 (42-53) Water Pump Bolt Except 8 X 65 mm ............................................ 9-11 (12-15) 8 X 65 mm ...................................................... 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt All Except Left Lower Rear Cover Bolt ............. 84-108 (9-12) Water Pump Pulley Bolt ........................................ 72-84 (8-9)
1
- All except Left Lower Rear Cover Bolt tighten to 84-108 INCH Lbs. (9-12 N.m).
Fig. 1: Aligning Camshaft Sprocket Timing Marks (8-Valve Engine)
MITSUBISHI 1.8L & 2.0L 4-Cylinder
413
Fig. 3: Aligning Oil Pump Sprocket
Fig. 2: Aligning Camshaft Timing Marks (16-Valve Engine)
414
MITSUBISHI *2.0L 4-Cylinder DOHC, Eclipse & Galant

Belt Part No.
TIMING BELT APPLICATION Labor Component Application Time Kit No. 2.0L 4-Cyl. DOHC (4G6) Eclipse Turbo & Non-Turbo 1990-94 ...... 1 & 2 3.6 Hrs. .... 2521670 ...... 3 250167 1990-94 ...... 1 & 2 3.6 Hrs. ......................... 4 250168 Eclipse Turbo 1995-99 ...... 1 & 2 3.6 Hrs. .... 252167 ...... 03 250167 1995-99 ...... 1 & 2 3.6 Hrs. ......................... 4 250168 Galant 1989-92 ...... 1 & 2 3.6 Hrs. .... 2521670 ...... 3 250167 1989-92 ...... 1 & 2 3.6 Hrs. ......................... 4 250168 1993 ........... 1 & 2 3.6 Hrs. .... 2522320 ...... 3 250232 1993 ........... 1 & 2 3.6 Hrs. ......................... 4 250168 1 - Balance shaft labor time included in camshaft labor time. 2 - With Air Cond. add .7 hours. With Pwr. Strng. add .2 hours. 3 Camshaft timing belt. 4 Balance shaft belt. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.

For 1989-94 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles. For 1995-97 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California. In California, timing belt replacement is recommended but not required at 60,000 miles. In California, replace belt at 100,000 miles, unless previously changed. For 1998-99 vehicles, the manufacturer recommends the belt be replaced every 60,000 miles, except in California, Connecticut and Massachusetts. In California, Connecticut and Massachusetts, timing belt replacement is recommended but not required at 60,000 miles. In California, replace belt at 100,000 miles, unless previously changed.

TIMING BELT & BALANCE SHAFT BELT
Removal: Disconnect negative battery cable. Remove engine undercover. Place wooden block between jack and oil pan and raise engine slightly. Remove engine mount assembly near timing belt cover. Remove clamp for power steering return hose near timing belt cover. Remove all drive belts and tensioner pulley bracket. See Fig. 1. Remove power steering and water pump pulleys. Rotate crankshaft clockwise so that No. 1 cylinder is at TDC of compression stroke. Remove crankshaft pulley.
Fig. 1: Exploded View Of Timing Belts & Components
415 MITSUBISHI *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.
Fig. 5: Holding Balance Shaft Stationary
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 tension. Remove timing belt. Remove timing belt auto tensioner. See Fig. 1. Remove plug from left side of cylinder block. Install a .31" (8.0 mm) diameter Phillips screwdriver into the hole against balance shaft. See Fig. 5. Screwdriver must go in at least 2.36 (60 mm) or more. If screwdriver will only go in about .79-.98 (20-25 mm) before striking balance shaft, turn sprocket one revolution and align timing mark. Keep screwdriver in place until timing belt is installed. This ensures balance shaft driven by oil pump sprocket remains in correct position. To remove timing belt B (balance shaft belt), hold crankshaft sprocket stationary with a spanner wrench. Remove crankshaft sprocket bolt. Using gear puller, remove outer crankshaft sprocket. 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 reference. Remove timing belt B. Inspection: Inspect timing belts for damaged teeth and cracking. Ensure belts are not contaminated with oil. Check tensioners for free rotation and grease leakage. Replace components if damaged or if grease leakage exists.
NOTE: The following revised information for timing belt tensioner inspection is from Mitsubishi technical service bulletin 96-11006; 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: 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 sprockets. If using old belt, install belt in original direction of rotation. Ensure there is no slack in tension side of belt.
CAUTION: Ensure tensioner pulley shaft does not rotate when bolt is tightened or excessive pressure will be applied to timing belt.
417 MITSUBISHI *2.0L 4-Cylinder DOHC, Eclipse & Galant (Cont.)

Install timing belt B tensioner so center of tensioner pulley is to the left and above of retaining bolt center. See Fig. 9. Rotate tensioner inward toward timing belt until belt is tight. Tighten tensioner retaining bolt without letting tensioner pulley rotate out of position. Check belt deflection at designated area. Belt deflection should be .20-.28" (5.0-7.0 mm). Readjust timing belt if belt deflection is not within specification.
CAUTION: Install crankshaft sensing blade and crankshaft sprockets in correct positions or timing belt may be damaged.
Install crankshaft sensing blade (if equipped) in front of crankshaft sprocket B, with offset in proper direction. See Fig. 10. Install crankshaft sprocket A. Apply light coat of engine oil to crankshaft sprocket bolt threads, and tighten bolt to specification. See TORQUE SPECIFICATIONS. Install idler pulley (if removed). Ensure camshaft, crankshaft and oil pump timing marks are still aligned. See Figs. 2 and 3. Do not remove screwdriver from side of engine block until timing belt is installed.
NOTE: Intake and exhaust camshafts use same camshaft sprocket. Camshaft sprockets are provided with 2 timing marks. For exhaust camshaft sprocket, use timing mark on right with dowel pin facing up. On intake camshaft, sprocket, use timing mark on the left, with dowel pin hole on top.
Rotate camshaft sprocket so dowel pins are upward and away from cylinder head and timing marks are aligned with cylinder head surface. Timing marks should face each other. See Figs. 2 and 3. Install timing belt on intake camshaft sprocket. Install spring clip to retain timing belt on sprocket. See Fig. 11. Place a wrench on each camshaft sprocket retaining bolt. Rotate camshafts so timing marks align with each other. Install timing belt over exhaust camshaft. Install spring clip to retain timing belt. Install timing belt over idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. Remove spring clips from camshaft sprockets. Timing Belt Tension Adjustment (1990-92) Position timing belt tensioner pulley so that the 2 pin holes in the center eccentric are facing to the left (as viewed from timing belt end of engine) of the center bolt. Finger tighten center bolt. Remove screwdriver from balance shaft hole in side of engine block. Install plug. Rotate crankshaft 1/4 turn counterclockwise, then rotate crankshaft 1/4 clockwise until timing marks are aligned again. No. 1 cylinder should be at TDC of compression stroke.
Attach Adapter (MD998767) to tensioner pulley eccentric. Attach torque wrench to adapter and apply 24 INCH lbs. (2.7 N.m) of torque in a clockwise direction. See Fig. 15. With torque applied to eccentric, tighten tensioner pulley center bolt to 32-40 ft. lbs. (43-55 N.m). Insert Set Screw (MD998738) through inner timing belt cover until it contacts tensioner arm. See Fig. 12. Slowly rotate set screw until set pin can be removed. Remove set screw from engine. Rotate crankshaft 6 complete turns clockwise. Wait 15 minutes without turning crankshaft. Measure distance between top of auto tensioner body and tensioner arm. The distance should be .15-.18 (3.8-4.5 mm). If distance is not correct, timing belt tension will have to be readjusted. Go to FINAL ASSEMBLY. Timing Belt Tension Adjustment (1993-98): Lift tensioner pulley upward to apply tension on timing belt. The 2 pin holes in the center of the tensioner must face down. See Fig. 12. Screw the Set Screw (MD998738) into engine support bracket until it makes contact with tensioner arm. At that point, screw the set screw in a few more threads and remove the set pin from the auto tensioner. Remove the set screw. Tighten timing belt tensioner pulley center bolt to 35 ft. lbs (48 N.m). Remove screwdriver from side of engine block and install plug. To tension timing belt, rotate crankshaft about 1/4 turn counterclockwise, then 1/4 turn clockwise until all timing marks align. Loosen tensioner pulley center bolt. Install Adapter (MD998767) or equivalent to tensioner eccentric. Install torque wrench on adapter. See Fig 13. Starting with eccentric pin holes still facing down, apply 31 INCH Ibs. (3.5 N.m) of torque counterclockwise on tensioner pulley. Hold tensioner pulley at specified torque, and tighten tensioner center bolt to specification. DO NOT let tensioner pulley turn with bolt. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 full revolutions clockwise so that timing marks are aligned. Allow engine to stand for 15 minutes without turning crankshaft. Distance between top of auto tensioner housing and tensioner arm should be .15.18" (3.8-4.5 mm). See Fig. 16, Dimension A. If distance is incorrect, repeat tensioning procedure until distance is correct. Go to FINAL ASSEMBLY. Final Assembly: To install remaining components, reverse removal procedure. Ensure proper length bolts are installed in timing belt covers. See Fig. 14. See TIMING COVER BOLT LENGTH & TORQUE. Adjust drive belts to proper tension. See page A60 for belt tension ranges.
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 Fig. 15: Adjusting Timing Belt Tension (1990-92)
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Auto Tensioner Bolt .................................................... 17 (24) Balance Shaft Sprocket Bolt ......................................... 33 (46) Camshaft Sprocket Bolt .............................................. 65 (90) Crankshaft Pulley Bolt ................................................ 18 (25) Crankshaft Sprocket Bolt ............................. 80-94 (108-127) Drive Belt Tensioner Pulley Bracket ..................... 17-20 (23-26) Engine Mount-To-Engine Bolt/Nut (1993-98) ..................................................... 49 (67) Engine Mount-To-Engine Bolt/Nut (1990-92) ........................................... 36-47 (50-65) Engine Mount-To-Body Through-Bolt (1993-98) ..................................... 72-87 (98-118) Engine Mount-To-Body Through-Bolt (1990-92) ...................................... 43-58 (60-80) 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)
TIMING COVER BOLT LENGTH & TORQUE Bolt Length INCH Lbs. (N.m) A : 6 x 16 mm Flange Bolt ............................. 89-106 (10-12) B : 6 x 18 Flange Bolt .................................... 89-106 (10-12) C: 6 x 25 Loose Washer Bolt .................................. 58 (6.5) D: 6 x 25 Flange Bolt .................................... 89-106 (10-12) E : 6 x 45 Flange Bolt .................................... 89-106 (10-12)
MITSUBISHI *2.4L 4-Cylinder DOHC

TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time 1& 2 2.4L 4-Cyl. DOHC Galant 1994 Balance Shaft .............. 1 ......................... 250168 Camshaft Thru 5/94 ..... 3.6 Hrs. ...... 2522560 ........ 250256 From 6/94 .... 3.6 Hrs. ............................. 250230 1995-96 Balance Shaft 1 ...................................... 250168 Camshaft ....... 3.6 Hrs. ............................. 250230 1 -Balance Shaft included in Camshaft labor time. 2 - With Air Cond. add .7 hours. With Pwr. Strng. add .3 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
419
To remove camshaft sprockets, hold camshaft hexagon (between camshaft journals No. 2 and 3) while removing camshaft sprocket bolt. Remove camshaft sprockets. Remove silent shaft access plug from cylinder block. Insert .31" (8.0 mm) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Remove oil pump sprocket nut and sprocket. Remove bolt, washer, crankshaft sprocket and flange. Note direction of flange installation. Remove rear timing belt tensioner assembly. Remove rear timing belt. Inspection: Check belt teeth for damage and oil contamination. Inspect belt for glossy, hardened or non-elastic surface. Ensure belt is not cracked, separated or showing canvas fiber. Inspect all sprockets fordamage. Check tensioner pulley and idler pulley for grease leakage and roughness in rotation. Replace components if damaged. Inspect automatic tensioner for leaks. Check rod end of automatic tensioner for wear. Measure distance from tensioner rod end to tensioner housing. Distance should be .47" (11.9 mm). Retract rod into tensioner housing by placing automatic tensioner assembly in a soft-jawed vise. Close vise to push rod back into tensioner. Replace automatic tensioner assembly if rod can be easily pushed into automatic tensioner.
NOTE: lf plug at bottom of tensioner protrudes past tensioner housing, place a washer over plug to prevent it from contacting vise when pushing rod into tensioner housing.

For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed.

TIMING BELT
CAUTION: To prevent engine damage, DO NOT rotate crankshaft counterclockwise (as viewed from timing belt end of engine).
Removal: Disconnect negative battery cable. Remove protective cover from below engine. Remove A/C and power steering hose mounting bracket. Support engine. Remove upper engine mount located near timing belt cover. Remove all drive belts. Remove tensioner pulley bracket. Remove pulleys from crankshaft, water pump and power steering. Remove drive belt tensioner. Remove upper and lower timing belt cover with gasket. Note bolt lengths and locations. Remove breather hose, PCV hose and center shield from valve cover. Disconnect spark plug wires from spark plugs. Remove rocker cover and semi-circular packing (located at rear of rocker cover). Remove rubber plug. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until all timing marks align and cylinder No. 1 is at TDC of compression stroke. See Fig. 1. Remove automatic tensioner. See Fig. 2. If timing belt is to be reused, mark timing belt to indicate original direction of rotation. Remove timing belt. Remove tensioner pulley, tensioner arm and idler pulley (if necessary). Inspect sprockets for damage.
Installation: Align timing marks on silent shaft rear crankshaft sprockets with timing marks on engine case. Install rear timing belt and tensioner. Hold tensioner tightly against belt while tightening bolts. To check tension, depress belt with finger midway between sprockets. Deflection should be .20-.28" (5.0-7.1 mm). Install crankshaft sprocket, oil pump sprocket and camshaft sprocket. Tighten camshaft sprocket bolts to specification while holding hexagon area of camshaft. See TORQUE SPECIFICATIONS. Install idler pulley. Retract automatic tensioner rod into tensioner housing by placing tensioner assembly in a soft-jawed vise. Push rod back into automatic tensioner in small increments until both rod and housing holes are aligned. See Fig. 6. Install a .055" (1.39 mm) diameter wire into holes. Remove automatic tensioner from vise with wire attached. Install tensioner and arm. Install tensioner pulley on tensioner arm. Ensure pin holes of tensioner pulley shaft are left of pulley center bolt. Tighten center bolt. Rotate camshaft sprockets so dowel pins face upward and timing marks on sprockets align. See Fig. 1. Outer marks on sprockets should be aligned with cylinder head surface. When exhaust camshaft sprocket is released, camshaft will rotate one tooth in counterclockwise direction. Ensure this rotation is compensated for when installing timing belt. Rotate crankshaft and oil pump sprockets to align timing marks. If reusing old timing belt, ensure belt is installed in original direction of rotation. Remove silent shaft access plug from cylinder block. Insert .31" (8.0 mm) diameter Phillips screwdriver. See Fig. 3. If screwdriver can be inserted 2.36" (59.9 mm) or more, timing mark alignment is okay.
420
MITSUBISHI *2.4L 4-Cylinder DOHC (Cont.)
To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise, and then rotate clockwise until cylinder No. 1 is at TDC. Ensure timing marks are aligned. Loosen center bolt on tensioner pulley. Note location of pin holes in tensioner pulley. Using INCH-lb. torque wrench and Socket Wrench (MD998767) or equivalent, apply 22 INCH Ibs. (2.6 N.m) on tensioner pulley. See Fig. 5. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to 35 ft. Ibs. (48 N.m). Install set screw in support bracket until set screw end contacts tensioner arm. See Fig. 8. Rotate set screw further until wire can be removed from automatic tensioner. Remove set screw. Rotate crankshaft clockwise 2 complete revolutions, and allow to remain in this position for about 15 minutes. Measure distance between tensioner arm and automatic tensioner body. Distance should be .15-.18" (3.8-4.5 mm). See Fig. 9, Dimension A. If distance cannot be measured due to lack of clearance, use alternate method. Install set screw until it contacts tensioner arm. Rotate set screw inward while counting number of turns until tensioner arm contacts automatic tensioner housing. Number of turns should be 2 1/2-3 if belt tension is correct. Remove set screw. Install rubber plug in rear timing belt cover. To complete installation, reverse removal procedure. Apply sealant to contact areas on semi-circular packing and rocker cover before installing. Ensure correct bolts are installed in proper location in timing belt covers. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
If screwdriver cannot be inserted at least 2.36" (59.9 mm), remove screwdriver and rotate oil pump sprocket one full turn. Reinsert screwdriver. Leave screwdriver in place until timing belt is installed. Install timing belt on intake camshaft sprocket. Use spring clip to hold belt on sprocket. See Fig. 7. Install wrench on both camshaft sprocket bolts. Install timing belt around exhaust camshaft sprocket while holding camshaft sprocket bolt so timing mark on camshaft sprocket is aligned with timing mark. Install another spring clip on timing belt and camshaft sprocket to hold belt on sprocket. Install timing belt in following sequence: around idler pulley, oil pump sprocket, crankshaft sprocket and tensioner pulley. Remove both spring clips. Rotate tensioner pulley inward toward timing belt until belt does not sag. Temporarily tighten center bolt on tensioner pulley. Ensure all timing marks are aligned. Remove Phillips screwdriver from silent shaft access hole. Install plug. Remove wrench from camshaft sprocket bolts.
Fig. 4: Installing Crankshaft Sprockets
MITSUBISHI *2.4L 4-Cylinder DOHC (Cont.)
421
Fig. 5: Adjusting Timing Belt Tensioner Pulley
Fig. 8: Measuring Timing Belt Adjustment
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27) Auto Tensioner Bolt .......................................... 14-20 (19-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt ...................................... 14-22 (19-30) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Engine Support Bracket Bolt Front ............................................................... 36-51 (49-69) Left .................................................................. 22-30 (30-41) Front Cover Bolt ................................................ 14-16 (19-22) Front Tensioner Pulley Bolt ............................... 31-40 (42-54) Idler Pulley Bolt ................................................. 25-30 (34-41) Rear Tensioner Retaining Bolt ......................... 11-16 (15-22) Silent Shaft Sprocket Bolt .................................. 31-35 (42-47) Water Pump Bolt Except 8 X 65 mm .................................................... 10 (14) 8 X 65 mm ...................................................... 15-19 (20-26) INCH Lbs. (N.m) Crankshaft Position Sensor Nut ....................... 84-108 (9-12) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Valve Cover Bolt .................................................... 24-36 (3-4) Water Pump Pulley Bolt ........................................ 72-84 (8-9)
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 INSTALLATION Belt Part No.
Installation: Lightly oil right silent shaft spacer and insert spacer with chamfered end toward seal. Install right silent shaft sprocket (if removed) and finger-tighten bolt. Align crankshaft sprocket and silent shaft sprocket timing marks with corresponding marks on front case. See Figs. 2 and 7. Install timing belt B, ensuring tension side has no slack. Install tensioner B so only light pressure is on belt. Ensure flange on tensioner is mounted away from engine and finger-tighten bolt. Lift tensioner with finger tip until slack is removed from tension side of belt. Tighten tensioner bolt, being careful to prevent turning shaft. Ensure timing marks are in alignment. Tighten right silent shaft bolt. Check belt tension by pressing center of tension side inward, using index finger and measuring belt deflection. Deflection should be .20-.30" (5.0-7.0 mm). Readjust if not within specification. Align camshaft timing belt sprockets with corresponding timing marks. See Fig. 6. To ensure oil pump sprocket is in correct alignment, insert screwdriver shaft in hole on left side of block. See Figs. 4 and 5. If screwdriver cannot be inserted at least 2.4" (60.0 mm), turn oil pump sprocket one revolution and realign marks. Insert screwdriver. Leave screwdriver inserted until timing belt installation is complete. Install crankshaft sprocket. See Figs. 1 and 8.
TIMING BELT APPLICATION Labor Component Application Time Kit No. 2.4L 4-Cyl. SOHC Galant 1985-87 ........ 1 & 2 2.4 Hrs. .. 2521240 ...... 3 250124 1985-87 ........ 1 & 2 2.4 Hrs. ....................... 4 250159 Van 1990-87 ........ 1 & 2 3.2 Hrs. .. 2521240 ...... 3 250124 1990-87 ........ 1 & 2 3.2 Hrs ........................ 4 250159 1 - Balance shaft belt labor time included in camshaft belt labor time. 2 - With Air Cond. add .7 hours. With Pwr. Strng. add .3 hours. 3 Camshaft timing belt. 4 Balance shaft belt.


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 pressure and secure tensioner toward water pump. If camshaft timing belt is to be reused, mark belt with an arrow indicating direction of rotation and remove belt. Remove camshaft and crankshaft sprocket bolts. Remove camshaft sprocket, crankshaft sprocket and crankshaft flange. Remove plug on left side of cylinder block. Insert a screwdriver 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. Remove belt tensioner B and timing belt B.
Fig. 1: Installing Crankshaft Sprockets (Galant)
Inspect back of belt for hardness, non-elastic and having a glossy surface. If no mark is produced when fingernail is forced into it, replace belt. Check for rounded sides on belt. Sides of belt should be straight and clear-cut. Flaking, peeling, cracking and rubber from canvas also indicates belt warrants replacement. Cracks are most evident at base of tooth. Abnormal wear most often occurs on load side of tooth. Fluffy canvas, unclear canvas texture, belt color changed to White from rubber missing, reduced tooth width or a missing tooth warrant belt replacement.
Fig. 2: Aligning Timing Marks For Timing Belt B
423 MITSUBISHI 2.4L 4-Cylinder 1985-90 Galant & Van (Cont.)

With tensioner secured fully toward water pump, install timing belt in order of crankshaft sprocket, oil pump sprocket and camshaft sprocket. Ensure tension side of belt has no slack. Loosen tensioner mounting bolt and nut to allow only tensioner spring pressure to tighten belt. Check belt to ensure each tooth is in proper mesh with camshaft sprocket. Tighten slot-side bolt before tightening nut. Otherwise, tension bracket will turn and belt will be over tensioned. Ensure all timing marks are in correct alignment. Remove screwdriver and install plug in block. Turn crankshaft, clockwise only, one revolution. Loosen mounting nut and bolt to allow tensioner to readjust and tighten slot-side bolt, then tighten nut. 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 A-60 for belt tension ranges.
Fig. 4: Aligning Oil Pump Sprocket
424
MITSUBISHI 2.4L 4-Cylinder 1985-90 Galant & Van (Cont.)
Fig. 8: Installing Crankshaft Sprockets (Van)
Fig. 9: Checking Timing Belt A Tension
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Tensioner Pulley Bracket Bolt .................... 17-20 (23-27) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt ........................................ 14-22 (19-30) Crankshaft Sprocket Bolt ............................. 80-94 (109-127) Engine Support Bracket Bolt Front ............................................................... 36-51 (49-69) Left .................................................................. 22-30 (30-41) Engine Support Bracket Bolts .......................... 29-36 (39-49) Front Cover Bolts .............................................. 15-19 (20-26) Front Roll Stopper Bracket Nuts ....................... 22-36 (30-49) Front Roll Stopper Insulator Nut ....................... 36-41 (49-56) Left Mounting Bracket-To-Engine Bolts & Nuts ................................................... 36-47 (49-64) Rear Roll Stopper Bracket-To-Rear Roll Stopper Insulator Nut .............................. 22-29 (30-39) Roll Stopper Stay Bolt ..................................... 11-15 (15-20) Rear Roll Stopper-To-No. 2 Crossmember Nuts ....................................... 43-58 (58-79) Rear Tensioner Retaining Bolt ....................... 11-16 (15-22) Silent Shaft Sprocket Bolt 1985-87 .......................................................... 25-28 (34-38) Timing Belt Tensioner Nut 1986-85 .......................................................... 16-21 (22-28) 1987-90 .......................................................... 32-39 (42-53) Water Pump Bolt Except 8 X 65 mm .................................................... 10 (14) 8 X 65 mm ...................................................... 15-19 (20-26) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 22-29 (30-39) Valve Cover Bolt ................................................ 84-108 (9-12) Water Pump Pulley Bolt ........................................ 48-60 (5-7)
Fig. 6: Aligning Camshaft Timing Marks (8-Valve Engine)
MITSUBISHI *2.4L 4-Cylinder SOHC, VIN G

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.4L 4-Cyl. SOHC Eclipse 2000-01 ............... 1 & 2 2.4 Hours ............. 3 250232 1996-98 ............... 1 & 2 2.4 Hours ............. 3 250230 1996-01 ............... 1 & 2 2.4 Hours ............. 4 250168 Galant 1999-01 ............... 1 & 2 2.4 Hours ............. 3 250232 1994-98 ............... 1 & 2 2.4 Hours ............. 3 250230 1994-01 ............... 1 & 2 2.4 Hours ............. 4 250168 Montero Sport 1997-99 ............... 1 & 2 1.8 Hours ............. 3 250230 1997-99 ............... 1 & 2 1.8 Hours ............. 4 250168 1 Balance shaft belt labor time included in camshaft belt labor time. 2 With Air Cond. add .7 hours for Galant. With Air Cond. add .2 hours for Eclipse. With Pwr. Strng. add .3 hours. 3 Camshaft timing belt. 4 Balance shaft belt.
NOTE: Engine VIN is eight character of vehicle VIN.
425

For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-00 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles. For 2001 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles.

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) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Ensure screwdriver can be inserted at least 2.36 (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36" (59.9 mm). Rotate balance shaft one revolution and realign timing mark. If reusing old balance shaft timing belt, mark belt with arrow to indicate rotation direction. Holding crankshaft stationary, 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
Courtesy of Mitsubishi Motor Sales of America Courtesy of Mitsubishi Motor Sales of America
Fig. 3: Locking Balance Shaft
Fig. 4: Exploded View Of Timing Belt Components (Montero Sport)
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 pulley. Remove crankshaft pulley. Noting bolt lengths and locations, remove upper and lower timing belt cover with gasket.
Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 is at TDC of compression stroke. Align timing mark on camshaft sprocket with timing mark on cylinder head. See Fig. 2. Loosen timing belt tensioner center bolt, and move tensioner toward water pump. Tighten center bolt to secure tensioner. Remove front timing belt. Remove timing belt auto tensioner.
Fig. 5: Aligning Balance Shaft Timing Marks

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.
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Rotate crankshaft clockwise so that No. 1 piston is at TDC of compression stroke. Leaving secondary wires attached, remove distributor cap and set aside. Note installed position of distributor and distributor rotor. Unplug distributor electrical connector. Remove distbutor housing and set aside. Disconnect ignition power transistor and ignition coil connector. 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 camshaft sprocket with timing mark on cylinder head. See Fig. 2. Loosen timing belt tensioner center bolt, and remove tensioner toward water pump. Tighten center bolt to secure tensioner. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. Remove timing belt auto tensioner. To remove balance shaft timing belt, remove left balance shaft access plug from cylinder block. Insert .31" (8.0 mm) diameter Phillips screwdriver to block left silent shaft. See Fig. 3. Ensure screwdriver can be inserted at least 2.36 (59.9 mm). Remove screwdriver if it cannot be inserted at least 2.36" (59.9 mm). Rotate balance shaft one revolution and realign timing mark. If reusing old balance shaft timing belt, mark belt with arrow to indicate rotation direction. Loosen balance shaft tensioner pulley center bolt. Remove balance shaft timing belt. Inspect back of belt for being hard, non-elastic and having a glossy surface. Check for rounded sides on belt. Sides of belt should be straight and clear-cut. Flaking, peeling, cracking 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 missing tooth warrant belt replacement.
Fig. 7: Adjusting Balance Shaft Timing Belt Tensioner
Fig. 8: Installing Crankshaft Sensing Blade (Eclipse & Galant)
Check timing belt and balance shaft belt tensioner pulleys for worn bearings. Replace as necessary. 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. (20 kg) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto tensioner.
Eclipse & Galant: Align crankshaft rear sprocket and balance shaft sprocket timing marks. See Fig. 5. Install balance shaft timing belt. If reusing old belt, install in original direction of rotation.
Courtesy of Mitsubishi Motor Sales of America Courtesy of Mitsubishi Motor Sales of America
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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 balance 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 specification. See TORQUE SPECIFICATIONS.
Fig. 11: Timing Belt Cover Bolt Installation Guide
NOTE: DO NOT remove Phillips screwdriver from side of engine block until camshaft timing belt is installed.
Using a soft-jawed vise, SLOWLY compress the timing belt auto tensioner push rod until rod pin hole aligns with pin hole in tensioner body. Insert a locking pin through tensioner body and tensioner push rod pin holes to lock auto tensioner in position. Install auto tensioner on engine with locking pin in place. 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. Set the timing belt tensioner pulley so that pin holes are at the bottom of the pulley. See Fig. 9. Press tensioner pulley lightly against the timing belt. Temporarily tighten tensioner pulley center bolt.
CAUTION: To prevent breaking auto tensioner push rod, turn Set Screw (MD998738) by hand only.
Install Set Screw (MD998738) into rear timing belt cover. See Fig. 9. Screw in set screw until tensioner bracket arm makes contact with auto tensioner push rod end. Remove Phillips screwdriver from engine block and install plug. To adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned. Loosen the tensioner pulley center bolt. Install Adapter (MD998767) and torque wrench on tensioner pulley. See Fig. 10. Apply 31 INCH lbs. (3.5 N.m) of torque while tightening tensioner pulley center bolt to specification. See TORQUE SPECIFICATIONS. DO NOT let tensioner pulley turn while tightening center bolt.
Remove locking pin from auto tensioner. Remove set screw. Turn crankshaft 2 revolutions clockwise. Align all timing marks. Let vehicle sit for 15 minutes. Measure auto tensioner rod protrusion between auto tensioner housing and point where it contacts tensioner arm. Protrusion should be .150-.177 (3.8-4.5 mm). If protrusion is not as specified, repeat timing belt tensioning procedure. Install timing belt covers. Ensure bolts are installed in original locations. See Fig. 11. Continue installation in reverse order of removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Montero Sport: Align crankshaft sprocket and balance shaft sprocket timing marks. See Fig. 5. Install balance shaft timing belt. If reusing old belt, install in original direction of rotation. 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 balance shaft tensioner pulley center bolt. Ensure balance shaft timing belt is taut (no slack), and tighten balance shaft tensioner pulley center bolt.
NOTE: When tightening balance shaft tensioner pulley center bolt, ensure tensioner pulley shaft does not rotate with bolt. This will place excessive tension on belt.
Press balance shaft belt on side opposite tensioner to check belt deflection. See Fig. 5. Balance shaft belt deflection should be .20-.28" (5.0-7.0 mm). Adjust as necessary. Using a soft-jawed vise, SLOWLY compress the timing belt auto tensioner push rod until rod pin hole aligns with pin hole in tensioner body. Insert a locking pin through tensioner body and tensioner push rod pin holes to lock auto tensioner in position. Install auto tensioner on engine with locking pin in place. Ensure all timing marks are still aligned. See Fig. 2. Install timing belt on engine. If reusing old timing belt, ensure belt is installed in original direction of rotation. Make sure there is no slack in timing belt between sprockets.

NOTE: DO NOT remove Phillips screwdriver from side of engine block until camshaft timing belt is installed.
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TORQUE SPECIFICATIONS (ECLIPSE & GALANT) Application Ft. Lbs. (N.m) Auto Tensioner Bolt .................................................... 18 (24) Camshaft Sprocket Bolt .............................................. 65 (90) Crankshaft Drive Belt Pulley Bolt ................................ 18 (25) Crankshaft Sprocket Bolt ............................ 1 80-94 (108-127) Drive Belt Tensioner Pulley Bracket Bolt .............. 17-20 (23-26) Engine Upper Mount Mount-To-Engine Bracket Nut/Bolt ................................ 49 (67) Mount-To-Body Through Bolt ............................ 71-85 (98-118) Power Steering Pump Pulley Bolt .................................. 45 (61) Tensioner Pulley Center Bolt Balance Shaft Belt Pulley ............................................ 14 (19) Camshaft Belt Pulley ................................................... 35 (48) Water Pump Bolt ........................................................ 10 (14) INCH Lbs. (N.m) Timing Belt Cover Bolt 6 mm (Except Flange Bolts) .................................... 78 (8.8) 6 mm (Flanged Bolt) ...................................... 89-106 (10-12) 8 mm Bolt .................................................................. 120 (14) Water Pump Pulley Bolt ........................................ 71-80 (8-9) 1 Apply engine oil to bolt threads. TORQUE SPECIFICATIONS (MONTERO SPORT) Application Ft. Lbs. (N.m) Auto Tensioner Bolt .................................................... 18 (24) Camshaft Sprocket Bolt .............................................. 65 (90) Crankshaft Drive Belt Pulley Bolt ................................ 18 (25) Distributor Bracket Bolt (M6 x 18 mm) ......................... 17 (24) Tensioner Pulley Center Bolt Balance Shaft Belt Pulley ............................................ 14 (19) Camshaft Belt Pulley ................................................... 35 (48) Water Pump Bolt ........................................................ 10 (14) INCH Lbs. (N.m) Cooling Fan Clutch-To-Stud Nut ....................... 89-106 (10-12) Distributor Bracket Bolt Except M6 x 18 mm ..................................................... 97 (11) Distributor Housing Hold-Down Bolt ........................... 115 (13) Timing Belt Cover Lower Cover Bolt ..................................................... 78 (8.8) Upper Cover Bolt ......................................................... 97 (11) Water Pump Pulley Bolt ............................................ 117 (13)
Set the timing belt tensioner pulley so that pin holes are at the bottom of the pulley. See Fig. 9. Press tensioner pulley lightly against the timing belt. Temporarily tighten tensioner pulley center bolt.
CAUTION: To prevent breaking auto tensioner push rod, turn Set Screw (MD998738) by hand only.
Install Set Screw (MD998738) into rear timing belt cover. See Fig. 9. Screw in set screw until tensioner bracket arm makes contact with auto tensioner push rod end. Remove Phillips screwdriver from engine block and install plug. To adjust timing belt tension, turn crankshaft 1/4 revolution counterclockwise. Turn crankshaft clockwise until all timing marks are aligned. Loosen the tensioner pulley center bolt. Install Adapter (MD998767) and torque wrench on tensioner pulley. See Fig. 10. Apply 31 INCH lbs. (3.5 N.m) of torque while tightening tensioner pulley center bolt to specification. See TORQUE SPECIFICATIONS. DO NOT let tensioner pulley turn while tightening center bolt. Remove locking pin from auto tensioner. Remove set screw. Turn crankshaft 2 revolutions clockwise. Align all timing marks. Let vehicle sit for 15 minutes. Measure auto tensioner rod protrusion between auto tensioner housing and point where it contacts tensioner arm. See Fig. 12, Dimension A. Protrusion should be .150-.177 (3.8-4.5 mm). If protrusion is not as specified, repeat timing belt tensioning procedure. Install timing belt lower cover, distributor bracket, and timing belt upper cover. Install distributor, distributor cap, and ignition coil. Install cooling fan clutch, pulley, fan shroud, and upper radiator hose. Continue installation in reverse order of removal procedure. Fill and bleed cooling system. Adjust ignition timing.
430
MITSUBISHI 3.0L V6 SOHC, 12-Valve Engine
On all models, remove engine support bracket. Remove crankshaft pulley. Remove timing belt covers. Remove flange from crankshaft. See Fig. 3. Rotate crankshaft to align all timing marks. See Fig. 4. Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to release belt tension. If reusing timing belt, mark belt to indicate direction of belt rotation. Loosen tensioner bolt. Pry tensioner counterclockwise to relieve belt tension. While holding tensioner, tighten tensioner bolt. Remove timing belt. Galant: Disconnect negative battery cable. Remove all accessory drive belts. Disconnect connector and pressure hoses at power steering pump. Remove power steering pump with return hose connected. Remove through-bolt from front engine mount.
CAUTION: Apply spray lubricant on reamer bolt during removal as bolt is sometimes seized in engine support.
TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time 1 3.0L V6 SOHC Diamante 1992-96 .......... 3.8 Hours ... 2521390 ........ 250139 Galant 1988 ............... 3.8 Hrs. ...... 2521390 ........ 250139 Montero (12-Valve Engine) 1989-94 .......... 3.5 Hrs. ...... 2521390 ........ 250139 Pickup (4WD) 1990-94 .......... 3.5 Hrs. ...... 2521390 ........ 250139 Sigma 1989-90 .......... 3.8 Hrs. ...... 2521390 ........ 250139 3000GT 1997-98 .......... 3.4 Hours ... 2521390 ........ 250139 1 - With Air Cond. add .2 hours. With Pwr. Strng. add .2 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
Support engine and remove front engine mount. Remove engine mount bracket bolts in sequence. Lubricate reamer bolt with penetrating oil before and during removal. See Fig. 2. Remove A/C tensioner pulley and mounting bracket. Remove No. 1 upper outer cover and gaskets. See Fig. 3. Remove engine support bracket bolts in proper sequence. See Fig. 2. Remove engine support bracket.

For 1988-93 models, the manufacturer recommends the belt be replaced at 60,000 miles. For 1994-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-99 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.

TIMING BELT REMOVAL
Diamante: Disconnect negative battery cable. Remove left front and left side splash shields. Using engine hoist, lift engine just enough to remove weight from engine mounts. Remove drive belts. Remove A/C tensioner pulley and bracket.
CAUTION: Apply spray lubricant on reamer bolt during removal as bolt is sometimes seized in engine support. Fig. 1: Locating Timing Belt & Sprocket
Remove engine mount bracket bolts in sequence. Lubricate reamer bolt with penetrating oil before and during removal. See Fig. 2. Remove power steering pump, leaving hoses attached. On 1996 models, remove crankshaft position sensor and right oxygen sensor. Remove crankshaft pulley. On vehicles with ABS, remove overflow tank and bracket.
Remove cover cap and No. 2 upper outer cover and gaskets. Remove under cover. Using Holder (MB990767-01) and Adapter Bolts (MD998719) or equivalent, remove crankshaft pulley. 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 counterclockwise to release belt tension. If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt and belt tensioner.
MITSUBISHI 3.0L V6 SOHC, 12-Valve Engine (Cont.)
431
Fig. 2: Removal & Installation Of Engine Support Bracket
Montero & Pickup: Disconnect negative battery cable. Drain cooling system. Disconnect upper radiator hose. Remove upper radiator shroud. Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove all accessory drive belts. Remove power steering pump with pressure and return hoses connected and set aside. Remove power steering pump brackets. Remove A/C tensioner pulley and mounting bracket. Remove A/C compressor with hoses connected and mounting bracket. Remove cooling fan bracket assembly. Remove timing belt No. 1 upper outer cover and gaskets. See Fig. 3. Remove timing belt No. 2 upper outer cover and gaskets. Remove timing belt lower outer cover and gaskets. Using Holder (MB998747) or equivalent, and a used V belt, remove crankshaft pulley bolt. Remove crankshaft pulley.
NOTE: V belt will be damaged by tool. DO NOT use engine V belt to hold crankshaft pulley unless belt is to be replaced.
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 tension. If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt and belt tensioner. Sigma: Disconnect negative battery cable. Remove all accessory drive belts. Disconnect connector and pressure hose at power steering pump. Remove power steering pump with return hose connected. Support engine. Remove throughbolt 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. Remove timing belt No. 1 upper outer cover and gaskets. See Fig. 3. Remove engine support bracket bolts in proper sequence. See Fig. 2. Remove engine support bracket. Remove cover cap and timing belt No. 2 upper outer cover and gaskets. Remove under cover. Using Holder (MB990767-01) and Adapter Bolts (MD998719) or equivalent, remove crankshaft pulley. 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 counterclockwise to release belt tension. If timing belt is to be reused, place arrow on belt to indicate rotation direction.
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Install flange onto crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. Using Crankshaft Socket (MD998716-01) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specification. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner. Belt tension should be 44-66 Ibs. (20-30 kg). Install proper length bolts in timing belt covers. See Fig. 6. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS.
3000GT: Remove engine lower splash shields. Remove cruise control actuator (if equipped) from right side fenderwell. Remove all drive belts. Remove A/C drive belt tensioner pulley assembly. Remove power steering and generator drive belt tensioner pulley bracket. Place floor jack under engine to support weight of engine. Remove engine-to-body mount from timing belt end of engine. Unplug power steering pump pressure switch electrical connector. Remove power steering pump with hoses attached and set out of way. Remove engine support bracket bolts, in specified sequence, from front of engine. Fig. 2. Note position of reamer bolt for reassembly reference.
CAUTION: Reamer bolt may be heat-seized to engine support bracket. Reamer bolt has R marking on bolt head.
NOTE: Engine support bracket reamer bolt must be tightened slowly while spraying lubricant on bolt.
Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley. Remove all timing belt covers. See Fig. 6. Noting position for reassembly reference, remove front flange from crankshaft. See Fig. 7. Rotate crankshaft to align all timing marks. See Fig. 4. Loosen belt tensioner bolt. Rotate belt tensioner pulley counterclockwise to relieve belt tension. Tighten tensioner pulley bolt. If reusing timing belt, place arrow on belt to indicate belt running direction. Remove timing belt.
All Models: Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner for smooth rotation. Replace parts, if defective.
Install engine support bracket and tighten bolts in sequence. See Fig. 2. Tighten bolts to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Galant: Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. Rotate belt tensioner counterclockwise as far as possible and temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Fig. 4. Install timing belt. Ensure belt is installed in original direction of rotation and all timing marks are aligned. Install flange on crankshaft. Loosen belt tensioner bolts slightly and allow tensioner to apply belt tension. Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specification. Using belt tension gauge, measure belt tension half way between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner.
CAUTION: Engine support bracket reamer bolt must be tightened slowly while spraying lubricant on bolt.
Diamante: Install timing belt onto crankshaft sprocket, then around left camshaft sprocket, with all slack removed from tension side of belt. Route timing belt onto water pump pulley, right camshaft sprocket, and tensioner. Apply torque to rear camshaft pulley to tighten belt. Ensure all timing marks are aligned.
Fig. 5: Identifying Timing Belt Cover Bolt Lengths (Pickup)
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 and engine support bracket. See Figs. 2 and 6. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Montero & Pickup: Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. Rotate belt tensioner counterclockwise as far as possible and temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Fig. 4. Install timing belt on crankshaft sprocket and then left camshaft sprocket with all slack removed from tension side of belt. Route timing belt onto water pump pulley, right camshaft sprocket and tensioner. Remove any slack from belt by rotating left and then right camshaft sprockets counterclockwise. Ensure all timing marks are aligned. Install flange on crankshaft. Loosen belt tensioner bolts slightly and allow tensioner to apply belt tension. 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 tension 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 bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
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Belt tension should be 57.3-83.8 lbs. (26-38 kg). To install remaining components, reverse removal procedure. Install proper length bolts in timing belt covers. See Fig. 6.
NOTE: Engine support bracket reamer bolt must be tightened slowly while spraying lubricant on bolt.
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 9600-003; February, 1996.
Before refilling cooling system, remove air bleed bolt on top of thermostat housing. Refill cooling system with 50/50 mix of water and coolant until it overflows from air bleed bolt hole. Install air bleed bolt with new .85 mm washer (if equipped). Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, refill radiator. Sigma: Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner with hook of spring pointing away from cylinder block. Rotate belt tensioner counterclockwise as far as possible and temporarily tighten bolt. Align all timing marks with No.1 cylinder at TDC of compression stroke. See Fig. 4. Install timing belt on crankshaft sprocket, rear head camshaft sprocket, water pump pulley, front head sprocket and timing belt tensioner. Ensure belt is installed in original direction of rotation and all timing marks are aligned on crankshaft. Loosen belt tensioner bolts slightly and allow tensioner to apply belt tension. Using Crankshaft Socket (MD998716) or equivalent, rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specification. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner.
Install engine support bracket . Tighten bolts in sequence to specification. See Fig. 2. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. 3000GT: Ensure all timing belt marks are aligned. See Fig. 4. If not already done, loosen tensioner center bolt. Turn tensioner counterclockwise. Temporarily tighten tensioner center bolt. Install timing belt on crankshaft sprocket, left hand camshaft sprocket (side away from tensioner pulley), water pump pulley, right hand camshaft sprocket, and timing belt tensioner. Apply counterclockwise force to right hand cam-
Fig. 7: Exploded View Of Timing Belt Components (3000GT SOHC)
Fig. 8: Identifying Timing Belt Cover Bolts (3000GT) Fig. 6: Timing Belt Cover Bolt Length Identification (Diamante, Galant & Sigma)
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TORQUE SPECIFICATIONS (MONTERO & PICKUP) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt Montero .................................................. 108-116 (146-157) Pickup .................................................... 130-137 (176-186) Left Engine Support Bracket Bolt ...................... 15-21 (20-30) Rear Engine Support Bracket Bolt .................... 13-18 (18-25) Right Engine Support Bracket Bolt 10 X 22 mm .................................................... 25-36 (34-49) 10 X 40 mm .................................................... 25-36 (34-49) 12 X 22 mm .................................................... 47-61 (64-83) 12 X 32 mm .................................................... 47-61 (64-83) Timing Belt Tensioner Bolt ............................... 16-21 (22-29) Water Pump Bolt .............................................. 14-20 (19-27) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Timing Belt Cover Cap Bolt .............................. 84-108 (9-12) TORQUE SPECIFICATIONS (SIGMA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt .............................. 110-118 (150-160) Engine Mount Bracket Nut ................................ 44-57 (60-77) Engine Support Bracket Bolt 10 X 40 mm .................................................... 25-36 (34-49) 10 X 53 mm .................................................... 47-54 (64-73) 12 X 56 mm 1989 ........................................................ 76-83 (103-113) 1990 ............................................................ 47-61 (65-85) Timing Belt Tensioner Bolt ............................... 16-21 (22-29) Water Pump Bolt .............................................. 14-20 (19-27) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 90-102 (10-12) TORQUE SPECIFICATIONS (3000GT) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 66 (90) Crankshaft Pulley Bolt .............................. 108-116 (150-160) Engine Mount To-Body Through-Bolt ................................................. 51 (70) To-Engine Support Bracket ......................... 72-87 (100-120) Engine Support Bracket-To-Engine Bolt 1 M10 Bolt ..................................................................... 51 (70) M12 Bolt ................................................................... 80 (110) Generator/Power Steering Tensioner Pulley Bracket Bolt ................................................................. 30 (42) Power Steering Pump Mount Bolt Short Bolt ................................................................... 29 (40) Long, Shoulder Bolt .................................................... 16 (22) Timing Belt Tensioner Pulley Center Bolt ......... 16-22 (22-30) Water Pump Bolt ........................................................ 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 89-106 (10-12) 1 Spray lubricant on reamer bolt while tightening.
shaft sprocket (camshaft closest to firewall) to remove any belt slack. Ensure all timing marks are still aligned. Install front flange on crankshaft. Loosen timing belt tensioner pulley center bolt. Allow the tensioner spring force to tension timing belt. Turn crankshaft 2 revolutions clockwise. DO NOT turn counterclockwise. Align all timing belt marks. Final tighten tensioner pulley center bolt. Using a belt tension gauge, measure timing belt tension midway between crankshaft sprocket and left hand camshaft sprocket (side opposite belt tensioner pulley). Belt tension should be 46.3-68.3 lbs. (21-31 kg). Install flange onto crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension. Install timing belt covers. Install timing belt cover bolts in correct locations. See Fig. 8.
NOTE: When installing engine support bracket reamer bolt, tighten it slowly while spraying lubricant on reamer bolt. Reamer bolt has R marking on bolt head.
Install crankshaft pulley. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install engine support bracket on engine block. Install bolts in correct location, and tighten in sequence. See Fig. 2. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS (DIAMANTE) Application Ft. Lbs. (N.m) Automatic Tensioner Bolt ............................................ 17 (23) Camshaft Sprocket Bolt .............................................. 66 (90) Crankshaft Pulley Bolt 1991 ....................................................... 108-116 (146-157) 1994-92 ................................................................ 136 (185) Engine Support Bracket Bolt 10 X 40 mm .................................................... 47-54 (64-73) Except 10 X 40 mm ..................................... 76-83 (103-113) Timing Belt Tensioner Arm Bolt .................................. 31 (42) Timing Belt Tensioner Pulley Nut ............................... 36 (49) Water Pump Bolt ........................................................ 17 (23) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) TORQUE SPECIFICATIONS (GALANT) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-72 (79-98) Crankshaft Pulley Bolt .............................. 108-116 (146-157) Engine Support Bracket Bolt 10 X 40 mm .................................................... 25-36 (34-49) 10 X 53 mm .................................................... 47-54 (64-73) 12 X 56 mm ................................................ 76-83 (103-113) Timing Belt Tensioner Bolt ............................... 16-21 (22-29) Water Pump Bolt .............................................. 14-19 (19-26) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 84-108 (9-12) Timing Belt Cover Cap Bolt .............................. 84-108 (9-12)
MITSUBISHI *3.0L V6 SOHC, 24 Valve Engine

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 SOHC Eclipse 2000-01 ................ 1 3.0 Hours ................. 250259 Galant 1999-01 ................ 1 2.4 Hours ................. 250259 Montero (24-Valve Engine) 1995-96 ................ 1 3.5 Hours ................. 250259 Montero Sport 1997-01 ................ 1 3.5 Hours ................. 250259 1 - With Air Cond. add .2 hours for Eclipse, and .6 hours for Galant and Montero Sport. With Pwr. Strng. add .3 hours.
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For 1995-96 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California. In California, timing belt replacement is recommended, but not required, at 60,000 miles. In California, replace timing belt at 100,000 miles, unless previously changed. For 1997-00 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Connecticut, and Massachusetts. In California, Connecticut, and Massachusetts, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed. For 2001 models, the manufacturer recommends the belt be replaced every 60,000 miles except in California, Massachusetts and Vermont. In California, Massachusetts and Vermont, timing belt replacement is recommended, but not required, at 60,000 miles. In these states, replace timing belt at 100,000 miles, unless previously changed.
Fig. 2: Aligning Timing Marks (Hydraulic Auto-Tensioner)

TIMING BELT REMOVAL
Eclipse & Galant: Disconnect negative battery cable. Raise and support vehicle. Remove engine splash shield from right wheelwell. Remove generator and A/C compressor drive belt. Remove dipstick tube from front of engine. Remove generator with wires attached and secure out of way. Remove power steering pump drive belt. Lower vehicle. Support weight of engine with jack. Remove engine mount from timing belt end of engine. Holding crankshaft pulley stationary, remove crankshaft pulley bolt. Remove crankshaft pulley. Remove upper and lower timing belt covers. See Fig. 1. Remove engine support bracket from front of engine.
CAUTION: Always turn crankshaft in clockwise direction (as viewed from front of engine).
Fig. 1: Exploded View Of Timing Belt Components (Galant)
If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Loosen center bolt of timing belt tensioner pulley, and remove timing belt. Remove timing belt auto-tensioner from engine block. Montero & Montero Sport: Disconnect negative battery cable. Drain cooling system. Disconnect upper radiator hose from engine. Remove upper radiator shroud. Loosen cooling fan clutch-to-pulley nuts. Relieve tension on accessory drive belts. Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove all accessory drive belts. Remove generator with wires attached and secure out of way. Remove power steering pump with hoses connected, and set aside. Remove A/C compressor with hoses connected, and set aside. Remove A/C compressor bracket. Remove accessory mount assembly. See Fig. 4.
436
MITSUBISHI *3.0L V6 SOHC, 24 Valve Engine (Cont.)
If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. Remove timing belt auto-tensioner.
All Models: Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner 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 compress the push rod. If there is a plug at the base of the autotensioner body, place flat washer around plug so it will not contact vise jaw.
CAUTION: Never compress the auto-tensioner too fast or the push rod will be damaged.
Fig. 3: Exploded View Of Timing Belt Components (Montero Sport)
Fig. 4: Exploded View Of Accessory Mount Assembly (Montero & Montero Sport)
Remove upper timing belt upper cover. See Fig. 3. Holding crankshaft pulley stationary, remove crankshaft pulley bolt. Remove crankshaft pulley.
Remove lower timing belt cover. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Loosen belt tensioner pulley center bolt.
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. 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 counterclockwise. 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. Install 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. Position tensioner pin holes at TOP of tensioner. Install Adapter (MD998767) on tensioner pulley. See Fig. 8. Us e a torque wrench to apply 39 INCH lbs. (4.4 N.m) of torque (clockwise direction) to tensioner pulley. Tighten tensioner center bolt to specification while holding tensioner stationary. On all models, 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 tensioner pulley bracket arm. Clearance should be 0.150.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure.
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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 procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
CAUTION: The sealing washer under the cooling system air bleed bolt was reduced to .85mm from 2.0mm. The .85 mm washer CANNOT be reused. Replace washer if bolt is loosened or removed. This information is from Mitsubishi technical service bulletin 9600-003; February, 1996.
Fig. 5: Checking Timing Belt Auto-Tensioner Movement
Install engine support bracket on engine block. Tighten top bolt first, then working in a counterclockwise direction, tighten the remaining bolts. See Fig. 7. Install timing belt covers. Install crankshaft pulley. Apply engine oil to crankshaft pulley bolt, then tighten bolt to specification. See TORQUE SPECIFICATIONS table. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Montero & Montero Sport: Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the autotensioner body, place flat washer around plug so it will not contact vise jaw.
Before refilling cooling system, remove air bleed bolt on top of thermostat housing. Refill cooling system with 50/50 mix of water and coolant until it overflows from air bleed bolt hole. Install air bleed bolt with new .85 mm washer (if equipped). Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, refill radiator. TORQUE SPECIFICATIONS (ECLIPSE & GALANT) Application Ft. Lbs. (N.m) Auto-Tensioner-To-Engine Block Bolt ............................ 18 (24) Camshaft Sprocket Bolt .............................................. 65 (88) Crankshaft Pulley Bolt ............................. 1 131-137 (177-186) Dipstick Tube Bolt ......................................................... 10 (14) Engine Mount To-Engine Support Bracket Nut/Bolt ......................... 63 (86) To-Body Through Bolt ................................................ 2 61 (83) Engine Support Bracket-to-Engine Bolt ......................... 32 (44) Generator Pivot Bolt ....................................................... 32 (44) Generator Top Bolt ........................................................ 15 (21) Power Steering Pump Belt Tensioner Bolt .................... 32 (44) Timing Belt Tensioner Center Bolt .............................. 35 (48) Timing Belt Tensioner Arm Pivot Bolt ............................ 32 (44) Water Pump Bolt M8 Bolt .......................................................................... 17 (23) M10 Bolt ....................................................................... 30 (41) INCH Lbs. (N.m) Timing Belt Cover Bolt .............................................. 106 (12)
1 2
SLOWLY compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine. 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 counterclockwise. 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 direction) 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 tensioner pulley bracket arm. Clearance should be 0.150.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. Install timing belt covers. Install crankshaft pulley. Install accessory mount assembly on front of engine.
Apply engine oil to bolt threads before installation. Final tighten bolt with full weight of engine on mount.
Fig. 6: Adjusting Timing Belt Tension (1999-00 Eclipse & (Galant; 1997-01 Montero & Montero Sport)
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Fig. 6: Adjusting Timing Belt Tension (2001 Eclipse & Galant)

Fig. 7: Engine Support Bracket Tightening Sequence (Eclipse & Galant)
TORQUE SPECIFICATIONS (MONTERO & MONTERO SPORT) Application Ft. Lbs. (N.m) Accessory Mount Assembly Bolt .................................... 33 (44) Auto-Tensioner-To-Engine Block Bolt ............................ 18 (24) Camshaft Sprocket Bolt .............................................. 65 (88) 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 Center Bolt .............................. 35 (48) 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) Timing Belt Cover Bolt M6 Bolt ......................................................................... 97 (11) M8 Bolt ....................................................................... 117 (13) 1 Apply engine oil to bolt threads before installation.
MITSUBISHI *3.5L V6 DOHC

TIMING BELT APPLICATION Application LaborTime Belt Part No. 3.5L V6 Montero 1994-96 ................ 1 4.5 Hours ................. 250253 1 - With Air Cond. add .6 hours. With Pwr. Strng. add .3 hours.
439

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.

TIMING BELT
NOTE: Ensure timing marks are aligned. Mark timing belt direction of rotation
Courtesy of Mitsubishi Motor Sales of America, Inc.
Removal: Disconnect negative battery cable. Drain engine coolant. Remove engine coolant reservoir tank, fan shroud and radiator. 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 position sensor connector. Using Holder (MB990767) and Bolts (MB998754) or equivalents, hold crankshaft stationary while remove crankshaft pulley center bolt. If reusing timing belt, place arrow on belt to indicate running direction. Rotate crankshaft to align all timing marks. See Fig. 3. Loosen timing belt tensioner center bolt. Remove timing belt and timing belt automatic tensioner.
NOTE: Revised auto-tensioner procedure is from Mitsubishi technical service bulletin 96-11-006; June, 1996.
Fig. 2: Exploded View Of Accessory Mount Components
Inspection: Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner pulley for smooth rotation. Check timing belt automatic tensioner for leaks. Hold timing belt auto-tensioner upright. Measure rod protrusion above edge of housing. Length should be .461-.484 (11.712.3 mm). Apply 40-44 lbs. (18-20 kg) of force to end of rod. If automatic tensioner rod moves more than 0.39 (1 mm), replace the automatic tensioner.
Installation: Place automatic tensioner assembly in a soft-jawed vise. SLOWLY close vise to press rod back into tensioner until both rod and housing holes are aligned. Install a .055" (1.40 mm) diameter wire or drill bit through both holes. Remove automatic tensioner from vise, and install assembly on engine with wire in place. Install crankshaft sprocket (if removed). Align timing marks on crankshaft and camshaft sprockets. See Fig. 3.
CAUTION: Turning camshaft sprockets while No. 1 piston is at TDC may damage valve and piston. Use care when aligning timing marks.
To lower No. 1 piston from TDC and prevent valve and piston contact, turn crankshaft back 3 sprocket teeth (measured at timing mark). See Fig. 4.
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MITSUBISHI *3.5L V6 DOHC (Cont.)
Fig. 5: Securing Timing Belt With Spring Clips

Fig. 4: Positioning Crankshaft For Timing Belt Installation
Starting with left (drivers side) bank of cylinders, verify intake and exhaust camshaft timing marks are correctly aligned with marks on rear timing belt cover. See Fig. 3. Rotate either camshaft sprocket clockwise to align timing marks.
WARNING: Use care when aligning timing marks. Camshaft is under valve spring pressure and may rotate suddenly, pinching hand between sprockets.
Align camshaft timing marks on right (passengers side) camshaft sprockets. See Fig. 3. Using box end wrenches, hold camshaft sprocket center bolts to prevent sprockets from turning. With right bank camshaft sprocket timing marks aligned with marks on rear timing belt cover, install timing belt on right bank camshaft sprockets. Hold camshaft sprockets in place with spring clips. See Fig. 5. Install timing belt around water pump pulley. With left bank camshaft sprockets correctly aligned, install timing belt on left hand camshaft sprocket. Secure timing belt onto sprockets with spring clips.
Install timing belt on the idler pulley. Realign the crankshaft sprocket timing mark with mark on oil pump housing. Turn crankshaft ONE turn counterclockwise (as viewed from front of engine). Set timing belt on crankshaft sprocket, then onto tensioner pulley. Rotate timing belt tensioner pulley until pin holes are located above center bolt. See Fig. 6. Push tensioner pulley against belt, and temporarily tighten center bolt. Ensure all timing marks are still aligned, and remove spring clips. Rotate crankshaft 1/4 revolution counterclockwise. Rotate crankshaft clockwise until timing marks are realigned. Loosen tensioner center bolt. Using Tensioner Pulley Socket (MD998767) or equivalent, apply approximately 83 INCH Ibs. (9.4 N.m) torque to tensioner pulley in a clockwise direction. Holding tensioner pulley to prevent it from turning, final tighten center bolt to 35 ft. lbs. (48 N.m). Ensure tensioner pulley does not rotate while tightening center bolt. Remove set pin or drill bit from automatic tensioner. Rotate crankshaft 2 revolutions clockwise. Wait 5 minutes. Verify wire or drill bit can still be easily removed and installed. Even if set pin or drill bit cannot be easily installed, the automatic tensioner is normal if its push rod protrusion is within .15-.18" (3.8-4.5 mm). Measure push rod protrusion between top of tensioner body and lever arm of tensioner pulley lever. See Fig. 7. If push rod protrusion is out of specification, timing belt tension adjustment will have to be repeated. Install timing belt covers. Install crankshaft pulley. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install generator. Install accessory mount. Install power steering pump and A/C compressor. Install cooling fan. Install accessory drive belts.
CAUTION: On later model years, the sealing washer under the cooling system air bleed bolt was reduced to .85 mm from 2.0 mm. The .85 mm washer CANNOT be reused. Replace washer if bolt is loosened or removed. This information is from Mitsubishi technical service bulletin 96-00-003; February, 1996.
Install radiator. Before refilling cooling system, remove air bleed bolt on top of thermostat housing. Refill cooling system with 50/50 mix of water and coolant until it overflows from air bleed bolt hole. Install air bleed bolt with new .85 mm washer (if equipped).
MITSUBISHI *3.5L V6 DOHC (Cont.)
441
Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, refill radiator. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N,m) Automatic Tensioner Bolt ............................................... 17 (24) Accessory Mount Bolts 10 x 80 mm ..................................................... 28-30 (38-41) 10 x 100 mm ................................................... 32-34 (43-46) 12 x 100 mm ................................................... 53-55 (72-75) Camshaft Sprocket Bolt .................................................. 64 (88) Crankshaft Pulley Center Bolt ................... 130-137 (177-186) Power Steering Pump Bolt ................................ 26-30 (38-41) Timing Belt Tensioner Pulley Bolt ............................... 35 (48) 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) Timing Belt Cover Bolt .................................... 89-106 (10-12)
Fig. 7: Measuring Push Rod Protrusion
442
MITSUBISHI *3.5L V6 SOHC

Montero & Montero Sport: Disconnect negative battery cable. Drain cooling system. Remove upper radiator hose. Remove radiator shroud. Loosen cooling fan clutch-to-pulley nuts. Relieve tension on accessory drive belts. Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove all accessory drive belts. Remove generator with wires attached and secure out of way. Remove power steering pump with hoses connected, and set aside. Remove A/C compressor from bracket ( hoses connected), and set aside. Remove A/C compressor bracket. On Montero Sport, remove timing mark indicator plate from front of engine. On Montero and Montero sport, remove accessory mount assembly. See Fig. 4. Remove upper timing belt upper cover. See Fig. 3. Holding crankshaft pulley stationary, remove crankshaft pulley bolt. Remove crankshaft pulley.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.5L V6 SOHC Diamante 1997-01 ................ 1 3.4 Hours ................. 250287 Montero 1997-00 ................ 1 3.5 Hours ................. 250287 Montero Sport 2000-01 ................ 1 3.5 Hours ................ 250287 1 - With Air Cond. add .6 hours for Montero and Montero Sport. With Pwr. Strng. add .3 hours.

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

NOTE: Replacement procedure for Diamante includes revised information from Mitsubishi technical service bulletin No. 0011-005; April, 2000.
TIMING BELT REMOVAL
Diamante: Disconnect negative battery cable. Remove accessory drive 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 direction of belt rotation. Turn crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Loosen center bolt of timing belt tensioner pulley, and remove timing belt. Remove timing belt auto-tensioner from engine block.
Fig. 1: Exploded View Of Timing Belt Components (Diamante Shown; Others Similar)
MITSUBISHI *3.5L V6 SOHC (Cont.)

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. If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. Remove timing belt auto-tensioner.
All Models: Inspect timing belt for wear on edges of drive teeth. Inspect belt for signs of oil contamination, cracks, separation, worn or missing teeth, or hardened black surface. Replace belt if worn, damaged or contaminated. Inspect belt tensioner 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 (11.712.3 mm). Apply 22-44 lbs. (98-196 N) of force to end of rod. If auto tensioner rod moves more than 0.39 (1 mm), replace the auto-tensioner.
Diamante: Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the autotensioner body, place flat washer around plug so it will not contact vise jaw.
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.
Fig. 3: Exploded View Of Timing Belt Components (Montero & Montero Sport)
Fig. 4: Exploded View Of Accessory Mount Assembly (Montero & Montero Sport)
444
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 counterclockwise. 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 direction) to tensioner pulley. Tighten tensioner center bolt to specification while holding tensioner pulley 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 tensioner pulley bracket arm. Clearance should be 0.150.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. Install timing belt covers. Install crankshaft pulley. Tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS table. Install accessory mount assembly on front of engine. Install A/C compressor. Install generator. Install upper radiator hose. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. To install remaining components, reverse removal procedure. When filling cooling system, use 50/50 mix of coolant and water. Open bleed screw on top of thermostat housing. Slowly fill cooling system until coolant flows out of bleed hole. Install bleed screw. Start engine and run to normal operating temperature. Race engine to 3000 RPM several times. Stop engine. After engine cools, refill radiator and coolant reservoir tank. TORQUE SPECIFICATIONS (DIAMANTE) Application Ft. Lbs. (N.m) Auto-Tensioner Bolt ....................................................... 17 (23) Camshaft Sprocket Bolt .............................................. 65 (88) Crankshaft Pulley Bolt ............................................ 1 134 (181) Engine Mount To-Engine Support Bracket Nut/Bolt ............. 73-87 (98-118) To-Body Through Bolt 2 ..................................... 73-87 (98-118) Engine Support Bracket-to-Engine Bolt ......................... 32 (44) Generator Pivot Bolt ....................................................... 32 (44) Generator Top Bolt ........................................................ 15 (21) Power Steering Pump Belt Tensioner Bolt .................... 32 (44) Timing Belt Idler Pulley Bolt ............................................ 32 (44) Timing Belt Tensioner Center Bolt .............................. 35 (48) Timing Belt Tensioner Arm Pivot Bolt ............................ 32 (44) Water Pump Bolt M8 Bolt .......................................................................... 17 (23) M10 Bolt ....................................................................... 30 (41) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 97 (11) Timing Mark Indicator Plate Bolt ..................................... 97 (11)
1 2
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 counterclockwise. 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. 5. Using torque wrench, apply 39 INCH lbs. (4.4 N.m) of torque (counterclockwise direction) to tensioner pulley. Tighten tensioner center bolt to specification while holding tensioner pulley stationary. 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 tensioner pulley bracket arm. Clearance should be 0.150.20 (3.8-5.0 mm). If protrusion is not correct, repeat timing belt tensioning procedure. Install engine support bracket on engine block. Tighten top bolt first, then working in a counterclockwise direction, tighten the remaining bolts. See Fig. 7. Install timing belt covers. Install crankshaft pulley. Apply engine oil to crankshaft pulley bolt, then tighten bolt to specification. See TORQUE SPECIFICATIONS table. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Montero & Montero Sport: Place auto-tensioner in soft-jawed vise to SLOWLY compress the push rod. If there is a plug at the base of the autotensioner body, place flat washer around plug so it will not contact vise jaw.
Slowly compress auto-tensioner push rod until holes in push rod and auto-tensioner housing are aligned. Insert a locking pin into the alignment holes. Install auto-tensioner on engine.
Fig. 5: Checking Timing Belt Auto-Tensioner Movement
Apply engine oil to bolt threads before installation. Arrow on engine mount plates must face toward front of vehicle.

TORQUE SPECIFICATIONS (MONTERO & MONTERO SPORT) Application Ft. Lbs. (N.m) Accessory Mount Assembly Bolt .................................... 33 (44) Auto-Tensioner Bolt ....................................................... 18 (24) Camshaft Sprocket Bolt .............................................. 65 (88) Crankshaft Pulley Bolt ............................................ 1 134 (181) Generator Pivot (Upper) Bolt ......................................... 38 (52) Generator Bottom Bolt ................................................... 16 (22) Power Steering Pump Bolt ............................................ 17 (24) Timing Belt Idler Pulley Bolt ............................................ 35 (48) Timing Belt Tensioner Center Bolt .............................. 35 (48) Timing Belt Tensioner Arm Pivot Bolt ............................ 32 (44) Water Pump Bolt ............................................................ 17 (23) INCH Lbs. (N.m) Cooling Fan Clutch-to-Pulley Nut ..................... 89-106 (10-12) Timing Belt Cover Bolt ................................................ 97 (11) 1 Apply engine oil to bolt threads before installation.
445
Fig. : Engine Support Bracket Tightening Sequence (Diamante)
446
NISSAN *1.5L & *1.6L 4-Cylinder SOHC

Belt Part No. * NOTE: This application is an interference engine. See page A-59 for interference engine cautions.
TIMING BELT APPLICATION Labor Component Kit No. Application Time 1 1.5L 4-Cyl. SOHC Sentra 1982-83 .......... 2.8 Hrs. ...... 2520770 ........ 250077 Pulsar NX 1983-84 .......... 3.0 Hrs. ...... 2520770 ........ 250077 310 1982 ............... 5.8 Hrs. ...... 2520770 ........ 250077 1.6L 4-Cyl. SOHC Pulsar & Pulsar NX 1983-88 .......... 2.3 Hrs. ...... 2520770 ........ 250077 Sentra 1983-88 .......... 2.8 Hrs. ...... 2520770 ........ 250077 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours.

TIMING BELT
CAUTION: DO NOT rotate crankshaft or camshaft separately with timing belt removed. Valves will contact piston and may cause damage.
Removal: Disconnect negative battery cable. Place crankshaft on TDC of compression stroke. Remove spark plugs. Remove right front under engine cover and splash cover. Remove accessory drive belts. Remove water pump pulley and crankshaft pulley. On 1988 models, support engine with a jack under oil pan and remove right side engine mount. On all models remove upper and lower timing belt cover. Check timing mark alignment. See Fig. 2. Mark timing belt rotation direction for installation reference. Loosen timing belt tensioner and retain tensioner away from timing belt. Remove timing belt. Remove tensioner and spring (if necessary). See Fig. 1.
CAUTION: Camshaft sprockets have 2 marks on them. Ensure the correct mark is aligned. See Fig. 2.

On 1982-85 models, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1986 and later models, the manufacturer recommends the belt be replaced every 60,000 miles.
Installation: Ensure camshaft and crankshaft sprocket timing marks are aligned at TDC on compression stroke. See Fig. 2. Install timing belt tensioner so no tension will be applied to belt during installation (if removed). If installing removed belt, properly position rotation direction mark made at removal. Install timing belt, keeping belt tight on jackshaft and camshaft sprockets side. Loosen tensioner and allow tension to be applied to timing belt. Rotate camshaft sprocket 20 degrees (2 cogs) clockwise.
NISSAN *1.5L & *1.6L 4-Cylinder SOHC (Cont.)

TORQUE SPECIFICATIONS (1.6L)
447
Using a screwdriver, prevent tensioner from turning and tighten tensioner lock nut. Recheck timing mark alignment. Ensure ignition rotor is firing No. 1 cylinder. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS (1.5L) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ................................... 29-35 (39-48) Crankshaft Pulley Bolt .............................. 108-145 (147-197) Crankshaft Pulley Damper Bolt .................... 90-98 (123-132) INCH Lbs. (N.m) Camshaft Lockplate ............................................. 35-43 (4-5) Timing Belt Tensioner ......................................... 52-70 (6-8)
Application Ft. Lbs. (N.m) Crankshaft Pulley Bolt ................................. 80-94 (108-127) Timing Belt Tensioner Lock Nut ...................... 12-15 (16-21) INCH Lbs. (N.m) Camshaft Sprocket Bolt .............................. 78-104 (8.8-11.8) Jackshaft Sprocket Bolt ............................... 78-104 (8.8-11.8) Valve Cover Bolt 1st Step ....................................................... 17-35 (1.9-4.0) 2nd Step ...................................................... 35-52 (4.0-5.9) Timing Belt Cover .......................................... 46-58 (5.2-6.6) Water Pump Pulley Bolt ............................... 74-96 (8.4-10.9) Water Pump Bolt ........................................... 46-58 (5.2-6.6)
448
NISSAN *1.6L & *1.8L 4-Cylinder DOHC

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.6L 4-Cyl. DOHC Pulsar 1987 ...................... 3.8 Hours .................. 250137 1.8L 4-Cyl. DOHC Pulsar NX 1988-89 ................. 3.8 Hours .................. 250137 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours.

Ensure No. 1 cylinder is at TDC of compression stroke. Align camshaft and crankshaft sprockets. See Fig. 2. Install timing belt. Ensure 39 teeth exist between marks on camshaft sprockets and 48 teeth between crankshaft and camshaft sprockets. See Fig. 2. Loosen tensioner pulley nut. Install crankshaft bolt and a spacer. Rotate crankshaft 2 revolutions. Tighten tensioner pulley nut to specification. Ensure all marks are aligned. Install timing belt covers. Install crankshaft pulley and washer. Install engine mount. Install crank angle sensor and water pump pulley. Ensure reference marks on crank angle sensor are aligned. Tighten bolts to specification. Install accessory drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Install upper radiator hose and refill cooling system. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ........................................ 10-14 (14-19) Crankshaft Pulley Bolt .............................. 105-112 (142-152) Engine Mount Bolt ............................................ 29-40 (39-54) Idler Nut ............................................................ 23-31 (31-42) Tensioner Pulley Nut ........................................ 16-22 (22-30) Timing Belt Tensioner Pulley Nut ..................... 16-22 (22-30) Water Pump Bolt .............................................. 12-14 (16-19) INCH Lbs. (N.m) Crank Angle Sensor Bolt ....................................... 61-70 (7-8) Rear Timing Belt Cover Bolt ................................. 61-70 (7-8)

TIMING BELT
Removal: Disconnect negative battery cable. Drain cooling system. Remove upper radiator hose. Remove undertray from right side. Remove accessory drive belts. Remove water pump pulley. Place reference mark on crank angle sensor and timing belt cover for reassembly reference. See Fig. 1. Remove crank angle sensor. Support engine and remove front engine mount support. Remove upper timing belt cover. See Fig. 1. Align timing marks on camshaft sprockets. See Fig. 2. Remove right side inner fender panel. Remove crankshaft pulley and lower timing belt cover. Loosen tensioner pulley nut and release tension. Remove timing belt. Using dial indicator, check camshaft sprocket runout. Replace sprocket if runout exceeds .004" (.10 mm). To remove camshaft sprocket, remove camshaft cover and hold hex area of camshaft. Remove sprocket retaining bolts. See Fig. 3. 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 timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Check tensioner and idler pulleys for smooth rotation. Inspect tensioner pulley return spring for distortion or corrosion. Installation: Install crankshaft sprocket and sprocket plates. Sprocket plates must be installed with flat side against crankshaft sprocket.
NISSAN *1.6L & *1.8L 4-Cylinder DOHC
449
Fig. 3: Removing Camshaft Sprocket
450
NISSAN *1.7L 4-Cylinder Diesel
TIMING BELT APPLICATION Belt Part No. Application Labor Time1 1.7L 4-Cyl. Diesel Sentra 1983-87 Camshaft ............ 4.0 Hours .................. 250096 Injection Pump ... 4.2 Hours .................. 250097 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours.

On 1984-85 models, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1986-87 models, the manufacturer recommends the belt be replaced at 60,000 mile intervals.

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: Ensure No. 1 cylinder is at TDC of compression stroke. Install timing belt ensuring timing marks are aligned. See Fig. 1. Ensure reference marks are 39 cogs apart. Rotate crankshaft 2 revolutions in normal direction of rotation. Tighten tensioner bolt while holding it to keep it from rotating. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 1: Installing Camshaft Timing Belt
INJECTION PUMP BELT

Removal: Disconnect negative battery cable. Remove timing belt cover from rear of engine. Loosen injection timing belt tensioner. Remove injection timing belt. Installation: Install injection timing belt. Ensure reference marks are 23 cogs apart. See Fig. 2. Rotate crankshaft 2 revolutions in normal direction of rotation. Tighten tensioner bolt while holding it to keep it from rotating. To complete installation, reverse removal procedure.
Fig. 2: Installing Injection Timing Belt
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ........................................ 68-75 (18-22) Crankshaft Pulley Bolt ................................. 90-98 (123-132) Front Tensioner Bolt ......................................... 27-33 (36-34) Rear Tensioner Bolt ......................................... 12-15 (16-21) INCH Lbs. (N.m) Timing Belt Cover Bolts ........................................ 27-43 (3-5)
NISSAN 1.8L & *2.0L 4-Cylinder

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cyl. Turbo 200SX (Includes Canadian) 1984-87 ................ 1 2.0 Hours ................. 250100 2.0L 4-Cyl. Stanza & Stanza Wagon 1982-89 ................ 1 4.4 Hours ................. 250078 200SX 1984-88 ................ 1 2.0 Hours ................. 250078 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours.
451

On 1985-82 models, the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1986 and later models, the manufacturer recommends the belt be replaced every 60,000 miles.
*NOTE: The 2.0L is an interference engine. See page A59 for interference engine cautions.

TIMING BELT
Removal (1982-88): Disconnect negative battery cable. Turn crankshaft until No. 1 cylinder is at TDC on compression stroke. Remove cooling fan, radiator shroud and accessory drive belts.
NOTE: After timing belt is removed, do not rotate crankshaft or camshaft.
Remove upper and lower dust cover mount bolts. Remove upper and lower covers and gaskets. Remove timing belt tensioner, bracket, and timing belt. Removal (1989): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove exhaust side spark
plugs. Turn crankshaft until No. 1 cylinder is at TDC on compression stroke. Remove dust cover and undercovers. Remove belts. Support engine with a chain hoist. Remove right side engine mount and bracket. Remove upper and lower timing belt covers and gaskets. Remove timing belt tensioner, bracket and timing belt. Installation (All Models): Do not tighten tensioner bolts to final specification before drive belt is installed. Install timing belt. Align belt mark to camshaft and crankshaft sprocket marks. See Fig. 1. Tighten belt tensioner and assemble spring. To set spring, hook one end on bolt B side and hook the other end on tensioner bracket pawl. Tighten bolt B and then bolt A. See Fig. 2. Belt tension will automatically be at the specified value. Install lower front cover with gaskets and tighten mount bolts. Install plate and front pulley damper. Complete installation by reversing removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS (1982-88) Application Ft. Lbs. (N.m) Camshaft Pulley Bolt ........................................ 10-14 (14-19) Crankshaft Pulley Bolt .............................. 105-112 (142-152) Engine Mount Bolt ............................................ 29-40 (39-54) Idler Nut ............................................................ 23-31 (31-42) Tensioner Pulley Nut ........................................ 16-22 (22-30) Water Pump Bolt .............................................. 12-14 (16-19) INCH Lbs. (N.m) Crank Angle Sensor Bolt ....................................... 61-70 (7-8) Front Cover Bolts .................................................. 27-43 (3-5) Rear Timing Belt Cover Bolt ................................. 61-70 (7-8) TORQUE SPECIFICATIONS (1989) Application Ft. Lbs. (N.m) Camshaft Lock Plate Bolt ................................. 58-65 (78-88) Camshaft Sprocket Bolt .................................... 58-65 (78-88) Crankshaft Pulley Bolt ................................. 90-98 (123-132) Engine Mount Bolt ............................................ 29-40 (39-54) Tensioner Pulley Nut ........................................ 16-22 (22-30) INCH Lbs. (N.m) Crank Angle Sensor Bolt ....................................... 61-70 (7-8) Front Cover Bolts .................................................. 27-43 (3-5) Rear Timing Belt Cover Bolt ................................. 61-70 (7-8) Water Pump Pulley Bolt ...................................... 54-86 (6-10)
Fig. 1: Timing Belt Alignment Procedure
452
NISSAN *3.0L V6 DOHC

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 3.0L V6 DOHC 300ZX 1990-93 ................. 4.6 Hours .................. 250180 1994-96 ................. 4.6 Hours .................. 250251 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours.


TIMING BELT
Removal: Disconnect negative battery cable. Remove engine undercover. Drain coolant from radiator and cylinder block. Remove radiator. Remove accessory drive belts. Remove cooling fan and coupling. Remove starter. Lock flywheel/flexplate to prevent crankshaft from rotating. Remove crankshaft pulley bolt and pulley. Remove water inlet and outlet hoses. Remove timing belt front covers. Remove spark plugs. Install a stopper bolt (M6 x 16) into timing belt tensioner arm to maintain tensioner position. See Fig. 1. Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft until timing marks align. Remove timing belt tensioner and timing belt. Inspection: Replace timing belt if cracked, worn or saturated with oil or coolant. Replace tensioner if it leaks oil. Installation: 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, adjust clearance until it is as specified. Install stopper bolt in tensioner to maintain clearance. Install tensioner. Handtighten tensioner nut and bolts. Install timing belt with arrow on timing belt facing front of engine. Align White lines on timing belt with marks on camshaft sprockets and crankshaft sprocket. White lines ensure correct number of teeth exist between timing marks on sprockets. Push tensioner gently toward timing belt to prevent belt from slipping (excessive pressure will overtighten belt). Maintain light pressure on tensioner. Turn crankshaft clockwise 10 degrees. Tighten tensioner bolts and nut. See TORQUE SPECIFICATIONS. Turn crankshaft counterclockwise 120 degrees. Turn crankshaft clockwise until cylinder No. 1 is at TDC of compression stroke.
Loosen tensioner nut and bolts 1/2 turn. Move tensioner as far pack as possible. Using Push/Pull Gauge (J-38387) or equivalent, apply 15.2-18.3 lbs. (6.9-8.3 kg) pressure to end of pusher. See Fig. 2. Tighten tensioner nut and bolts. Turn crankshaft 120 degrees clockwise, then turn it 120 degrees counterclockwise to TDC. Fabricate a small steel plate. See Fig. 3. Set plate at each position shown (A, B, C and D). Using push/pull gauge, apply 11 lbs. (5 kg) pressure. Measure and record timing belt deflection in each position. Divide sum of measurements (A + B + C + D) by 4 to obtain average. Average timing belt deflection should be .24-.28" (6-7 mm). If deflection is not as specified, repeat last five (5) steps. If timing belt deflection is excessive, change amount of pushing force applied in third step back. Remove tensioner stopper bolt. After 5 minutes, ensure clearance between pusher rod and tensioner arm is .138.205" (3.5-5.2 mm). Check for slippage or misplacement of timing belt at each sprocket. Install timing belt covers. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts Exhaust .......................................................... 10-14 (14-19) Intake ......................................................... 90-98 (122-133) Crankshaft Pulley Bolt .............................. 159-174 (216-236) Timing Belt Idler Pulley Nut .............................. 32-43 (43-58) Timing Belt Tensioner Lock Nut ....................... 12-15 (16-20) Water Pump Bolt .............................................. 12-15 (16-20) INCH Lbs. (N.m) Timing Belt Cover ................................................. 27-43 (3-5)
Fig. 1: Installing Timing Belt & Tensioner
NISSAN *3.0L V6 DOHC (Cont.)
453
Fig. 3: Checking Timing Belt Deflection
454
NISSAN *3.0L V6 SOHC

Remove front upper and lower belt covers. Remove drive belts and set No. 1 cylinder at TDC of compression stroke. Remove idler bracket of compressor drive belt and crankshaft pulley. Remove timing belt by removing timing belt tensioner and return spring. Inspection: Visually inspect condition of timing belt. Inspect for cracks, wear, breaks, and oil/coolant saturation. Installation: Ensure that piston No. 1 is at TDC of compression stroke. Remove valve covers and loosen all rocker shaft bolts. Do not bend timing belt. Install tensioner and return spring. Turn tensioner clockwise and temporarily tighten lock nut. Install timing belt. Align White lines on timing belt with punch mark on camshaft pulleys and crankshaft pulley. Arrow on timing belt must be pointing toward front belt covers. Using Allen wrench, slowly turn tensioner clockwise and counterclockwise 2 or 3 times. When camshafts and crankshaft marks are aligned, tighten tensioner lock nut. See Fig. 3. Ensure that camshaft lobes are correctly positioned. Tighten rocker shaft bolts in 2 stages. Refill and bleed air from from cooling system. To complete installation, reverse removal procedures. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (Maxima & Quest): Disconnect negative battery cable. Raise and support vehicle. Remove covers from below engine. Drain cooling system. Remove right front wheel and engine side cover. Remove accessory drive belts. Remove crankshaft pulley bolt and pulley. Remove upper radiator hose and water inlet hose. Remove A/C compressor idler pulley and bracket. Remove water pump pulley. Remove upper and lower timing belt front covers. Temporarily install crankshaft pulley bolt so crankshaft can be rotated. Set cylinder No. 1 at TDC of compression stroke by rotating crankshaft until marks on camshaft sprockets align with marks on timing belt upper rear cover, and mark on crankshaft sprocket aligns with mark on front cover housing. See Fig. 2.
TIMING BELT APPLICATION Application 3.0L V6 SOHC Maxima 1985-88 .............. 6.0 Hrs. .... 2521040 ...... 250104 1989-91 .............. 5.7 Hrs. .... 2521040 ...... 250104 1992-94 With Square Tooth Sprocket ........ 5.7 Hrs. .... 2521040 ...... 250104 With Round Tooth Sprocket ........ 5.7 Hrs. ......................... 250249 Pathfinder & Pickup 1986-92 .............. 4.5 Hrs. .... 2521040 ...... 250104 1993-94 With Square Tooth Sprocket ........ 4.5 Hrs. .... 2521040 ...... 250104 With Round Tooth Sprocket ........ 4.5 Hrs. ......................... 250249 1995-96 .............. 4.5 Hrs. ......................... 250249 Quest 1993-94 With Square Tooth Sprocket ....... 3.5 Hrs. .... 2521040 ...... 250104 With Round Tooth Sprocket ....... 3.5 Hrs. ......................... 250249 1995-98 .............. 3.5 Hrs. ......................... 250249 200SX 1987-88 .............. 4.8 Hrs. .... 2521040 ...... 250104 300ZX 1984-89 .............. 6.0 Hrs. .... 2521040 ...... 250104 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours.

On 1984-85 models, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. On 1986 and later models, the manufacturer recommends the belt be replaced every 60,000 miles.

TIMING BELT
Removal (200SX, 300ZX): Disconnect negative battery cable. Release fuel pressure from system. Raise and support vehicle. Remove right wheel and engine side cover (if necessary). Drain cooling system. Remove cooling fan duct. Remove engine coolant reservoir. Remove actuator and remove radiator hoses. Do not allow coolant to contact drive belts.
Fig. 1: Exploded View Of Timing Belt & Related omponents
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 below engine. Drain and remove radiator. Remove cooling fan and water pump pulley. Remove accessory drive belts. Remove spark plugs. Remove distributor protector. Remove A/C compressor idler pulley and bracket. Remove fresh air tube from cylinder head cover. Remove thermostat housing coolant hose. Remove crankshaft pulley bolt and pulley. Remove upper and lower timing belt front covers. Temporarily install crankshaft pulley bolt to rotate crankshaft. Set cylinder No. 1 at TDC of compression stroke by aligning marks on camshaft sprockets with marks on timing belt upper rear cover and mark on crankshaft sprocket with mark on front cover housing. See Fig. 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. See Fig. 2. Install tensioner and return spring if removed. If return spring stud was removed, apply thread lock sealant to threads before installing stud. Insert an Allen wrench into hole in tensioner, turn tensioner fully clockwise, and temporarily tighten lock nut. Install timing belt with arrow on timing belt facing front of engine. Align White lines on timing belt with marks on camshaft sprockets and crankshaft sprocket. White lines ensure correct number of teeth exist between timing marks on sprockets. Loosen tensioner lock nut. Using Allen wrench, rotate tensioner by turning Allen wrench clockwise 70-80 degrees. Temporarily tighten lock nut. Rotate crankshaft clockwise at least 2 revolutions. Return cylinder No. 1 to TDC of compression stroke. Using Push/Pull Gauge (J-38387) or equivalent, apply 22 lbs. (10.0 kg) pressure to timing belt between right camshaft sprocket and tensioner. Hold tensioner in position with Allen wrench, and loosen tensioner lock nut. Place a .0138" (.351 mm) feeler gauge at tensioner pulley and timing belt, and rotate crankshaft until feeler gauge is centered between tensioner pulley and timing belt. See Fig. 3. Tighten tensioner lock nut to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft to remove feeler gauge. Rotate crankshaft clockwise at least 2 revolutions until cylinder No. 1 is at TDC of compression stroke. Measure timing belt deflection halfway between camshaft sprockets. If deflection is not .51-.59" (13-15 mm), repeat procedure. To complete installation, reverse removal procedure. Refill and bleed air from cooling system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
NISSAN *3.0L V6 SOHC (Cont.)
455
Fig. 2: Installing Timing Belt & Sprocket
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-65 (79-88) Crankshaft Pulley Bolt ................................. 90-98 (122-133) Rocker Shaft Bolts ............................................ 13-16 (16-20) Timing Belt Tensioner Lock Nut/Bolt ................ 32-43 (43-58) Water Pump Bolt .............................................. 13-16 (16-20) INCH Lbs. (N.m) Timing Belt Cover ................................................. 27-43 (3-5)
456
NISSAN 3.3L V6 SOHC
Turn tensioner clockwise fully outward with hexagon wrench and temporarily tighten lock nut. Align White lines on timing belt with punch marks on camshaft sprockets and crankshaft sprocket. See Fig. 6. Point arrow on timing belt toward front belt cover. There should be 40 teeth between left and right camshaft sprockets and 43 teeth between left camshaft sprocket and crankshaft sprocket. Loosen tensioner lock nut. Using hex wrench, turn tensioner clockwise and counterclockwise at least 2 times. Tighten tensioner lock nut. Turn crankshaft clockwise at least 2 revolutions, then slowly set No. 1 cylinder at TDC on compression stroke. Apply 22 lbs. (10 kg) of force to belt (downward direction) midway between camshaft sprockets. Belt deflection should be 0.51-0.59 (13-15 mm). If not, readjust belt tension. Install lower and upper belt covers. Install crankshaft pulley. Tighten bolt to specfication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedures. Fill and bleed cooling system.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.3L V6 VG33E (SOHC) Frontier 1999-01 ................ 1 3.1 Hours ................. 250249 Pathfinder 1996-00 ................ 1 2.8 Hours ................. 250249 QX4 1997-00 ................. 3.9 Hours .................. 250249 Quest 1999-01 ................ 1 2.6 Hours ................. 250249 Xterra 2000-01 ................ 1 3.1 Hours ................. 250249 1 - With Air Cond. add .3 hours. With Pwr. Strng. add .3 hours. With Supercharger add .2 hours.

*NOTE: The 1996-00 3.3L engine used in the Pathfinder is an interference engine. See page A-59 for interference engine cautions.

Removal (Frontier, Pathfinder, QX4 & Xterra): Disconnect negative battery cable. Remove the engine under cover. Drain coolant and remove the radiator. Remove engine cooling fan and water pump pulley. Remove accessory 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 compression stroke. See Fig. 2. Remove crankshaft pulley bolt and remove crankshaft pulley. Remove front upper and lower belt covers. Align punch mark on left camshaft sprocket with punch mark on timing belt upper rear cover. Align punch mark on crankshaft sprocket with notch on oil pump housing. See Fig. 3. Install crankshaft pulley bolt so that crankshaft can be rotated. Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner, and remove timing belt. Inspection (Frontier, Pathfinder, QX4 & Xterra): Check timing belt for cracks and broken or worn teeth. Check belt tensioner for smooth turning. Check condition of tensioner spring. Replace parts as necessary. Installation (Frontier, Pathfinder, QX4 & Xterra): Install timing belt when engine is cold. Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft sprocket mark should align with mark on rear cover. See Fig. 5. If removed, install timing belt tensioner and tensioner spring.
NOTE: If stud for tensioner spring is removed, apply thread sealant to stud threads before installing.
TIMING BELT
96B14499
96E14500
Fig. 2: Setting Crankshaft To TDC
NISSAN 3.3L V6 SOHC (Cont.)
457
96G14502
Fig. 4: Loosening Timing Belt Tensioner Nut
96F14501
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 coolant starts to drip from air relief plug. Tighten air relief plug to 61-69 INCH lbs. (7-8 N.m). Fill radiator and coolant reservoir tank to MAX mark. Install and tighten radiator cap. Start and run engine until warm. Run engine at 3000 RPM for at least 10 seconds (repeat 23 times). Stop engine and allow it to cool. Refill radiator and coolant reservoir as necessary. Repeat previous step at least 3 times with temperature control lever at several different positions between full COLD and full HOT positions. System is full when water noise is no longer heard at heater core and coolant level no longer drops. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (Quest): Raise and support vehicle. Remove the engine under cover. Remove right side wheel and engine side cover. Drain coolant from radiator. Remove accessory drive belts.
96H14503
Fig. 5: Positioning Camshaft & Crankshaft Sprockets
Rotate crankshaft to set No. 1 cylinder at TDC on compression stroke. See Fig. 2. Remove crankshaft pulley bolt and remove crankshaft pulley using a gear puller. Remove upper radiator hose and water inlet hose from timing belt end of engine. Remove A/C compressor drive belt idler bracket. Remove water pump pulley. Remove breather pipe from timing belt front upper cover. Remove front upper and lower belt covers. Align punch mark on left camshaft sprocket with punch mark on timing belt upper rear cover. Align punch mark on crankshaft sprocket with notch on oil pump housing. See Fig. 3. Install crankshaft pulley bolt so that crankshaft can be rotated. Loosen timing belt tensioner nut. See Fig. 4. Turn tensioner, and remove timing belt.
NOTE: After removing timing belt, DO NOT turn crankshaft or camshaft separately or valves will strike pistons.
458
On all models, loosen radiator and engine air relief plugs. Remove heater pipe air relief cap. See Fig. 9. Connect one end of 40 clear, heat resistant hose to heater pipe air relief. Fill coolant reservoir to MAX mark and place hose from heater pipe air relief into reservoir. Ensure hose is below coolant level at all times. Slowly add coolant through radiator filler neck allowing several minutes for air to escape. When coolant starts to drip from radiator air relief plug, close plug. Tighten radiator air relief plug to 15-19 ft. lbs. (20-26 N.m). Continue adding coolant while gently moving upper radiator hose up and down until coolant no longer lowers in filler neck. Place wire under radiator filler cap negative pressure relief valve. See Fig. 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).
Inspection (Quest): Check timing belt for cracks and broken or worn teeth. Check belt tensioner for smooth turning. Check condition of tensioner spring. Replace parts as necessary. Installation (Quest): Install timing belt when engine is cold. Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft sprocket mark should align with mark on rear cover. See Fig. 5. If removed, install timing belt tensioner and tensioner spring.
NOTE: If stud for tensioner spring is removed, apply thread sealant to stud threads before installing.
NOTE: Ensure coolant level in reservoir tank is maintained at MAX mark for the following steps.
Turn tensioner clockwise fully outward with hexagon wrench and temporarily tighten lock nut. Align white lines on timing belt with punch marks on camshaft sprockets and crankshaft sprocket. See Fig. 6. Point arrow on timing belt toward front belt cover. There should be 40 teeth between left and right camshaft sprockets and 43 teeth between left camshaft sprocket and crankshaft sprocket. Loosen tensioner lock nut. Using hex wrench, turn tensioner clockwise and counterclockwise at least 2 times. Tighten tensioner lock nut. Turn crankshaft clockwise at least 2 revolutions, then slowly set No. 1 cylinder at TDC on compression stroke. Apply 22 lbs. (10 kg) of force to belt (downward direction) midway between camshaft sprockets. Belt deflection should be 0.51-0.59 (13-15 mm). If not, readjust belt tension. Install lower and upper belt covers. Install crankshaft pulley. Tighten bolt to specfication. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedures. Fill and bleed cooling system. If vehicle is equipped with manual A/C, turn ignition on. Move temperature control lever to full COOL position. Select any fan speed and mode except OFF. If vehicle is also equipped with rear heater, set rear controls to the full HOT position. If vehicle is equipped with automatic A/C, turn ignition on. Move temperature control lever to full HOT position. Select any fan speed and mode except OFF. If vehicle is also equipped with rear heater, set rear control to the full HOT position.
On vehicles without rear heater, ensure temperature control lever is in full HOT position. Select any fan speed and mode except OFF. Ensure A/C control unit is in ON position. Run engine at 3000 RPM for 5 minutes or until outlet air is hot. Repeat this step at least 3 times. Ensure no water noise is present in heater core. On vehicles with rear heater, run engine at 3000 RPM with front temperature control lever in full COLD position. Move rear temperature control lever to full HOT position. Select any fan speed except OFF. Ensure A/C control unit is in ON position. Start and run engine for 5 minutes or until rear outlet air is hot. Move rear temperature control lever to full COLD position. Move front temperature control lever to full HOT position. Select any fan speed and mode except OFF. Start and run engine for 5 minutes or until front outlet air is hot. Repeat previous step and this step at least 3 times. Ensure no water noise is present in front or rear heater core. On all models, stop engine. Fill coolant reservoir to MAX mark. Let engine cool down. Remove radiator cap and remove wire from negative pressure valve. Fill radiator as necessary and reinstall radiator cap. Remove hose from heater pipe air relief and quickly install cap on pipe. Fill reservoir as necessary and install reservoir cap. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 58-65 (79-88) Crankshaft Pulley Bolt .............................. 141-156 (191-211) Spark Plugs ......................................................... 14-22 (20-29) Timing Belt Tensioner Lock Nut/Bolt ................ 32-43 (43-58) Water Pump Bolt .............................................. 12-15 (16-20) Wheel Lug Nut Quest ............................................................... 72-87 (98-118) INCH Lbs. (N.m) Cooling Fan & Water Pump Pulley Bolts ............ 52-89 (6-10) Radiator Mounting Bolts ................................. 34-42 (3.8-4.8) Timing Belt Cover ................................................. 27-43 (3-5)
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

Insert Peugeot Lock Pin Tool (0153-G) or equivalent through crankshaft lock pin holes. Both camshaft lock pins should be able to be inserted through lock pin holes without effort. See Fig. 1. If not, timing belt must be removed and reinstalled. Position belt tension tool on timing belt. Meter reading should be between 40-50 SEEM units. If meter reading is not within limits, timing belt must be retensioned. Remove belt tensioning tool, then locking pins. Install lower cover. Lock flywheel in position with Peugeot Lock Tool (J-36358) or equivalent. Install crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. Removal (SOHC): Disconnect negative battery cable. Remove right mud shield. Remove A/C compressor and alternator drive belts. Remove upper timing belt cover. Rotate crankshaft using pulley bolt, aligning holes in camshaft sprocket and crankshaft pulley for pin installation. Insert Peugeot Locking Pin Tool (No. 0-0163) or equivalent, through camshaft sprocket and crankshaft pulley locking pin holes. See Figs. 2 and 4. Remove locking pins. Remove lower flywheel cover. Using Flywheel Stop Tool (No. 91-86) or equivalent, lock flywheel in position. Remove crankshaft pulley retaining bolt and crankshaft pulley. Remove stop tool that was used to lock flywheel in position. Remove upper portion of timing belt lower cover. Remove lower portion of timing belt lower cover. Loosen three timing belt tensioner nuts. Do not remove timing belt tensioner nuts. Push timing belt tensioner away from timing belt to relieve tension. Tighten tensioner retaining bolt next to pulley to hold tensioner in position. Remove timing belt from sprockets. Installation (SOHC): Position crankshaft pulley and key to crankshaft, then loosely install crankshaft pulley retaining bolt. Insert Peugeot Locking Pin Tool (No. 0-0163) or equivalent, through camshaft sprocket and crankshaft pulley locking pin holes. See Figs. 2 and 4. Remove crankshaft retaining bolt and pulley. Install timing belt over camshaft sprocket, crankshaft sprocket and water pump sprocket, then position timing belt on tensioner pulley. Ensure timing belt is properly seated on sprockets. Loosen tensioner nut, then turn tensioner square to release spring. Remove locking pins, then tighten tensioner retaining nuts. Rotate crankshaft 2 turns in direction of engine rotation and bring No. 1 cylinder to TDC of compression stroke. Loosen timing belt tensioner retaining nuts to tension timing belt. After timing belt has tensioned, tighten tensioner retaining bolts. Position crankshaft pulley and key to crankshaft then loosely install crankshaft pulley retaining bolt. Insert Peugeot Locking Pin Tool (No. 0-0163) or equivalent, through camshaft sprocket and crankshaft pulley locking pin holes. See Figs. 2 and 4. If pins are not aligned with holes, timing belt must be removed and reinstalled. Remove crankshaft retaining bolt and pulley. Install lower and upper portions of timing belt lower cover. Position crankshaft pulley and key to crankshaft, then loosely install crankshaft pulley retaining bolt. Using Peugeot Flywheel Stop Tool (No. 91-86) or equivalent, lock flywheel in position, then tighten crankshaft pulley retaining bolt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.9L 4-Cyl. 405 1989-91 DOHC ................. 4.0 Hours .................. 250188 SOHC ............... 4.0 Hours .................. 250189


TIMING BELT
Removal (DOHC): Disconnect negative battery cable. Raise and support front of vehicle. Remove A/C compressor drive belt. Remove A/C compressor from mounting bracket with refrigerant hoses attached. Suspend compressor from lower frame at bottom of engine compartment. Remove alternator drive belt, then alternator. Support engine. Remove upper engine mount and two upper cover bolts. Tilt engine and transmission assembly as far as possible. Disconnect wiring harnesses from relay box, then pull up on clip and lift upper cover upward. Remove lower flywheel housing cover. Hold flywheel in position with Peugeot Lock Tool (J-36358) or equivalent. Remove right mud shield. Remove 4 crankshaft pulley retaining bolts, then crankshaft pulley. Remove lower cover. Remove flywheel locking tool. Rotate engine, using crankshaft pulley bolt, to align crankshaft lock pin hole with engine lock pin hole. See Fig. 1. Insert Peugeot Lock Pin (No.0153-G) or equivalent through crankshaft lock pin holes, remove pin. Insert Peugeot Lock Pins (No. 0153-M) or equivalent through camshaft sprocket lock pin holes. Loosen timing belt tensioner bolts, then turn tensioner to relieve tension on timing belt. Remove timing belt from sprockets. Installation (DOHC): Ensure that camshaft and crankshaft locking pins are in position. See Fig. 1. Install belt in order, observing direction of engine rotation. Start with camshaft sprockets, tensioner, crankshaft sprocket, water pump sprocket and tensioner. See Fig. 3. Lift and tilt engine and transmission assembly as far as possible, then position belt tensioning tool on indicated section of timing belt and lock in position. Rotate tensioner one full turn. Using Peugeot Tensioner Tool (No. 0153-P) or equivalent, rotate tensioner counterclockwise until 19 SEEM units are displayed on belt tensioning tool meter. See Fig. 3. Without changing tensioner position, torque tensioner bolt to 18 ft. lbs., then remove belt tensioning meter. Rotate tensioner counterclockwise until 21 SEEM units are displayed on belt tensioning tool meter. See Fig. 3. Without changing tensioner position, torque tensioner bolt to 18 ft. lbs. Remove three locking pins and rotate crankshaft two turns in normal direction of engine rotation.
PEUGEOT 1.9L 4-Cylinder (Cont.)

TIGHTENING SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts ............................................ 11 (15) Crankshaft Pulley Bolts DOHC ....................................................................... 18 (25) SOHC ...................................................................... 81 (111) Timing Belt Tensioner Nut/Bolt DOHC (4 Bolts) ........................................................ 18 (26) SOHC ....................................................................... 12 (16) Upper Engine Mount DOHC ....................................................................... 33 (45)
461
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
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 4-Cyl. 505 1986-91 ................. 2.7 Hours .................. 250140


TIMING BELT
Removal: Disconnect battery. Drain cooling system including cylinder block. Remove radiator and fan shroud. Remove thermostat housing and auxiliary air device. Align timing marks for crankshaft, camshaft and intermediate shaft. See Fig. 1. Remove crankshaft pulley bolt and pulley. Ensure that crankshaft does not rotate. Remove timing belt cover. Loosen timing belt tensioner bolts and position tensioner out of way. Remove camshaft pulley and timing belt. Installation: Ensure timing marks remain in alignment. See Fig. 1. Remove distributor cap and check rotor position. Distributor rotor must be at a 90 degree angle to the crankshaft. If not, turn intermediate shaft once or twice. Install timing belt, centered on pulleys and tensioner. Loosen belt tensioner mounting bolts and allow spring to adjust timing belt. Tighten belt tensioner bolts. To complete installation, reverse removal procedures. Crankshaft pulley bolt must be reinstalled using Loctite. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TIGHTENING SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolts ............................................ 11 (15) Crankshaft Pulley Bolts ............................................ 98 (133) Timing Belt Tensioner Nut/Bolt ................................... 18 (26)
Fig. 1: Locating 2.2L Timing Marks
PORSCHE *2.0L 4-Cylinder

TIMING BELT APPLICATION Application 2.0L 4-Cyl. 924 1977-82 .......... 1.0 Hrs. ...... 2520170 ........ 250017 Labor Time Component Kit No. Belt Part No.
463

TIMING BELT
Removal: Disconnect negative battery cable. Remove accessory drive belts and any components as necessary to access camshaft sprocket cover. Remove camshaft sprocket cover. Align mark on camshaft sprocket with indicator on cylinder head cover. The TDC mark on flywheel and housing must align with each other. Loosen timing belt tensioner. Remove timing belt. Installation: To install components, reverse removal procedure. Belt must be tightened until belt can be turned 90 degrees with thumb and index finger at a point midway between crankshaft and camshaft. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 58 (79) Crankshaft Pulley ................................................... 180 (245) Tensioner Pulley ......................................................... 29 (39) INCH Lbs. (N.m) Camshaft Sprocket Cover ........................................... 84 (10)

The manufacturer recommends that under normal operating conditions, check tension at 2,000 miles, then every 15,000 miles. Replace belt every 45,000 miles.
464
PORSCHE *2.5L, *2.7L & *3.0L 4-Cylinder

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.5 L 4-Cyl. 924 1987-88 Balance Shaft ... 1.5 Hours .................. 250293 Camshaft ............. 1.5 Hours .................. 250107 944 1983-89 Balance Shaft ... 4.0 Hours .................. 250293 Camshaft ............. 4.0 Hours .................. 250107 944S 1987-88 Balance Shaft ... 2.4 Hours .................. 250293 Camshaft ............. 2.4 Hours .................. 250152 2.7L 4-Cyl. 944 1989 Balance Shaft ... 3.5 Hours .................. 250293 Camshaft ............. 3.5 Hours .................. 250107 3.0L 4-Cyl. 944 1989-91 Balance Shaft ... 3.5 Hours .................. 250293 Camshaft ............. 3.5 Hours .................. 250152 968 1992-95 Balance Shaft ... 3.4 Hours .................. 250293 Camshaft ............. 3.4 Hours .................. 250152 1 - With Pwr. Strng. add .3 hours.
Turn crankshaft clockwise to align camshaft sprocket TDC mark with mark in distributor cap console. See Fig. 2. Ensure mark on upper and lower balance shaft sprockets align with mark on rear timing belt cover. See Fig. 3. The flywheel mark for No. 1 cylinder must also align with cast boss on clutch housing. On 1986 and earlier models, release belt tension. On 1987 and later models, mechanical belt tensioner must be removed. See Fig. 5. Remove balance shaft drive belt. Loosen camshaft belt tensioning sprocket lock nut and then sprocket by turning it clockwise. Remove camshaft timing belt. Installation (Camshaft Belt): Ensure No. 1 cylinder is at TDC and marks on flywheel and cast clutch housing are aligned. Align mark on camshaft sprocket with mark on rear drive belt cover. Install camshaft timing belt by placing belt on crankshaft sprocket, tensioner sprocket, water pump pulley and camshaft sprocket. See Fig. 4. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. After drive belt tension is adjusted, install balance belt. To complete installation, reverse removal procedure. Tension Adjustment: Rotate crankshaft clockwise until TDC mark on camshaft sprocket aligns with cast mark in distributor cap mount. Ensure TDC marks on flywheel and cast clutch housing are aligned. Loosen tensioner adjustment bolts. See Fig. 5. Using thumb pressure, press downward on camshaft belt between water pump pulley and camshaft sprocket. Force camshaft belt against belt cover.
NOTE: On 944-S models, intake camshaft is chain driven from the exhaust camshaft.
Repeat procedure twice to ensure free movement of belt idler pivot. Allow idler spring tension to apply tension against belt. Tighten adjustment bolts to 15 ft. lbs. (20 N.m).

CAUTION: DO NOT remove balance shaft sprocket mounting bolts to replace drive belt. Handle metal insert drive belts carefully. Mark belt direction of rotation prior to removal if belt is to be reused.

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.
Installation (Balance Belt): Ensure No. 1 cylinder is at TDC and marks on flywheel and cast clutch housing are aligned. Align mark on camshaft sprocket with mark on rear drive belt cover. Install balance belt with color coded tooth facing out. Adjust drive belts to proper tension. To complete installation, reverse removal procedure.
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. Disconnect vent hose and position to one side. Remove timing belt cover assembly. Remove distributor cap and position to one side. Raise and support vehicle. Ensure pressure rod bolts are are slightly loose prior to loosening lock nuts. See Fig. 1. Remove accessory drive belts.
Fig. 1: Loosening Pressure Rod
PORSCHE *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 2.43.0 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 between drive belt (at lower balance shaft sprocket) and idler pulley is maintained when upper portion of drive belt is preloaded at .04-.08" (1.0-2.0 mm). Tighten idler pulley. See Fig. 3. If correct gap cannot be reached, rotate idler pulley 180 degrees and repeat adjustment. Tighten mounting nut. Install and adjust poly-rib belt. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Balance Shaft Bearing Cover ............................................... 1 Step 1: 2 Bolts @ Bearing (8 mm) ..................................... 11 (15) Step 2 6 mm ....................................................................... 7 (10) 8 mm ..................................................................... 15 (20) Step 3: 2 Bolts @ Bearing (8 mm) ..................................... 24 (33) Balance Shaft Sprocket Mounting Bolt ........................ 33 (45) Belt Tensioner Mounting Bolt ...................................... 33 (45) Camshaft Housing Mounting Bolt .............................. 15 (20) Camshaft Plug (Aluminum) ........................................ 30 (41) Camshaft Sprocket Hex Mounting Bolt ..................................................... 33 (45) Polygon Mounting Bolt .................................... 47-51 (64-69) INCH Lbs. (N.m) Camshaft Bearing Cap Bolt ......................................... 96 (8) Transport Clamp-to-Camshaft Housing ...................... 96 (8)
1
465
Fig. 2: Aligning Camshaft Sprocket Timing Mark
- Check movement of balance shaft between each tightening step.
Fig. 3: Aligning Upper Balance Shaft Timing Mark
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 *4.5L, 4.7L, 5.0L & 5.4L V8

TIMING BELT APPLICATION Application Labor Time Belt Part No. 4.5L V8 928 1978-82 ................. 4.6 Hours .................. 250196 4.7L V8 928 1983-84 ................. 4.6 Hours ................. 250196 5.0L V8 928 1985-91 ................. 6.5 Hours .................. 250196 5.4L V8 928 1992-95 ................. 6.5 Hours .................. 250196
467

On 4.5L V8, align TDC mark on vibration damper with red indicator on cover. On 4.7L, 5.0L & 5.4L V8, align mark for 45 degrees BTDC on vibration damper with Red needle. Turn crankshaft clockwise. See Fig. 2. On 4.5L V8, rotate crankshaft clockwise until timing marks (notches) on camshaft sprockets align with marks cast on camshaft bearing caps. On 4.7L, 5.0L & 5.4L V8, lock crankshaft by installing Porsche Tool (9161/1) or equivalent. Secure tool with slave cylinder mounting bolts. Remove crankshaft pulley mounting bolt, both pulleys, vibration damper and collar. Remove oil dipstick tube. Remove alternator. Remove left upper and center timing belt covers. Loosen timing belt tensioner. Loosen tensioning roller. Remove timing belt. Installation: On 4.5L V8, align TDC mark on vibration damper with Red indicator on cover. On 4.7L, 5.0L & 5.4L V8, align mark for 45 degrees BTDC on vibration damper with Red needle. Turn crankshaft clockwise. See Fig. 2. On 4.5L V8, rotate crankshaft clockwise until timing marks (notches) on camshaft sprockets align with marks cast on camshaft bearing 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 intake hoses. Remove accessory drive belts. Disconnect cables for throttle, cruise control and automatic transaxle. Remove retainers and clamp on console and position cable aside. Remove clutch slave cylinder.
CAUTION: NEVER operate clutch pedal when slave cylinder is removed.
Fig. 1: Camshaft Sprocket & Timing Belt Types
468
PORSCHE *4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)

TIMING BELT TENSIONER
NOTE: The timing belt tensioning mechanism uses hydraulic dampening and a temperature compensation mechanism to reduce belt load and dampen oscillation. See Fig. 4. The tensioner roller and carrier is supported against the pull of toothed belt by a push rod and piston on a 7 packet (5 each) bi-metallic diaphragm spring set. Tensioner is filled with engine oil (which is added only after installation on block). Replacement tensioners are not oil filled so oil must be added and unit bled for proper operation. Pockets between tensioner roller housing and engine block are used as oil reservoirs to aid in heat transfer between engine block and tension roller housing and activate bimetallic diaphragm springs.
NOTE: Manufacturer indicates sufficient clearance exists so pistons and valves will not collide when crankshaft is turned with camshaft timing belt removed.
Preload belt by hand and install belt on sprockets in order of crankshaft, oil pump, left camshaft, water pump, right camshaft and tension roller. See Fig. 2. Ensure belt and camshaft sprocket teeth match. If necessary, rotate camshaft counterclockwise until teeth match. Tighten timing belt to specification. Rotate engine 2 revolutions and align cylinder No. 1 at TDC of compression stroke. Check camshaft timing marks for proper alignment and retighten camshaft drive belt. Ensure tester is not turned or pushed during tension measurement. Recheck belt adjustment at least once. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Adjustment: With both upper drive belt guards removed, rotate crankshaft (in direction of rotation) and position cylinder No. 1 at TDC of compression stroke. Mark on vibration damper should be in alignment with Red indicator on cover. Ensure each camshaft sprocket timing mark is in alignment with mark cast on camshaft bearing cap. Turn engine over 2 more times until TDC is reached again. Check timing belt for damage and wear. Pull out lock pin, then completely push out gauge pin (opposite lock pin) on Timing Belt Tension Tester (9201) or equivalent. Move telltale to 0 position on gauge. See Fig. 3. Slide tension tester onto belt section between tension roller and lower camshaft sprocket. Ensure measuring pin is resting in belt grove. Push tester down on side closer to tensioner, until gauge needle, resting on air pump bracket, engages. Read measured valve while keeping tester horizontal to belt and free of tension. Tester must not touch plastic cover. Move telltale to 0 position on gauge. Pull out lock pin to disengage gauge needle again. Remove tester from timing belt and read measured value. Correct belt tension if necessary. Adjustment screw is located on bottom of engine, at right front side. To adjust, loosen adjustment screw lock nut and turn adjustment screw until tension is correct. Tighten lock nut and turn engine 2 revolutions. Recheck tension adjustment. TIMING BELT TENSION Application Scale Value New or used ..................................................................... 4.5
When installing tensioner, ensure sealing surface on block is in good condition. Apply Locktite (No. 574) to sealing surface before installation. When filling tensioner, damping chamber may be bled by pumping tension roller carrier. Ensure belt is loose and oil filler bolt and bleeder are open. To fill, remove the larger oil filler and open Allen head bleeder screws on tensioner housing. Using an oil can, slowly pour oil into filler hole until air-free oil flows from bleeder hole. Install and tighten filler and bleeder screws. Check fluid level after 1000 miles and at 15,000 mile intervals thereafter. To check, remove filler bolt. If oil can be seen, level is okay. If not, add oil as necessary. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Housing Mounting Bolt .............................. 14 (20) Camshaft Pulley Mounting Bolt ................................... 33 (45) Front Pulley Mounting Nut ......................... 181-188 (250-260)
Fig. 2: View Of Camshaft Drive Belt Installation
PORSCHE *4.5L, 4.7L, 5.0L & 5.4L V8 (Cont.)
469
Fig. 3: Drive Belt Tension Tester
470
RENAULT *1.7L 4-Cylinder
Align timing belt marks with timing mark on camshaft sprocket and crankshaft sprocket. See Fig. 2. Remove TDC tool from crankcase, then rotate crankshaft clockwise, 2 complete revolutions. Reinstall TDC tool through crankcase into crankshaft. Ensure that the camshaft sprocket timing mark is aligned with mark on rear cover plate. See Fig. 1.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.7L 4-Cyl. Alliance & Encore 1985-87 .................... 2.3 Hours .................. 250119

NOTE: The intermediate shaft sprocket does not have a timing mark.

TIMING BELT
Removal: Disconnect negative battery cable. Remove accessory drive belts. Remove timing belt cover. Rotate crankshaft until No. 1 cylinder is at TDC of compression stroke. Ensure that camshaft is positioned as shown. See Fig. 1. Insert Renault TDC Lock Pin (Mot. 861) or equivalent through opening in side of block. Ensure that tool engages slot in crankshaft. Loosen timing belt tensioner, then remove timing belt.
NOTE: If there is no reference mark on camshaft sprocket rear cover plate, scribe a matching mark in line with timing mark on sprocket. NOTE: DO NOT rotate crankshaft or camshaft with timing belt removed.
There should be 66 timing belt teeth (cogs) between camshaft sprocket timing mark and crankshaft sprocket timing mark. See Fig. 2. Remove TDC tool and install plug into cylinder block. Check timing belt deflection between intermediate shaft sprocket and idler pulley. With belt cold, deflection should be .295 (7.49 mm). With belt hot, deflection should be .216 (5.48 mm). If deflection is excessive, loosen tensioner pulley lock nut, then turn tensioner pulley nut counterclockwise to increase tension or counterclockwise to decrease tension. While holding tensioner pulley lock nut with a suitable wrench, tighen tensioner pulley lock nut to specification. To complete installation, reverse removal procedures. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Tensioner Pulley Lock Nut .......................................... 30 (41)
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 crankshaft 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 *1.7L 4-Cylinder (Cont.)
471
472
RENAULT 2.2L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 4-Cyl. Fuego 1984-85 ................ 2.2 Hours ................. 250140 Sportwagon 1984-86 ................ 2.0 Hours ................. 250140

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

TIMING BELT
Removal: Disconnect negative battery cable. Drain cooling system. Remove radiator upper support. Remove upper and lower hoses from radiator. Disconnect wiring harness connectors from cooling fan and thermo switch. Remove radiator and A/C condenser as an assembly. Release tension and remove serpentine drive belt. Remove timing belt cover. Remove hose from water pump. Remove water pump pulley bolt and pulley. Remove water pump. Remove timing belt tension spring and plunger from water pump and install them in replacement water pump. Clean gasket mating surfaces. Loosen timing belt tensioner idler bolts. Remove timing belt. Installation & Adjustment: Position camshaft sprocket timing index in line with static timing mark. Position crankshaft so No. 1 piston is at TDC of compression stroke. Remove plug in cylinder block and insert TDC Rod (Mot. 861) or equivalent, into TDC hole in crankshaft. Install timing belt. See Fig. 1. Position timing belt cover over sprockets and check camshaft timing mark with index on cover. Remove TDC rod and install plug in cylinder block. Rotate crankshaft clockwise 2 complete revolutions. DO NOT rotate counterclockwise. Remove timing belt cover and loosen timing belt tensioner bolts a maximum of 1/4 turn. Spring loaded timing belt tensioner will automatically adjust to correct position. Ensure clearance between timing belt tensioner and intermediate shaft cover is .004" (.10 mm). See Fig. 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" (5.57.0 mm). Install timing belt cover. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 37 (50) Crankshaft Pulley Bolt .............................................. 96 (130)
Fig. 2: Adjusting Intermediate Shaft Cover Clearance
RENAULT 2.2L 4-Cylinder (Cont.)
473
Fig. 3: Timing Belt Cover TDC Marks
Fig. 5: Aligning Camshaft & Crankshaft Sprockets
474
SAAB *2.5L & 3.0L V6
Turn engine 2 revolutions in normal direction of rotation. Recheck camshaft and crankshaft timing mark alignment. To complete installation, reverse removal procedure. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 37 (50) Crankshaft Pulley Bolt ................................................ 15 (20) Valve Cover Nuts ........................................................ 86 (10)
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L V6 900 1994-97 ................. 2.3 Hours ................. 250285 3.0L V6 9000 1995-97 ................. 2.3 Hours ................. 250285


TIMING BELT
Removal: Move power steering reservoir out of the way, and remove right side engine-to-frame torque arm. Remove the power steering line clamp from the torque arm engine mount. Remove torque arm engine mount. Relieve tension on serpentine belt and remove serpentine belt. Remove the water pump pulley. Remove upper part of alternator air intake. Remove the serpentine belt tensioner. Remove the power steering pump with lines attached, and move out of way. Remove the timing belt cover. Remove the 6 outer bolts from the crankshaft pulley, NOT the center bolt. Turn crankshaft so No. 1 cylinder is at TDC of compression stroke. Ensure marks on camshaft sprockets and timing cover align. See Fig. 1. Install Belt Holder (KM-800-1 and KM-800-2) to hold camshaft sprockets in place. See Fig. 2. If belt is to be reused, mark belt with direction of rotation. Remove timing belt from engine.
NOTE: Use the marks on each side of the direction of rotation arrows to line up the left (drivers side) camshaft sprockets. For this design (idler pulley located above crankshaft) engine, use the remaining 3 White marks on the NAPA timing belt. Correct belt marks MUST be used.
Courtesy of Saab-Scania of America, Inc.
Installation: Ensure crankshaft and camshaft timing marks are still aligned. Install timing belt. Adjust lower roller counterclockwise to belt tension of 205-221 ft. lbs. (275-300 N.m). Adjust tensioning pulley with a hex head wrench until 2 marks are aligned. Tighten bolt. 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 locking tools.
Courtesy of Saab-Scania of America, Inc.
Fig. 2: Camshaft Belt Holders
STERLING *2.5L & *2.7L V6

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L V6 825 1987-88 .................. 4.0 Hours ................ 250129 2.7L V6 827 1989-91 .................. 4.0 Hours ................ 250129
475
Ensure timing belt is seated properly on pulleys. Tighten adjuster bolt. Reverse removal procedure to complete installation.
NOTE: After timing belt installation, rotate engine clockwise several times to ensure valves DO NOT contact pistons.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolts ............................................... 16 (22) A/C Compressor Bracket Bolts .................................. 33 (45) Alternator Bracket Bolts .............................................. 33 (45) Alternator Mount Bolts ................................................ 16 (22) Camshaft Pulley Bolts ................................................ 23 (31) Crankshaft Pulley Bolt ............................................ 123 (170) Engine Mount Bolts .................................................... 40 (54) Power Steering Pump Mount Bolt ............................... 33 (45) Timing Belt Tensioner Bolt ......................................... 33 (45) INCH Lbs. (N.m) Timing Belt Cover Bolts .............................................. 86 (10) Valve Cover Bolts ...................................................... 106 (12) Water Pump Bolts .................................................... 106 (12)


TIMING BELT
Removal: Remove negative battery cable. Turn crankshaft clockwise to bring No. 1 cylinder to TDC of compression stroke. Remove pulley cover from upper timing belt cover. Remove engine wiring harness clamp from right side of engine compartment. Support front of engine. On right side of engine compartment, remove engine-to-body mount (on front of engine). Remove lower engine splash shield. Remove A/ C, power steering, and all other drive belts. Remove alternator. Leaving hoses connected, remove power steering pump and secure out of way. Remove upper timing belt pulley covers. Remove crankshaft pulley. Remove timing belt lower cover. Loosen timing belt tensioner to relieve tension on timing belt. If reusing timing belt, mark direction of belt rotation before removing. Slide belt off pulleys. Check belt for damage, missing teeth, or cracks. Installation: Remove spark plugs. Turn crankshaft clockwise to bring No. 1 cylinder to TDC of compression stroke. Advance crankshaft an additional 15 degrees from TDC position. Rotate camshaft pulleys to compression stroke (TDC position) of No. 1 cylinder. See Fig. 1. Return crankshaft pulley 15 degrees to TDC position. Push timing belt tensioner to full release position and snug adjuster bolt. Install timing belt over crankshaft pulley, front camshaft pulley, water pump pulley, tensioner and then over rear camshaft pulley. See Fig. 1. Note position of timing belt pulley guides on both sides of crankshaft. Install pulley guides so guides form a V groove for belt to ride in. Loosen timing belt tensioner bolt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension.
NOTE: Always adjust timing belt tension with engine cold.
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.
476
STERLING *2.5L & *2.7L V6 (Cont.)
SUBARU 1.2L 3-Cylinder

TIMING BELT APPLICATION Belt Part No. Application Labor Time 1.2L 3-Cyl. Justy 1987-95 ................. 1.4 Hours .................. 250135 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .2 hours.
1
477
TORQUE SPECIFICATIONS Ft. Lbs. (N.m) Crankshaft Pulley Bolt ...................................... 58-72 (78-98) INCH Lbs. (N.m) Camshaft Sprocket Bolt ............................ 97-106 (11.0-12.0) Tensioner Bolt ................................................ 50-53 (5.7-6.0) Valve Cover Bolt .............................................. 53-71 (6.0-8.0) Water Pump Impeller Bolt ............................ 80-89 (9.0-10.0) Application


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 retaining bolts. Move tensioner toward outside of engine. Tighten bolts to hold tensioner. See Fig. 2. Mark timing belt for direction of rotation. Remove crankshaft belt drive sprocket plate and timing belt.
NOTE: Before removing timing belt, mark it indicating direction of rotation. Timing belt must be installed in original direction of rotation.
Inspection: Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect all drive sprockets for wear in drive belt area. Inspect tensioner for noise and grease leakage. Replace tensioner as necessary. Installation: Using Pulley Holder (499205500) or equivalent, rotate camshaft to align camshaft sprocket alignment mark with alignment mark on timing belt cover. See Fig. 1. Install crankshaft belt drive sprocket (if removed) with flanged side facing inward. Rotate crankshaft so crankshaft belt drive sprocket aligns with crankcase alignment mark. Remove valve cover (if it was not previously removed). Loosen valve adjusting screws to gain rocker arm free play. Loosen tensioner retaining bolts. Apply tension to timing belt. Tighten inner and then outer tensioner retaining bolts. Ensure all timing marks are aligned. Install crankshaft belt drive sprocket plate. Reverse removal procedure for remaining components. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Adjust valve clearance. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
478
SUBARU 1.8L 4-Cylinder Except Impreza & Legacy

Installation: Install belt tensioners and belt idler. Position belt tensioners to allow belt installation. Install inner (sprocket without dowel pin) and outer crankshaft sprockets on crankshaft. Temporarily install crankshaft pulley. Align center mark on flywheel with mark on flywheel housing. See Fig. 3. Align timing mark on left camshaft sprocket (sprocket for timing belt closest to engine) with notch in belt cover. See Fig. 4. Install left timing belt first on inner crankshaft sprocket and then around oil pump sprocket. Install left timing belt on idler and then camshaft sprocket. If reusing belt, install it in original direction of rotation. Loosen left tensioner retaining bolt to apply tension to timing belt. Push timing belt by hand to ensure smooth operation and movement of tensioner. Using Belt Tensioner Wrench (499437000) or equivalent, apply 17-19 ft. lbs. (2326 N.m) of torque to camshaft sprocket in a counterclockwise direction. While applying torque, tighten tensioner bolts. Ensure all timing marks are aligned. See Figs. 3 and 4.
NOTE: After installing left side timing belt, crankshaft is rotated 1 full turn (360 degrees). This will be the position for installing the right side camshaft belt. The camshaft timing mark for the left side timing belt will now be pointing straight down (6 oclock position). See Fig. 5.
TIMING BELT APPLICATION Application 1.8L 4-Cyl. DL, GL & RX (Coupe, Sedan & Station Wagon) 1985-89 Left Side ..... 2.7 Hrs ...... 2522990 ......... 250299 Right Side ... 2.7 Hrs. ..... 2522990 ......... 250300 Loyale 1990-94 Left Side ..... 2.7 Hrs. ..... 2522990 ......... 250299 Right Side ... 2.7 Hrs. ..... 2522990 ......... 250300 XT 1985-91 Left Side ..... 2.7 Hrs. ..... 2522990 ......... 250299 Right Side ... 2.7 Hrs. ..... 2522990 ......... 250300 1 - Both Belts. With Air Cond. add .4 hours. With Pwr. Strng. add .2 hours.


TIMING BELT
Removal: Disconnect negative battery cable. Remove alternator drive belt. Remove water pump pulley. Remove dipstick and tube. Remove crankshaft pulley. If engine is removed from vehicle, crankshaft can be held using Flywheel Stopper (498277000) or equivalent, for M/T models or Drive Plate Stopper (498497000) or equivalent, for A/T models.
CAUTION: If reusing timing belt, mark belt to indicate normal direction of rotation.
To install right (outer) timing belt, rotate crankshaft clockwise 360 degrees and align center line on flywheel with timing mark on flywheel housing. Align camshaft sprocket timing mark with notch in housing. See Fig. 4. Install right timing belt over crankshaft and camshaft sprockets, keeping slack out of side opposite tensioner. Ensure reused belt is installed in original direction of rotation. Loosen inner tensioner bolt and allow tensioner to apply belt tension. While turning camshaft sprocket counterclockwise, apply 17-19 ft. lbs. (23-26 N.m) of torque using Belt Tension Wrench (499437000) or equivalent.
NOTE: When timing belts are properly installed, left side camshaft sprocket timing mark will be pointing DOWN and right side camshaft sprocket timing mark will be pointing UP. Engine timing marks for both camshafts are located on TOP side of rear timing belt covers. See Figs. 4 and 5.
Remove center, left and right timing belt covers. To remove right side timing belt, loosen tensioner bolts on No. 1 cylinder 1/2 turn, rotate tensioner to release belt tension, and retighten bolts. See Fig. 1. If reusing timing belt, mark belt to indicate normal direction of rotation. Remove timing belt. Loosen left side timing belt tensioner bolts on No. 2 cylinder 1/2 turn. See Fig. 1. Using tensioner wrench, rotate tensioner until belt is slack. Tighten tensioner bolts. If reusing timing belt, mark belt to indicate normal direction of rotation. Remove outer crankshaft sprocket. Remove timing belt. Inspection: Inspect timing belt for wear and rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect idler pulleys and tensioners for smooth rotation. Check belt tensioner roller for squareness. See Fig. 2. Replace tensioner if outof-square exceeds .02" (.5 mm).
Fig. 1: Identifying Timing Belts & Engine Components
479 SUBARU 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.
While applying torque, tighten inner and then outer tensioner retaining bolts. Ensure all timing marks are aligned. To install remaining components, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Idler Bolt .................................................... 29-35 (39-47) Belt Tensioner Bolt ........................................... 13-15 (18-20) Camshaft Case Bolt ......................................... 13-15 (18-20) Crankshaft Pulley Bolt 1 .................................. 66-79 (90-107) Oil Pump Pulley Nut ......................................... 13-15 (18-20) INCH Lbs. (N.m) Camshaft Sprocket Bolt ...................................... 80-89 (9-10) Camshaft Support Bolt ......................................... 53-62 (6-7) Timing Belt Cover Bolt .......................................... 35-44 (4-5) Valve Cover Bolt .................................................... 35-44 (4-5) Water Pump Pulley Bolt ...................................... 80-89 (9-10)
1
Fig. 5: Final Installed Position Of Left Timing Belt Sprocket
- Coat bolt threads with oil before installation.
480
SUBARU 1.8L & 2.2L 4-Cylinder Impreza & Legacy

Slight trace of oil at rod oil seal does not indicate a problem. While holding tensioner using both hands, push rod section against floor or wall using a force of 33-110 lbs. (15-50 kg) to ensure rod section does not move. If rod section moves, replace tension adjuster. Measure extension of rod beyond body. Rod extension should be .606-.646" (15.40-16.40 mm). Replace belt tension adjuster if extension of rod is not as specified. Inspect belt tensioner and belt adjuster rod mating surface. Check spacer and tensioner bushing.
TIMING BELT APPLICATION Application 1.8L 4-Cyl. Impreza 1993 ............... 1 2.2 Hrs. .... 2521720 ........ 250172 1994-97 .......... 1 2.2 Hrs. ........................... 250254 2.2L 4-Cyl. Impreza 1995-98 .......... 1 2.2 Hrs. ........................... 250254 Legacy 1990-93 .......... 1 2.2 Hrs. .... 2521720 ........ 250172 1994-98 .......... 1 2.2 Hrs. ........................... 250254 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .2 hours.
CAUTION: DO NOT allow press pressure to exceed 2205 lbs. (992 kg). DO NOT release pressure until stopper pin is completely installed.

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.
Installation: Ensure timing marks are aligned. Using a press, align holes in belt tension adjuster rod and adjuster body, and push rod into body. DO NOT allow press pressure to exceed 2205 lbs. (992 kg). Install a stopper pin with a diameter of .059" (1.5 mm) through holes in adjuster body and rod. See Fig. 2. Temporarily tighten mount bolts while tension adjuster is pushed completely right. Install belt tensioner. Ensure belt direction of rotation is correct. Install timing belt, being careful not to move sprockets. Install belt idler No. 2 and belt idler. Loosen tension adjuster mount bolts and push tension adjuster completely left. Tighten adjuster mount bolts.

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 equivalent 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 rotation before removal. Use Crankshaft Socket (499987500) to turn crankshaft pulley. Align crankshaft and camshaft timing notches with corresponding notches on timing cover and engine block. See Fig. 1. Use White paint to mark timing belt in relation to sprocket timing marks. Loosen tensioner adjuster mounting bolts. Remove belt idler. Remove belt idler No. 2. Remove timing belt. Inspection: Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect belt tension adjuster oil seals for leaks. Inspect rod ends for abnormal wear and scratches. Timing belt bend diameter must be greater than 2.36" (60.0 mm).
Fig. 1: Removing & Installing Timing Belt
Fig. 2: Installing Tension Adjuster Rod Stopper Pin
481 SUBARU 1.8L & 2.2L 4-Cylinder Impreza & Legacy (Cont.)
Ensure the marks on timing belt and sprockets align. See Fig. 1. Remove stopper from tension adjuster. Remove rocker covers and ensure valve lash adjuster does not contain air. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................... 55-61 (75-83) Camshaft Support Bolt ............................................... 12 (16) Crankshaft Pulley Bolt .................................... 69-76 (93-103) Timing Belt Idler Bolt ........................................ 26-32 (35-43) Timing Belt Tension Adjuster Bolt ..................... 17-20 (23-27) Timing Belt Tensioner Bracket Bolt .................. 17-20 (23-27) INCH Lbs. (N.m) Rocker Cover Bolt ...................................................... 44 (5.0) Rocker Shaft Support Bolt Long .................................................................... 108 (12.2) Short ........................................................................ 44 (5.0) Timing Belt Cover Bolt ............................................... 44 (5.0) Water Pump Bolt ...................................... 89-124 (10.0-14.0)
482
SUBARU 2.2L & 2.5L 4-Cylinder SOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.2L 4-Cyl. Impreza 1999-01 ................ 1 2.2 Hours ................. 250304 Legacy 1999 ..................... 1 2.5 Hours ................. 250304 Outback 2000-01 ................ 1 2.5 Hours ................. 250304 2.5L 4-Cyl. Forester 1999-01 ................ 1 2.2 Hours ................. 250304 Impreza & Outback Sport 1999-01 ................ 1 2.2 Hours ................. 250304 Legacy & Outback 2000-01 ................ 1 2.5 Hours ................. 250307 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .2 hours.

The manufacturer recommends the belt be replaced every 105,000 miles on all 1999-01 vehicles.

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove engine under cover. Lower vehicle. Remove radiator coolant reservoir and set aside. Remove electric cooling fan and radiator shroud. On Impreza and Forester, remove accessory drive belt cover. On all models, remove accessory drive belts. Hold crankshaft pulley stationary, remove crankshaft pulley center bolt. Remove crankshaft pulley. Remove timing belt covers. Turn crankshaft to align crankshaft and camshaft timing notches with marks on rear timing cover and engine block. See Figs. 1 and 2. On manual transmission models, remove 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 number of teeth between crankshaft sprocket and camshaft sprockets so that belt will be installed in same position. See Fig. 3.
Z1 = 44 Teeth 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: Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect belt 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 2.2L & 2.5L 4-Cylinder SOHC (Cont.)
483
Fig. 4: Removing No. 2 Timing Belt Idler Pulley
Measure extension of rod beyond tensioner body. Holding tensioner with rod facing up, rod extension should be .224 plus or minus .020 (5.7 mm plus or minus 0.5 mm). See Fig. 5. Replace automatic tensioner if rod extension is not as specified.
Fig. 5: Checking Automatic Tensioner Rod Extension
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 bearings or lubricant leaks. Replace as necessary. TORQUE SPECIFICATIONS
CAUTION: To prevent damage, DO NOT apply more than 2205 lbs. (9807 N) to automatic adjuster rod. Do NOT press automatic tensioner rod past the top surface of the housing. DO NOT allow press pressure to exceed 2205 lbs. (1000 kg).
Fig. 6: Compressing Automatic Tensioner Rod
Installation: Ensure crankshaft and camshaft timing marks are still aligned. Place automatic adjuster in a press with rod facing up. Apply 66 lbs. (294 N) pressure to end of rod. SLOWLY (taking more than 3 minutes) compress rod into housing until rod and housing holes are aligned. Insert locking pin through holes. See Fig. 6. Install automatic tensioner on engine with locking pin in place. Install idler pulleys (if removed). Ensure crankshaft and camshaft timing marks are still 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 clearance 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 crankshaft pulley bolt threads with engine oil. Install bolt, While holding crankshaft pulley stationary, tighten bolt to specification. See TORQUE SPECIFICATIONS.
CAUTION: If tightening angle of crankshaft pulley bolt is less than 45 degrees, bolt is damaged. Bolt must be replaced.
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 58 (78) Crankshaft Pulley Bolt 2.2L ........................................................................ 94 (127) 2.5L ...................................................................... 130 (177) Idler Pulley Bolt ............................................................. 29 (39) Timing Belt Automatic Tensioner Bolt ............................ 29 (39) INCH Lbs. (N.m) Timing Belt Cover Bolt ..................................................... 44 (5) Timing Belt Guide Bolt (M/T) ....................................... 89 (10) Valve Cover Bolt ................................................................ 44 (5) Water Pump Bolt ...................................... 89-124 (10.0-14.0)
Install accessory drive belts. Install radiator fan assembly. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 7: Checking Timing Belt Guide Clearance
484
SUBARU 2.5L 4-Cylinder DOHC
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L 4-Cyl. DOHC Forester 1998 ..................... 1 2.5 Hours ................. 250277 Impreza 1996-99 ................ 1 2.5 Hours ................. 250277 Legacy & Outback 1996-99 ................ 1 2.5 Hours ................. 250277 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .2 hours.

The manufacturer recommends the belt be replaced every 60,000 miles on 1996-97 Federal vehicles. Replace belt at 105,000 miles on all 1998-99 vehicles.
96I14512
Fig. 1: Removing Drive Belt Cover

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 crankshaft pulley bolt. See Fig. 2. Remove crankshaft pulley. Remove left and right timing belt covers. Remove front belt cover. See Fig. 6. Rotate crankshaft and align crankshaft and camshaft timing notches. See Fig. 5. On manual transmission models, remove timing belt guide from top of crankshaft pulley. On all vehicles, if reusing timing belt, mark belt with arrow to indicate original direction of rotation. Also, place mating marks on timing belt and crankshaft and camshaft sprockets. Remove lower timing belt idler pulley. Remove timing belt. Remove timing belt automatic tensioner.
CAUTION: To prevent intake and exhaust valves from contacting each other, DO NOT rotate crankshaft or camshafts with timing belt removed.
96A14514
Fig. 2: Removing Crankshaft Pulley Bolt
Inspection: Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect belt automatic tensioner oil seals for leaks. Slight trace of oil at rod oil seal does not indicate a problem. Inspect rod ends for abnormal wear and scratches. Measure extension of rod beyond tensioner body. Holding tensioner with rod facing up, rod extension should be .224 plus or minus .020 (5.7 mm plus or minus 0.5 mm). See Fig. 3. Replace automatic tensioner if rod extension is not as specified. Place automatic tensioner in a press with tensioner rod facing up. Apply 66 lbs. (29.9 kg) of pressure on rod. If rod moves down easily, replace automatic tensioner. Inspect automatic tensioner and idler pulleys for worn bearings or lubricant leaks. Replace as necessary.
CAUTION: To prevent damage to automatic tensioner, DO NOT apply more than 2205 lbs. (1000 kg) to automatic adjuster rod. Compress tensioner rod with using vertical press. DO NOT use bench vise. DO NOT press automatic tensioner rod past the top surface of the housing.
Fig. 3: Measuring Automatic Tensioner Rod Extension
Installation: Ensure crankshaft and camshaft timing marks are still aligned. Place automatic adjuster in a press with rod facing up. Apply 66 lbs. (29.9 kg) pressure to end of rod. SLOWLY (taking more than 3 minutes) compress rod into housing until rod and housing holes are aligned. Insert locking pin through holes. Install automatic tensioner on engine with locking pin in place. Install idler pulleys (if removed). Install timing belt in correct routing order. Ensure camshaft double marks are aligned. If reusing old belt, ensure belt direction of rotation is correct and mating marks are aligned.
SUBARU 2.5L 4-Cylinder DOHC (Cont.)
485
96J14513
Fig. 5: Aligning Timing Marks & Sprocket Alignment Marks
486
SUBARU 2.5L 4-Cylinder DOHC (Cont.)
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 locking 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 complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs.. (N.m) Camshaft Sprocket Bolt ................................................ 58 (78) Crankshaft Pulley Bolt .............................................. 130 (177) Timing Belt Idler Pulley Bolt ........................................ 29 (39) Timing Belt Tensioner Bolt ......................................... 29 (39) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................. 44 (5.0) Timing Belt Guide Bolt .................................................. 89 (10) Water Pump Bolt ...................................... 89-124 (10.0-14.0)

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 2.7L 6-Cyl. XT6 1988-91 Left Side ............ 2.9 Hours ................. 250151 Right side .......... 2.9 Hours ................. 250150 1 - Both Belts. With Air Cond. add .4 hours. With Pwr. Strng. add .2 hours.
487

Fig. 1: Removing Oil Level Gauge & Guide

TIMING BELT
Removal: Loosen water pump pulley and alternator mounting bolts. Loosen serpentine belt tensioner pulley lock nut and release belt tension. Ensure adjuster bolt is turned fully counterclockwise and remove serpentine belt. 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 center, 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 direction 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 tension. Install Belt Adjuster Stopper (13082AA000) or equivalent, on tension adjuster. See Fig. 7. Remove left hand timing belt tensioner. If timing belt is to be reused, place arrow on belt to indicate direction of belt rotation. Remove timing belt. Remove belt tension adjuster. Inspection: Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if damaged or contaminated. Inspect idler pulleys and tensioners for smooth rotation. Check belt tensioner roller for squareness. See Fig. 8. Replace tensioner in out-ofsquare exceeds .020" (.51 mm). Installation: If not already done, remove Phillips screw from bottom of belt tension adjuster. Insert a standard slot screwdriver into hole in bottom of belt tension adjuster. Turn screw clockwise to compress rubber boot. Install belt adjuster stopper on top of belt tension adjuster.
Fig. 2: Loosening Right Hand Timing Belt Tension
Fig. 3: Removing Left Timing Belt Idler Pulley
Using syringe, add engine oil through vent hole on top of rubber boot. Add oil until it overflows. Install Phillips screw and new gasket. Install belt tension adjuster on engine. Keep belt adjuster stopper in place. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install rubber plug and retaining bolt on engine Install left timing belt idler pulley. Tighten bolt to specification. See TORQUE SPECIFICATIONS. Install crankshaft sprocket (if removed). Align center line of the 3 lines on flywheel or drive plate with mark on housing. Align left camshaft sprocket timing mark with notch in rear timing belt cover. See Fig. 9.
488
SUBARU 2.7L 6-Cylinder (Cont.)
G00019666
489
Fig. 8: Checking Belt Tensioner Roller Squareness

Fig. 5: Removing Rubber Plug & Retaining Bolt
Fig. 6: Removing Phillips Screw From Belt Tension Adjuster
Fig. 9: Aligning Camshaft & Crankshaft Timing Marks 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 camshaft timing mark for the left side timing belt will now be pointing straight down (6 oclock position). See Fig. 10.

Fig. 7: Installing Belt Adjuster Stopper
Install left (driver side) timing belt starting from the crankshaft sprocket. If installing used belt, ensure belt is installed in original direction of rotation. Install belt tension adjuster. See Fig. 7. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove belt adjuster stopper from belt tension adjuster. Ensure tensioner moves smoothly after it is installed.
To install right (passenger side) timing belt, rotate crankshaft clockwise 360 degrees. Align flywheel or drive plate timing marks with mark on housing. Align camshaft sprocket timing mark with notch in rear timing belt cover. See Fig. 9. Install right hand timing belt tensioner. Rotate tensioner assembly down and temporarily tighten retaining bolts. Install outer crankshaft sprocket. Install right timing belt starting from crankshaft. If reusing old timing belt, ensure belt is installed in original direction of rotation. Loosen right hand tensioner bolts, and allow tensioner to apply belt tension. Install Belt Tension Wrench (499437100) on right camshaft sprocket. Using torque wrench and belt tension wrench, apply 17-18 ft. lbs. (24-25 N.m) or torque in a counterclockwise direction to right camshaft sprocket. While applying torque, temporarily tighten tensioner bolt closest to the tensioner pulley, and then the tensioner pivot bolt.
490
Check belt tension. Belt tension should be 33-55 lbs. (1525 kg). If belt tension is correct, tighten tensioner bolt closest to the tensioner pulley, and then the tensioner pivot bolt to specification. See TORQUE SPECIFICATIONS. Ensure all timing marks are still aligned.
NOTE: When timing belts are properly installed, left camshaft sprocket timing mark will be pointing DOWN and right camshaft sprocket timing mark will be pointing UP. Engine timing mark notches for both camshafts are located on TOP side of rear timing belt covers. See Figs. 9 and 10.
Fig. 10: Final Installed Position Of Left (Driver Side) Camshaft Sprocket
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. To install remaining components, reverse removal procedure. Tighten alternator belt so belt tension is 143-165 lbs. (65-75 kg) on new belt or 99-143 lbs. (45-65 kg) on used belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
CAUTION: Readjust new alternator belt after 5 minutes of operation.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Tension Adjuster Bolt ................................. 17-20 (23-27) Crankshaft Pulley Center Bolt 1 ....................... 66-79 (90-107) Timing Belt Tensioner Bolt Left Hand Tensioner ....................................... 29-35 (39-47) Right Hand Tensioner .................................... 17-20 (23-27) INCH Lbs. (N.m) Camshaft Sprocket Bolt .................................. 97-108 (11-13) Oil Level Guide Bolt .............................................. 40-48 (4-5) Timing Belt Cover Bolt .......................................... 40-48 (4-5) Water Pump Pulley Bolt ...................................... 80-92 (9-10)
1

TIMING BELT APPLICATION Belt Part No. Application Labor Time1 3.3L 6-Cyl. SVX 1992-97 ................. 2.6 Hours .................. 250209 1 - With Air Cond. add .4 hours. With Pwr. Strng. add .2 hours.
491
CAUTION: Readjust new alternator belt after 5 minutes of operation.
Tighten adjuster bolts. Once all timing marks are aligned, remove stopper pin from tension adjuster. Install front timing belt covers. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Belt Idler Bolt .................................................... 26-32 (35-43) Belt Tension Adjuster Bolt ................................. 17-20 (23-27) Camshaft Sprocket Bolt ............................... 80-94 (108-127) Crankshaft Pulley Bolt 1 ............................ 108-123 (147-167) Tensioner Bolt .................................................. 26-32 (35-43) INCH Lbs. (N.m) Timing Belt Cover Bolt .................................... 35-44 (4.0-5.0) Valve Cover Bolt ................................................ 5-44 (4.0-5.0) Water Pump Pulley Bolt ............................ 84-120 (10.0-14.0)
1

For 1992-94 model years, the manufacturer recommends belt be replaced every 60,000 miles. For 1995-97 model years, the manufacturer recommends belt be replaced at 60,000 miles on Federal vehicles, and 105,000 miles on California vehicles.

TIMING BELT
Removal: Disconnect negative battery cable. Remove undercover. Disconnect power steering cooler hoses from body. Disconnect cooling fan connectors. Remove drive belt cover. Remove upper radiator brackets. Remove radiator fan and sub-fan assemblies. Remove charcoal canister and bracket. Remove alternator/power steering drive belts and A/C drive belt. Remove alternator and drive belt cover bracket. 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 removing. Turn crankshaft to align marks on crankshaft sprocket and camshaft sprockets with marks on cylinder block and timing belt cover. See Fig. 1. Using White paint, put alignment marks and/or arrows on timing belt in relation to sprockets. Loosen tensioner adjuster bolts. Remove timing belt idlers. See Fig. 1. Remove timing belt. Inspection: Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replace belt if it is damaged or contaminated. Inspect 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 adjuster 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 sprockets, position timing belt properly. Ensure belt rotating direction is correct. Install idler pulleys. Loosen tension adjuster attaching bolts and move adjuster fully left.
Fig. 1: View Of Timing Belt Components
Fig. 2: Setting Tension Adjuster
492
SUZUKI *1.3L 4-Cylinder DOHC

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Mount & Adjusting Bolts .................... 13-21 (18-28) Alternator Pulley Bolts 1992-94 ........................................................ 70-96 (95-130) Camshaft Sprocket Bolt .................................... 41-47 (56-64) Crankshaft Sprocket Bolt .............................. 77-85 (105-115) Timing Belt Tensioner Bolt ............................... 18-22 (24-30) INCH Lbs. (N.m) Alternator Pulley Bolt 1989-91 ........................................................ 90-108 (10-13) Crankshaft Pulley Bolt ...................................... 80-106 (9-12) Timing Belt Outer Cover Bolt ............................ 80-106 (9-12) Timing Belt Tensioner Stud Nut ........................ 80-106 (9-12) Water Pump Mounting Bolt ............................... 80-106 (9-12) Water Pump Pulley Bolt .................................. 89-115 (10-13)
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.3L 4-Cyl. DOHC Swift 1989-94 .............. 1 2.6 Hours ................. 252171 1 - With Air Cond. add .2 hours.

For 1992-89 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1993-94 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals.

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 engine. See Fig. 1. Move timing belt tensioner up and secure. Mark timing belt for direction of rotation if it is to be reused. Remove timing belt from sprockets. Installation: Align timing marks. Bolts with flanged nuts may be wedged between cam sprocket teeth to hold camshaft on timing mark during belt installation (if necessary). See Fig. 2.
CAUTION: While aligning timing marks, DO NOT turn camshaft sprockets more than 20 degrees in either direction from aligned position. DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. Fig. 1: Aligning Timing Belt Marks
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 timing belt outer covers and tighten to specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure. Tighten bolts to specification. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
SUZUKI *1.3L 4-Cylinder DOHC (Cont.)
493
Fig. 2: Securing Intake & Exhaust Camshaft Sprockets For Timing Belt Installation
Fig. 3: Identifying Sprocket Movement Limits
494
SUZUKI 1.3L 4-Cylinder SOHC
Turn crankshaft clockwise until punch mark on crankshaft sprocket is aligned with arrow mark on oil pump housing. With timing marks aligned, install timing belt. Ensure direction arrow mark on timing belt is pointed in direction of crankshaft rotation. Ensure drive side of belt is free of slack. Move tensioner plate up with finger pressure, and loosely secure tensioner bolt. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Tighten tensioner nut and then tensioner bolt. See TORQUE SPECIFICATIONS. Ensure timing marks are aligned. Install timing belt outer cover and tighten to specification. See TORQUE SPECIFICATIONS. Reverse removal procedure to complete installation. Adjust valve clearance. See VALVE CLEARANCE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (Swift): Disconnect negative battery cable. Raise and support vehicle. Remove right side fender apron extension by pushing center pin into clip. DO NOT push in too far as pin may fall into fender. Lower vehicle. Remove air cleaner assembly. Support engine with floor jack. Remove engine mount from timing belt end of engine. Loosen water pump pulley bolts. Remove accessory drive belts. Remove water pump pulley. Remove crankshaft pulley-to-crankshaft bolts. Remove crankshaft pulley. It is NOT necessary to remove crankshaft center bolt. Remove resonator and timing belt cover. Rotate crankshaft clockwise to align camshaft and crankshaft timing marks. See Fig. 2. Camshaft sprocket mark should align with V mark on rear cover. Punch mark on crankshaft sprocket should align with mark on oil pump case. If reusing timing belt, mark belt with an arrow indicating direction of rotation for installation reference.
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 1.3L 4-Cyl. SOHC Samurai 1985-93 .......... 1 3.0 Hrs. ........................... 250095 1994 ............... 1 3.0 Hrs. ......................... 2 250095 1994 ............... 1 3.0 Hrs. ......................... 3 250243 1995 ............... 1 3.0 Hrs. ........................... 250243 Sidekick 1989 ............... 1 3.0 Hrs. ........................... 250095 Swift 1989-93 .......... 1 2.6 Hrs. ........................... 250095 1994 ............... 1 2.6 Hrs. ........................... 250243 1995-97 .......... 1 2.6 Hrs ............................ 250272 1998-01 .......... 1 2.6 Hrs. .... 2521941 ........ 250194 1 - With Air Cond. add .4 hours. 2 For VIN R4100375 and earlier. 3 For VIN R4100376 and later. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.


TIMING BELT
Removal (Samurai & Sidekick): Disconnect negative battery cable. Remove cooling fan and fan shroud. Discharge A/C system using approved refrigerant recovery/recycling equipment and disconnect compressor flexible suction hose from suction pipe (if equipped). Remove A/C compressor belt (if equipped). 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 position. DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. Doing so could damage piston(s) and/or valve(s) by interference. Also, DO NOT bend timing belt.
Installation (Samurai & Sidekick): Loosen all valve adjusting screws fully before installing timing belt. Allow camshaft to rotate freely during belt tension adjustment. Align timing mark on camshaft sprocket with V mark on timing belt inner cover. See Fig. 2.
Courtesy of Suzuki of America Corp.
SUZUKI 1.3L 4-Cylinder SOHC (Cont.)
495
Fig. 3: Releasing Timing Belt Tensioner
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. Remove timing belt.
CAUTION: With timing belt removed, DO NOT turn camshaft sprocket more than 20 degrees in either direction from aligned position. DO NOT turn crankshaft more than 90 degrees in either direction from aligned position. Doing so could damage piston(s) and/or valve(s) by interference. Also, DO NOT bend timing belt.
Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components. Installation (Swift): If the tensioner was removed, install tensioner plate on tensioner. Ensure tensioner plate lug engages hole on rear of tensioner. Install tensioner spring. Tighten tensioner bolt finger tight to allow movement of tensioner.
NOTE: It is NOT necessary to loosen valve adjusting screws on 1995 models.
Fig. 4: Adjusting Valve Clearance
On 1989-94 models with 8-valve engine, remove valve cover. Loosen all valve adjusting screws before installing timing belt. Camshaft must be free to rotate during tension adjustment. On all models, ensure all timing marks align. See Fig. 2. If timing marks are not aligned, rotate camshaft or crankshaft to align timing marks. DO NOT rotate camshaft or crankshaft so timing mark moves more than 90 degrees or engine damage may occur.
Install timing belt. If reusing old belt, ensure belt is installed in original direction of rotation. Ensure there is no slack in belt. Move timing belt tensioner plate up with finger pressure, and loosely secure tensioner bolt. See Fig. 3. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Ensure timing marks are aligned. Tighten tensioner stud nut and then tensioner bolt. See TORQUE SPECIFICATIONS. Install timing belt outer cover and resonator. Make sure there are rubber seals installed between water pump and oil pump case, and another between water pump and cylinder head. Install crankshaft pulley.
496
SUZUKI 1.3L 4-Cylinder SOHC (Cont.)
On 1989-94 Swift with 8-valve engine, adjust valves. See VALVE CLEARANCE SPECIFICATIONS. Install valve cover. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt 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) TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Mount & Adjusting Bolts .................... 13-21 (18-28) Camshaft Sprocket Bolt .................................... 41-47 (56-64) Crankshaft Pulley-To-Crankshaft Bolt ................ 7-10 (10-13) Crankshaft Sprocket Center Bolt Except 2000-01 Swift ...................................... 77-85 (105-115) 2000-01 Swift ............................................................. 94 (130) Engine Mount Bolt (Swift) ............................................... 40 (55) Timing Belt Tensioner Pulley Bolt ..................... 18-22 (24-30) INCH Lbs. (N.m) Timing Belt Cover Bolt ...................................... 80-106 (9-12) Timing Belt Tensioner Stud Nut ........................ 80-106 (9-12) Water Pump Pulley Bolt .................................. 89-115 (10-13)
SUZUKI 1.6L 4-Cylinder

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. SOHC Esteem 1995-00 ................ 1 2.3 Hours ................. 250212 Esteem (Canadian) 2001 ..................... 1 2.3 Hours ................. 250212 Sidekick 1989-91 ................ 1 3.6 Hours ................ 250164 1992-95 Convertible ....... 1 3.6 Hours ................. 250164 Hardtop ............. 1 3.6 Hours ................. 250212 1996-98 ................ 1 3.6 Hours ................. 250212 Vitara 1999-01 ................ 1 4.0 Hours ................. 250212 X-90 1996-98 ................ 1 4.0 Hours ................. 250212 1 - With Air Cond. add .4 hours, except Esteem. For Esteem, add .2 hours.
497
Remove 5 crankshaft pulley-to-crankshaft bolts. Remove pulley. It is NOT necessary to remove crankshaft center bolt. Remove timing belt cover. See Fig. 1. Rotate crankshaft clockwise to align timing marks. See Figs. 2 and 3. Stamped E or punch mark on camshaft sprocket must straight up. Loosen timing belt tensioner bolt and stud nut. Move tensioner away from belt, and hand tighten bolt and nut. See Fig. 4. If reusing old belt, mark belt with an arrow indicating direction of rotation for installation reference. Remove timing belt.
CAUTION: With timing belt removed, DO NOT turn camshaft more than 20 degrees in either direction from aligned position. To prevent piston and valve damage, DO NOT turn crankshaft more than 90 degrees in either direction from aligned position.


TIMING BELT
Removal (Esteem): Disconnect negative battery cable. Remove right side engine under cover. Remove power steering and A/C compressor 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. Remove 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 direction of rotation for installation reference. Remove timing belt.
CAUTION: With timing belt removed, DO NOT turn camshaft or crankshaft sprocket more than 90 degrees in either direction from aligned position. Doing so could damage pistons and valves.
Inspection (All Models): Inspect timing belt for damaged teeth, cracking and oil contamination. Check timing belt tensioner for worn bearing. Replace damaged components. Installation (All Models): If the tensioner was removed, install tensioner plate on tensioner. Ensure tensioner plate lug engages hole on rear of tensioner. Install tensioner spring. Tighten tensioner bolt finger tight to allow movement of tensioner. On 1989-94 Sidekick with 8-valve engine, remove valve cover. Loosen all valve adjusting screws. On all models, ensure timing marks are still aligned. Install timing belt. If reusing old belt, ensure direction arrow mark on timing belt is pointed in direction of crankshaft rotation. Ensure drive side of belt is free of slack. Loosen tensioner bolt and stud nut to place tension on timing belt. Turn crankshaft 2 revolutions clockwise to remove all slack from belt. Tighten tensioner stud nut and then tensioner bolt. See TORQUE SPECIFICATIONS. Ensure timing marks are aligned. Install timing belt cover and tighten bolts to specification. Reverse removal procedure to complete installation. If coolant was drained, fill and bleed air from system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Adjust valve
Removal (Sidekick, Vitara & X-90): Disconnect negative battery cable. Remove accessory drive belts.Remove radiator cooling fan, water pump pulley, and fan shroud. It may be necessary to drain cooling system and remove upper radiator hose to remove fan shroud.
498
SUZUKI 1.6L 4-Cylinder (Cont.)
lash on 1989-94 Sidekick with 8-valve engine. See VALVE CLEARANCE SPECIFICATIONS. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Mounting Bolt (Esteem) .................... 17 (23) Alternator Mount & Adjusting Bolts .................... 13-21 (18-28) Camshaft Sprocket Bolt .............................................. 43 (60) Crankshaft Sprocket Center Bolt ............................... 80 (110) Engine Mount Bolt/Nut (Esteem) ................................... 40 (55) Power Steering Pump Bolt (Esteem) ............................. 25 (35) Timing Belt Tensioner Bolt ......................................... 18 (25) INCH Lbs. (N.m) Crankshaft Pulley-To-Crankshaft Bolt ........................ 106 (12) Timing Belt Cover Bolt .................................................. 97 (11) Timing Belt Tensioner Stud Nut .................................... 97 (11) Water Pump Pulley Bolt .................................................. 97 (11)
Fig. 4: Releasing Timing Belt Tensioner
VALVE CLEARANCE SPECIFICATIONS Cold Hot Valve In. (mm) In. (mm) Intake ................. .005-.007 (.13-.18) ........... .009-.011 (.23-.28) Exhaust ............. .006-.008 (.15-.20) ........ .010-.011 (.25-.28)
TOYOTA 1.5L 4-Cylinder 1A-C & 3A-C

TIMING BELT APPLICATION Labor Component Application Time Kit No. 1.5L 4-Cyl. Corolla Tercel 1980-82 A/T ............... 2.8 Hrs. ...... 2520700 ....... M/T .............. 2.8 Hrs. ...... 2520700 ....... Tercel 1983-86 .......... 1 2.7 Hrs. .... 2520700 ....... 1987-88 Wagon 3A-C ........... 1 2.7 Hrs. .... 2520700 ....... 1 With Air Cond., add .3 hours. Belt Part No.
499

For 1980-85 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-89 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe service operating conditions.
250070 250070 250070 250070

TIMING BELT
NOTE: Do not bend or twist timing belt. Keep belt free of oil, water or dust.
Removal: Drain engine coolant. Remove radiator. Remove air cleaner assembly. Remove accessory drive belts. Remove water pump pulley. If equipped with A/C, remove A/C drive belt idler pulley with bracket. Remove PCV valve from valve cover. Remove valve cover. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Timing notch on crankshaft pulley must align with 0 timing mark on timing belt cover.
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. 5: Installing Used Timing Belt
Fig. 3: Measuring Tensioner Spring Free Length
Ensure cylinder No. 1 rocker arms are loose and cylinder No. 4 rocker arms are tight. If conditions are not as described, rotate crankshaft one complete revolution. Holding crankshaft stationary, remove crankshaft pulley center bolt. Remove crankshaft pulley. Remove timing belt covers and gaskets. See Fig. 1. Remove timing belt guide. See Fig. 1. If reusing old timing belt, mark belt with arrow indicating direction of rotation. Also place mating marks on timing belt and camshaft timing pulley. Place mating marks on timing belt and crankshaft timing pulley. Loosen idler pulley retaining bolt. Move idler pulley away from timing belt and tighten retaining bolt. Remove timing belt.
Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulley rotates freely. Inspect all sprockets for damage. Replace damaged components. Measure free length of tension spring. Free length should be 1.512" (38.40 mm) for models up to 1986, and 1.705 (43.3 mm) for 1987-88 models. See Fig. 3. Replace tension spring if free length is not as specified. Measure tension of spring at installed length. Tension should be 8 lbs. at 1.976 (3.83 kg at 50.2 mm) up to 1986 models. For 1987-88 models, tension should be 15.4 lbs. at 1.976 (7 kg at 50.2 mm). Replace tension spring if necessary. Installation: Ensure crankshaft and camshaft timing pulley timing marks are correctly aligned. See Fig. 2. Install idler pulley and tension spring (if removed). Secure idler pulley as far to the left as possible and retighten bolt. Install timing belt on engine. If reusing old belt, align mating 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 retaining bolt to rotate crankshaft clockwise 2 full rotations from TDC to TDC. Ensure camshaft and crankshaft timing marks are still aligned. If they are not aligned, remove and reinstall timing belt. Tighten idler pulley mounting bolt. Measure timing belt tension by applying 4.4 lbs. (2 kg) pressure to belt. See Fig. 4. Timing belt deflection should be .236-.276 (6-7 mm). If not, readjust timing belt tension. Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley. Install and tighten crankshaft pulley center bolt to specification. See TORQUE SPECIFICATIONS. Install water pump pulley. Install A/C idler pulley (if equipped). Install accessory drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Install valve cover and air cleaner assembly. Install radiator. Fill and bleed cooling system. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 34 (47) Crankshaft Pulley Bolt .............................................. 87 (118) Idler Pulley Retaining Bolt ......................................... 27 (37 )
TOYOTA *1.5L 4-Cylinder 3E

TIMING BELT APPLICATION Labor Component Kit No. Application Time1 1.5L 4-Cyl. 3E Tercel Sedan 1987 ............... 2.3 Hrs. ............................. 250136 Tercel 1988-94 .......... 2.3 Hrs. ...... 2522330 ........ 250233 1 - With Air Cond. add .4 hours. Belt Part No.
501

TIMING BELT
CAUTION: On models equipped with air bag, DO NOT start work until after 90 seconds from time ignition switch is turned to LOCK position and negative battery cable is disconnected.

The manufacturer recommends the belt be replaced every 60,000 miles under severe service operating conditions.
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove right side engine under cover (splash) shield. Lower vehicle. Remove accessory drive belts. Disconnect accelerator cable. On A/T models, disconnect throttle cable. On all models, disconnect PCV hoses. On 1987-91 models, remove air cleaner assembly. On all models, remove bolt, ground strap and vacuum transmitting valves with bracket on right engine mount. This is mount on timing belt end of engine. Using floor jack, support weight of engine from below. Remove right engine mount from timing belt end of engine. Remove valve cover. Remove spark plugs. Set No. 1 cylinder at TDC on compression stroke. Turn crankshaft pulley and align groove on crankshaft with 0 mark on timing belt cover. Ensure rocker arms on No. 1 cylinder are loose. If not, turn crankshaft pulley one complete 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
Fig. 2: Routing Timing Belt
Remove timing belt cover. Noting installed position for reassembly 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 crankshaft 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: Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure No. 1 and No. 2 idler pulleys rotate freely. Inspect all sprockets for damage. Replace damaged components. 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.
On 1991-94 models with A/C and/or power steering, remove accessory drive pulley from crankshaft pulley. See Fig. 1. Using Holder (09213-14010) or equivalent, hold crankshaft pulley. Loosen crankshaft pulley center bolt. Remove holder. Remove crankshaft pulley bolt. Use gear puller, remove crankshaft pulley.
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 camshaft sprocket bolt to specification. See TORQUE SPECIFICATIONS. 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 temporarily 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 crankshaft CLOCKWISE 2 revolutions from TDC to TDC. Realign camshaft and crankshaft sprocket timing marks. If timing marks do not align, remove and reinstall timing belt. If timing marks do align, tighten No. 1 idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Install timing belt guide. Install timing belt covers.
TOYOTA *1.5L 4-Cylinder 3E (Cont.)
503
Install crankshaft pulley. Holding crankshaft pulley stationary, tighten crankshaft pulley bolt to specification. On 199194 models, install accessory drive pulley. On all models, install spark plugs. Install valve cover. Install right engine mount to engine and body. Install vacuum switching valves and engine ground strap to engine mount (if equipped). Connect negative battery cable. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) 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) Camshaft Sprocket Bolt .............................................. 37 (51) Crankshaft Pulley Bolt .............................................. 112 (152) Engine Mount Mount-To-Cylinder Block Bolt/Nut ............................. 47 (64) Through-Bolt 1987-90 ...................................................................... 47 (64) 1991-94 ...................................................................... 54 (73) Idler Pulley Bracket Bolt 12 mm ...................................................................... 20 (27) 14 mm ...................................................................... 27 (37) No. 1 Idler Pulley Bolt .................................................. 13 (18) No. 2 Idler Pulley Bolt .................................................. 20 (27) Power Steering Bracket Bolt ....................................... 32 (43) Power Steering Pump Bolt .......................................... 32 (43) Spark Plugs .................................................................... 13 (18) Timing Belt Idler Mount Bolt ........................................ 27 (37) Water Pump Bolt/Nut .................................................. 13 (18) INCH Lbs. (N.m) No. 1 Timing Belt Cover Bolt ...................................... 66 (7.5) No. 2 Timing Belt Cover Bolt ...................................... 66 (7.5) Valve Cover Nut ......................................................... 61 (6.5)
Fig. 5: Aligning Camshaft Knock Pin With Bearing Cap
504
TOYOTA 1.5L 4-Cylinder 5E-FE
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.5L 4-Cyl. Paseo 1992-95 ................. 2.5 Hours .................. 250208 1996-99 ................. 3.5 Hours .................. 250208 Tercel 1995-99 ................. 2.8 Hours .................. 250208 1 With Air Cond. & Pwr. Strng. add .4 hours.

For 1992-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe service operating conditions. For 1998 model year, the manufacturer recommends the belt be replaced every 90,000 miles for severe service operating conditions. For 1999 model year, the manufacturer recommends the belt be replaced every 90,000 miles or 72 months.

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove right engine undercover. Remove accessory drive belts. Remove charcoal canister for access to timing belt covers. Slightly raise engine to remove weight from right (timing belt side) engine mount. Remove the through-bolt and right engine mount insulator. Remove No. 2 timing belt cover and gasket. See Fig. 1. Rotate crankshaft clockwise (viewed from timing belt end of engine) so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Remove No. 2 timing belt cover. With cylinder No. 1 at TDC on compression stroke, ensure hole (5E timing mark) on camshaft sprocket aligns with timing mark on camshaft bearing cap. See Fig. 3. If timing mark is not aligned, rotate crankshaft clockwise one revolution (360 degrees). Remove bolt and accessory drive belt pulley from front of crankshaft pulley. Using Pulley Holder (SST 09213-14010) or equivalent, and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley, and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 3 and No. 1 timing belt cover and gasket. See Fig. 1. Note direction of timing belt guide installation for installation reference. See Fig. 3. Remove timing belt guide.
CAUTION: If reusing timing belt, mark direction of timing belt rotation and place reference mark on timing belt at all sprockets for reassembly reference.
If removing crankshaft sprocket, use soft-faced hammer to lightly tap sprocket from crankshaft. DO NOT pry on outer edges of sprocket. Also, note position of outer timing belt guide on crankshaft sprocket. Concave surface should face away from engine. Inspection: Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulleys rotate freely. Inspect all sprockets for damage. Replace damaged components. Measure free length of tension spring. Replace tension spring if free length is not 1.512" (38.40 mm). Measure tension required to extend tension spring to 1.866" (47.40 mm). Replace tension spring if tension is not 7.3 lbs. (3.3 kg). Installation: If removed, install crankshaft sprocket with flange toward engine. Install tension spring and No. 1 idler pulley with bolt loosely installed. DO NOT tighten bolt at this time. Move No. 1 idler pulley away from timing belt area as far as possible. Temporarily tighten No. 1 idler pulley bolt. Ensure all sprockets and idler pulleys are clean. Temporarily install crankshaft pulley bolt, and rotate crankshaft so timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3 or Fig. 4.
CAUTION: If reusing timing belt, ensure reference marks on timing belt align with those placed on all sprockets and timing belt is installed in original direction of rotation.
Remove tension spring from No. 1 idler pulley. See Fig. 1. Loosen No. 1 idler pulley bolt. Move No. 1 idler away from timing belt as far as possible and tighten bolt. Remove timing belt, idler pulley bolt and No. 2 idler pulley (if necessary).
Remove crankshaft pulley bolt. Install timing belt on crankshaft sprocket, oil pump drive sprocket, No. 1 idler pulley and then No. 2 idler pulley in sequence. Ensure belt is tensioned between crankshaft sprocket and camshaft sprocket. Loosen No. 1 idler pulley bolt, allowing tension spring to move pulley against timing belt. Rotate crankshaft clockwise 2 full turns from TDC to TDC. Ensure camshaft timing marks are still aligned. If all timing marks are aligned, tighten No. 1 idler pulley bolt to specification. See TORQUE SPECIFICATIONS.
TOYOTA 1.5L 4-Cylinder 5E-FE (Cont.)
505
Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install No. 1 and No. 3 timing belt covers and gasket. Align crankshaft pulley key groove with key in crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. Install accessory drive belt pulley on front of crankshaft and tighten bolt to specification. See TORQUE SPECIFICATIONS. Install gasket and No. 2 timing belt cover. To install remaining components, reverse removal procedure. 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 SPECIFICATIONS. Adjust drive belts to proper tension. See page A60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Accessory Drive Belt Pulley Bolts ............................... 14 (19) A/C Compressor Bolt ................................................. 18 (24) A/C Compressor Mounting Bracket Bolt ..................... 20 (27) A/C Idler Pulley Bolt 12 mm Bolt ............................................................... 20 (27) 14 mm Bolt ............................................................... 27 (37) Camshaft Sprocket Bolt .............................................. 37 (51) Crankshaft Pulley Bolt ............................................ 114 (155) Engine Mount Right (Timing Belt Side) Mount-To-Cylinder Block Bolt/Nut ............................. 47 (64) Through-Bolt ............................................................. 54 (73) Idler Pulley Bolt No. 1 Idler Pulley ....................................................... 13 (18) No. 2 Idler Pulley ....................................................... 20 (27) Oil Pump Drive Sprocket Nut ...................................... 27 (37) Power Steering Pump Adjusting Bracket Bolt .............................................. 15 (20) Power Steering Pump Bolt Lower Bolt ................................................................ 29 (39) Upper Bolt ................................................................ 32 (43) Spark Plugs ................................................................ 13 (18) Water Pump Bolt/Nut .................................................. 13 (18) INCH Lbs. (N.m) Valve Cover Nut ......................................................... 61 (6.9)
Fig. 2: Cylinder Head Sealant Application Areas
506
TOYOTA 1.6L 4-Cylinder DOHC, 4A-GE
Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.713" (43.5 mm). Inspect spring tension at installed length. Installed tension is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if not to specification. Installation (1985-87 RWD Corolla): If removed, install timing belt idler pulley (tensioner) and spring. Secure pulley as far to the left as possible and temporarily tighten bolt. Install timing belt. If reusing old belt, ensure mating marks made on disassembly match crankshaft and camshaft marks. Ensure arrow points in direction of rotation. Loosen tensioner pulley bolt allowing tensioner to apply tension to belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE 2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If timing marks align, tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Remove crankshaft pulley. Measure timing belt deflection midway between camshaft sprockets. See Fig. 3. If deflection is not correct, readjust timing belt tension. Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley. Install and tighten center bolt to specification. See TORQUE SPECIFICATIONS. Install water pump pulley and fan assembly. Install generator drive belt. Install power steering pump pulley and drive belt. Adjust drive belt to proper tension. See page A60 for belt tension ranges. Removal (1985-88 FWD Corolla): Raise and support vehicle. Remove right front wheel. Remove engine under cover. Drain engine coolant. If equipped with cruise control, disconnect accelerator cable and cruise control cable from actuator. Disconnect cruise
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.6L 4-Cyl. DOHC Corolla FX-16, GTS & Sport (4A-GE) 1985-88 ......................... 1 ......................... 250112 Corolla GTS (4A-GE, 4A-GELC) 1989-91 ................... 1.6 Hrs. .................... 250176 MR2 1985-88 .................. 2 2.7 Hrs. ................... 250112 1989 ....................... 2 2.7 Hrs. ................... 250176 1 - 2.6 hours with FWD. 1.6 hours with RWD. 2 - With Air Cond. add .5 hours.

For 1985 model year, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-91 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.

TIMING BELT
Removal (1985-87 RWD Corolla): Remove air cleaner intake duct above radiator. If equipped with power steering, remove power steering belt. Remove the power steering pump with hoses attached and set aside. Loosen water pump pulley bolts. Remove cooling fan belt. Remove cooling fan assembly. Remove spark plugs. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Crankshaft pulley notch must align with 0 timing mark on lower timing belt cover. With valve cover oil filler cap removed, cavity in camshaft should be visible. If not, turn crankshaft one complete revolution. Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley using gear puller. Remove timing bel covers and gaskets. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 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 direction of rotation. Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley as far left as possible and temporarily tighten bolt. Remove timing belt. Inspection (1985-87 RWD Corolla): Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on flat side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. 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 1.6L 4-Cylinder DOHC, 4A-GE (Cont.)
507
Fig. 3: Timing Belt Deflection
control electrical connector. Remove cruise control actuator. Remove windshield washer tank and set aside. On FX-16 models, remove ignition coil with wires attached and secure out of way. On all models, remove the upper radiator hose. Loosen water pump pulley bolts. Remove all accessory drive belts. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch on crankshaft pulley must align with 0 timing mark on timing belt cover. Remove oil filler cap from valve cover. Cavity in camshaft should be visible in hole. If not, turn crankshaft one complete revolution. Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley using gear puller. Remove timing bel covers and gaskets. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 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 direction of rotation. Support weight of engine with floor jack. Remove engine mount from timing belt end of engine. Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley as far left as possible and temporarily tighten bolt. Remove timing belt. Inspection (1985-88 FWD Corolla): Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on flat side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.713" (43.5 mm). Inspect spring tension at installed length. Installed tension is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if not to specification. Installation (1985-88 FWD Corolla): If removed, install timing belt idler pulley (tensioner) and spring. Secure pulley as far to the left as possible and temporarily tighten bolt.
Install timing belt. If reusing old belt, ensure mating marks made on disassembly match crankshaft and camshaft marks. Ensure arrow points in direction of rotation. Loosen tensioner pulley bolt allowing tensioner to apply tension to belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE 2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If timing marks align, tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Remove crankshaft pulley. Measure timing belt deflection midway between camshaft sprockets. See Fig. 3. If deflection is not correct, readjust timing belt tension. 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 bolts to specification. See TORQUE SPECIFICATIONS. Install water pump pulley. Install accessory drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Install right front wheel and engine under cover. Install upper radiator hose. Install windshield washer tank. On FX-16, install ignition coil. On all models, install cruise control actuator (if equipped). Fill radiator with coolant and bleed air from system. Removal (MR2): Raise and support vehicle. Remove right front wheel. Remove engine under cover. Loosen water pump pulley bolts. Remove all accessory drive belts. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch on crankshaft pulley must align with timing mark on timing belt cover. Remove oil filler cap from valve cover. Cavity in camshaft should be visible in hole. If not, turn crankshaft one complete revolution. Support weight of engine with floor jack. Remove engine mount through bolt from timing belt end of engine. Holding crankshaft stationary, remove crankshaft pulley bolt. Remove crankshaft pulley using gear puller. Remove timing bel covers and gaskets. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. 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 direction of rotation. Loosen idler pulley (tensioner) bolt. See Fig. 1. Move tensioner pulley as far left as possible and temporarily tighten bolt. Remove timing belt. Inspection (MR2): Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on flat side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.713" (43.5 mm). Inspect spring tension at installed length. Installed tension is 22 lbs. at 1.976 (9.97 kg at 50.2 mm). Replace spring if not to specification. Installation (MR2): If removed, install timing belt idler pulley (tensioner) and spring. Secure pulley as far to the left as possible and temporarily tighten bolt.
508
TOYOTA 1.6L 4-Cylinder DOHC, 4A-GE (Cont.)

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 34 (47) Crankshaft Pulley Bolt Corolla (FWD) .......................................................... 101 (137) Corolla (RWD) .......................................................... 105 (142) Engine Mounts (Corolla FWD) FX-16 Through Bolt .......................................................... 58 (78) Except FX-16 Mount-To-Engine Bracket Nut ................................ 34 (52) Through Bolt .......................................................... 64 (87) Engine Mount (MR2) Through Bolt ............................................................. 43 (58) Power Steering Pump-To-Bracket Bolts ..................... 29 (39) Power Steering Pump Pulley Bolt Corolla (RWD) .............................................................. 33 (44) Spark Plug .................................................................. 13 (18) Timing Belt Tensioner Pulley Bolt ............................... 27 (37) Water Pump Bolts ...................................................... 11 (15) Wheel Lug Nut ............................................................. 76 (103) INCH Lbs. (N.m) Valve Cover Bolts ....................................................... 69 (7.8)
Install timing belt. If reusing old belt, ensure mating marks made on disassembly match crankshaft and camshaft marks. Ensure arrow points in direction of rotation. Loosen tensioner pulley bolt allowing tensioner to apply tension to belt. Temporarily install crankshaft pulley. Turn crankshaft CLOCKWISE 2 revolutions. Align camshaft and crankshaft timing marks. See Fig. 1. If timing marks align, tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Remove crankshaft pulley. Measure timing belt deflection midway between camshaft sprockets. See Fig. 3. If deflection is not correct, readjust timing belt tension. 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 bolts to specification. See TORQUE SPECIFICATIONS. Install right front wheel and engine under cover. Install water pump pulley. Install accessory drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
TOYOTA 1.6L 4-Cylinder SOHC

TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. 1.6L 4-Cyl. SOHC Corolla, FWD 1984-88 .......... 1 3.1 Hrs. .... 2520700 ........ 250070 Corolla RWD 1983 ............... 2 2.5 Hrs. .... 2520700 ........ 250070 1984-87 .......... 1.6 Hrs. ...... 2520700 ........ 250070 Corolla FX 1987-88 .......... 2.7 Hrs. ...... 2520700 ........ 250070 Corolla SR5 1985-87 .......... 1.6 Hrs. ...... 2520700 ........ 250070 1988 (FWD) ... 3.1 Hrs. ...... 2520700 ........ 250070 1 - With Air Cond. and Pwr. Strng. add .4 hours. 2 - With Air. Cond. add .2 hours; with Pwr. Strng. add .1 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
509

For 1983-85 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 1986-88 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.
Fig. 1: Aligning Timing Marks For Timing Belt Installation

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 compression stroke. Align crankshaft and camshaft timing marks. See Figs. 1 and 2. If reusing timing belt, place mating marks on belt and sprockets for reassembly reference. See Fig. 3. Place arrow on belt to indicate original direction of rotation. Loosen idler pulley bolt. Push idler pulley as far left as possible and temporarily tighten center bolt. Remove timing belt. Inspection (RWD Models): Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulley rotates freely. Inspect all sprockets for damage. Replace damaged components.
Fig. 2: Aligning TDC Marks On Crankshaft Sprocket & Oil Pump Body
Measure free length of tension spring. Free length should be 1.705 (43.3 mm). See Fig. 4. Replace tension spring if free length is not as specified. Measure tension of spring at installed length. Tension should be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension spring if necessary. Installation (RWD Models): Align camshaft sprocket timing hole with camshaft bearing cap mark. See Figs. 1 and 2 . Align timing marks on oil pump body and crankshaft timing sprocket.
510
TOYOTA 1.6L 4-Cylinder SOHC (Cont.)
Install idler pulley (tensioner) and spring (if removed). Pry idler pulley toward left and temporarily tighten. Install timing 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 TORQUE SPECIFICATIONS. Check timing belt deflection. See Fig. 5. If timing belt deflection is not correct, readjust timing belt tension. Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley and tighten bolt to specification. Install valve cover. Install air cleaner assembly. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS. Apply sealant to cylinder head when installing valve cover. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (FWD Models: Raise and support vehicle. Remove right front wheel. Remove right undercover from wheelwell. Drain engine coolant. Disconnect upper radiator hose. Loosen water pump pulley bolts. Remove all accessory drive belts. Remove generator with wires attached and set aside. Remove A/C compressor from mount with hoses attached, and set aside. Remove water pump pulley. Remove upper and center timing belt covers. Turn crankshaft until No. 1 cylinder is at TDC of compression stroke. Crankshaft pulley notch must align with 0 timing mark on lower timing belt cover. Remove valve cover. Camshaft sprocket timing mark must align with mark on bearing cap. See Fig. 1. Hold crankshaft stationary and remove crankshaft pulley center bolt. Remove crankshaft pulley using a gear puller. Remove lower timing belt cover. Noting installed position for reassembly reference, remove timing belt guide from crankshaft. If reusing timing belt, place mating marks on belt and sprockets for reassembly reference. See Fig. 3. Place arrow on belt to indicate original direction of rotation. Loosen idler pulley bolt. Push idler pulley as far left as possible and temporarily tighten center bolt.
Support weight of engine from below with a floor jack. Working from below the vehicle, remove the 4 lower engine mount bolts from the engine crossmember. Remove engine mount through-bolt from mount at timing belt end of engine. Raise engine slightly and remove timing belt. Inspection (FWD Models): Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulley rotates freely. Inspect all sprockets for damage. Replace damaged components. Measure free length of tension spring. Free length should be 1.705 (43.3 mm). See Fig. 4. Replace tension spring if free length is not as specified. Measure tension of spring at installed length. Tension should be 1.976 at 15.4 lbs. (3.73 kg at 50.2 mm). Replace tension spring if necessary. Installation (FWD Models): Insert timing belt between engine mount and body. Lower engine and install engine mount through-bolt through body and mount insulator. Tighten bolt to specification. See TORQUE SPECIFICATIONS. Align camshaft sprocket timing hole with camshaft bearing cap mark. See Figs. 1 and 2 . Align timing marks on oil pump body and crankshaft timing sprocket. Install idler pulley (tensioner) and spring (if removed). Pry idler pulley toward left and temporarily tighten. Install timing 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.
TOYOTA 1.6L 4-Cylinder SOHC (Cont.)

Loosen timing belt idler pulley bolt so that pulley applies tension to belt. Rotate crankshaft 2 revolutions from TDC to TDC. Recheck alignment of sprockets and timing belt. Tighten idler pulley (tensioner) bolt to specification. See TORQUE SPECIFICATIONS. Check timing belt deflection. See Fig. 5. If timing belt deflection is not correct, readjust timing belt tension. Install timing belt guide on crankshaft. Install timing belt covers. Install crankshaft pulley and tighten bolt to specification. Install water pump pulley. Install valve cover. Install air cleaner assembly. Install A/C compressor to engine mount. Install generator. Install valve cover. Apply sealant to cylinder head when installing valve cover. Install upper radiator hose. Refill cooling system.
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Install right under cover. Install right front wheel. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor-To-Block Bolts (4) ........................... 18 (25) Camshaft Sprocket Bolt .................................................. 34 (47) Crankshaft Pulley Bolt .............................................. 87 (118) Engine Mount Through-Bolt (FWD Models) 58 (78) Engine Mount-To-Crossmember Bolt ............................ 29 (39) Timing Belt Idler Pulley Bolt ........................................ 27 (37) Wheel Lug Nut ............................................................. 76 (103) INCH Lbs. (N.m) Valve Cover Bolts ....................................................... 69 (7.8)
512
TOYOTA 1.6L & 1.8L 4-Cylinder DOHC

Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left as possible, and snug tighten bolt. Remove timing belt. Inspection (Celica): Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on flat side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.51" (38.4 mm) for 1.6L (4AF engine), or 1.252 (31.8 mm) for 1.8L (4AF engine). Check tension at installed length. Tension should be 8.8 lbs. at 1.976 (4 kg at 50.2 mm) for 1.6L (4AF engine), or 11.7 lbs. at 1.480 (5.3 kg at 37.6 mm) for 1.8L (7AF engine). If tension is not as specified, replace spring. Installation (Celica): Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft Woodruff key will be at 12 oclock position. On 1.6L engine, timing mark notch on crankshaft sprocket will align with timing mark on oil pump housing. See Fig. 3. Crankshaft sprocket on 1.8L engine does not have notch. On 1.6L and 1.8L, hole in camshaft sprocket must align with mark on bearing cap.
TIMING BELT APPLICATION Belt Labor Component Part Application Time Kit No. No. No. 1.6L 4-Cyl. DOHC Celica 1990-92 .......... 3.1 Hrs. ...... 2520360 ........ 250036 1993 ............... 3.1 Hrs. ............................. 250239 Corolla (4A-FE) 1988-92 .......... 2.6 Hrs. ...... 2520360 ........ 250036 1993-97 .......... 2.6 Hrs. ...... 2522360 ........ 250236 1.8L 4-Cyl. DOHC Celica 1994-97 .......... 2.8 Hrs. ............................. 250235 Corolla 1993-97 .......... 2.6 Hrs. ............................. 250235 1 - 2.6 hours with FWD. 1.6 hours with RWD. 2 - With Air Cond. add .5 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.

For 1988-97 model years, the manufacturer recommends the belt be replaced at 60,000 mile intervals for severe service operating conditions.
Ensure idler pulley (tensioner) is pushed as far to the left as possible and pulley bolt is snug tight. If reusing old timing belt, install belt and align match marks made during removal. Install new timing belt. Loosen idler pulley (tensioner) bolt and allow pulley to move against belt. Install timing belt guide on crankshaft (dished side facing away from belt).

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 mount at timing belt end of engine. Loosen water pump pulley bolts, then remove all accessory drive belts. On 1.8L (7AF engine), remove A/C compressor front engine mount with hoses attached. Remove A/C compressor mount from engine. On 1.6L and 1.8L engine, remove upper and center timing belt covers. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch in crankshaft pulley must align with 0 timing mark on timing belt cover. Hole in camshaft timing pulley must align with mark on bearing cap. See Fig. 3. Remove water pump pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove lower timing belt cover. See Fig. 6. Remove timing belt guide (large washer) from crankshaft sprocket. If reusing timing belt, mark direction of rotation on timing belt. Match mark timing belt with marks on both sprockets for installation reference. See Fig. 1. Place arrow on belt to indicate original direction of rotation.
Fig. 1: Placing Mating Marks On Timing Belt & Sprockets
TOYOTA 1.6L & 1.8L 4-Cylinder DOHC (Cont.)
513
Fig. 6: Exploded View Of Timing Belt & Components (1993-97 1.6L & 1.8L)
Fig. 3: Aligning Timing Marks (1.6L; 1.8L Uses Same Camshaft Sprocket Timing Mark)
Measure Deflection Here
Fig. 4: Timing Belt Deflection
Fig. 5: Identifying Cylinder Head Sealant Application Areas
Install lower timing belt cover. Install crankshaft pulley. Install 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 timing marks align. If timing marks are not aligned, remove and reinstall timing belt. If timing marks are aligned, final tighten crankshaft pulley center bolt. See TORQUE SPECIFICATIONS. With idler pulley bolt still loose, measure timing belt deflection at midway point of belt longest run. See Fig. 4. Deflection should be .20-.24" with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. See Fig. 4. If deflection is not as specified, readjust tension on belt by moving idler pulley (tensioner). Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Install upper and center timing belt covers. When installing valve cover, ensure sealant is apply in correct position. See Fig. 5. Install water pump pulley. On 1.8L engine, install A/C compressor 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 tension ranges. Final tighten water pump pulley bolts. Install engine mount to timing belt end of engine. Install front wheel and engine under cover. Install cruise control actuator (if equipped). Removal (1988-92 Corolla): 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 mount at timing belt end of engine. Remove water pump pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove timing belt covers. Remove timing belt guide (large washer) from crankshaft sprocket.
514
Remove upper timing belt cover. With No. 1 cylinder at TDC, hole in camshaft sprocket must align with mark on bearing cap. See Fig. 3. Support weight of engine with a floor jack. Remove engine mount at timing belt end of engine. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove center and lower timing belt covers. Remove timing belt guide (large washer) from crankshaft sprocket. If reusing timing belt, mark direction of rotation on timing belt. Match mark timing belt with marks on both sprockets for installation reference. See Fig. 1. Place arrow on belt to indicate original direction of rotation. Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left as possible, and snug tighten bolt. Remove timing belt. Inspection (1993-97 Corolla): Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on flat side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. Check free length of idler pulley tension spring. See Fig. 2. See TENSION SPRING FREE LENGTH (1993-97 COROLLA). Replace spring if free length is not to specification. Check tension at installed length. See TENSION SPRING INSTALLED TENSION (1993-97 COROLLA). Replace spring if tension is not to specification. TENSION SPRING FREE LENGTH (1993-97 COROLLA) Free Length Application In (mm) 1993-94 1.6L (4AF) ................................................ 1.453 (36.9) 1995-97 1.6L (4AF) ................................................ 1.717 (43.6) 1993-97 1.8L (7AF) ................................................ 1.252 (31.8) TENSION SPRING INSTALLED TENSION (1993-97 COROLLA) Application 1993-94 1.6L (4AF) 1993-94 1.8L (7AF) 1995-97 1.6L (4AF) 1995-97 1.8L (7AF) Tension At Installed Length Lbs. At In. (Kg At mm) .............................. 13 at 1.988 (5.9 at 50.5) ......................... 26.5 at 1.988 (12.4 at 50.5) ............................. 8.6 at 1.717 (3.9 at 43.6) ........................... 11.7 at 1.480 (5.3 at 37.6)
If reusing timing belt, mark direction of rotation on timing belt. Match mark timing belt with marks on both sprockets for installation reference. See Fig. 1. Place arrow on belt to indicate original direction of rotation. Loosen idler pulley (tensioner) bolt. Push idler pulley as far to the left as possible, and snug tighten bolt. Remove timing belt. Inspection (1988-92 Corolla): Check timing belt teeth for cracks or damage. If tooth damage is found, ensure camshaft and crankshaft sprockets are okay. If wear or cracks on flat side of belt face are found, check for nicks on idler pulleys. If wear or damage to only one side of belt is found, check belt guide and alignment of each pulley and sprocket. Check free length of idler pulley tension spring. See Fig. 2. Replace spring if free length is not 1.51" (38.4 mm). Check tension at installed length. Tension should be 8.8 lbs. at 1.976 (4 kg at 50.2 mm). Installation (1988-92 Corolla): Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft key will be at 12 oclock position, and timing mark notch on crankshaft sprocket will align with timing mark on oil pump housing. See Fig. 3. Hole in camshaft sprocket must align with mark on bearing cap.
Ensure idler pulley (tensioner) is pushed as far to the left as possible and pulley bolt is snug tight. If reusing old timing belt, install belt and align match marks made during removal. Install new timing belt. Loosen idler pulley (tensioner) bolt and allow pulley to move against belt. Rotate crankshaft CLOCKWISE 2 revolutions from TDC to TDC. Recheck timing mark alignment. If timing marks are not aligned, remove and reinstall timing belt. With idler pulley bolt still loose, measure timing belt deflection at midway point of belt longest run. See Fig. 4. Deflection 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 timing belt guide to crankshaft sprocket. Install timing belt covers. Install crankshaft pulley. Tighten center bolt to specification. See TORQUE SPECIFICATIONS. When installing valve cover, ensure sealant is apply in correct position. See Fig. 5. Install water pump pulley. Install accessory drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Final tighten water pump pulley bolts. Install front wheel and engine under cover. Removal (1993-97 Corolla): Raise and support vehicle. Remove right front wheel and engine undercover. Lower vehicle. Remove windshield washer tank. Remove cruise control actuator from right side of engine compartment. Loosen water pump pulley bolts, then remove all accessory drive belts. Remove water pump pulley. Remove valve cover. On models with A/C, remove A/C compressor from mount bracket with hoses attached, and set aside. Remove A/C compressor mount bracket from engine. Disconnect engine wiring harness from upper timing belt cover. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Notch in crankshaft pulley must align with 0 timing mark on timing belt cover.
Installation (1993-97 Corolla): Ensure No. 1 cylinder is at TDC on compression stroke. Crankshaft woodruff key will be at 12 oclock position. On 1.6L engine, timing mark notch on crankshaft sprocket will align with timing mark on oil pump housing. See Fig. 3. Crankshaft sprocket on 1.8L engine does not have notch. On 1.6L and 1.8L, hole in camshaft sprocket must align with mark on bearing cap. Ensure idler pulley (tensioner) is pushed as far to the left as possible and pulley bolt is snug tight. If reusing old timing belt, install belt and align match marks made during removal. Install new timing belt. Loosen idler pulley (tensioner) bolt and allow pulley to move against belt. Install timing belt guide on crankshaft (dished side facing away from belt).

Install lower timing belt cover. Install crankshaft pulley. Install 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 timing marks align. If timing marks are not aligned, remove and reinstall timing belt. If timing marks are aligned, final tighten crankshaft pulley center bolt. See TORQUE SPECIFICATIONS. With idler pulley bolt still loose, measure timing belt deflection at midway point of belt longest run. See Fig. 4. Deflection should be .20-.24" with pressure of 4.4 lbs. (5-6 mm at 2.0 kg) applied. See Fig. 4. If deflection is not as specified, readjust tension on belt by moving idler pulley (tensioner). Tighten idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Install upper and center timing belt covers. When installing valve cover, ensure sealant is apply in correct position. See Fig. 5. Install water pump pulley. Install A/C compressor mount to engine. Install A/C compressor. Install all accessory drive belts. Adjust belts to proper tension. See page A-60 for belt tension ranges. Final tighten water pump pulley bolts. Install engine mount to timing belt end of engine. On 199597 models, ensure engine ground strap is connected to ground wire on passenger side shock tower. Install front wheel and engine under cover. Install cruise control actuator (if equipped). TORQUE SPECIFICATIONS
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Application Ft. Lbs. (N.m) A/C Compressor Mount Bracket-To-Engine Celica (1.8L) ................................................................. 35 (47) A/C Compressor-To-Mount Bolts Celica (1.8L) ............................................................. 18 (25) Camshaft Sprocket Bolt .............................................. 43 (58) Crankshaft Pulley Bolt .................................................. 87 (118) Engine Mounts Celica (1993) Mount Bolt .............................................................. 47 (64) Mount Nut .............................................................. 38 (52) Celica (1994-97) & Corolla (1988-92) Mount-To-Engine Bracket Bolt ............................... 47 (64) Mount-To-Engine Bracket Nut ................................ 38 (52) Through-Bolt .......................................................... 64 (87) Corolla (1993-97) Mount-To-Body Bolt ................................................ 19 (25) Mount-To-Engine Bracket Bolt ............................... 47 (64) Mount-To-Engine Bracket Nut ................................ 38 (52) Power Steering Pump-To-Bracket Bolts ..................... 29 (39) Spark Plug .................................................................. 13 (18) Timing Belt Tensioner Pulley Bolt ............................... 27 (37) Wheel Lug Nut ............................................................. 76 (103) INCH Lbs. (N.m) Timing Belt Cover Bolt ............................................... 65 (7.4) Valve Cover Cap Nuts 1988-92 1.6L ............................................................... 69 (7.8) 1993-97 1.6L & 1.8L ................................................... 52 (5.9) Water Pump Pulley Bolt ................................................. 82 (9.3)
516
TOYOTA 1.8L 4-Cylinder Diesel

Inspection (All Models): Check timing belt for wear, cracks or missing teeth. If defective, check if injection pump camshaft is locked or there are nicks on belt side of idler pulley lock. Replace belt and components as needed. Inspect belt for excessive wear on one side only. If damaged, check the belt guide and the alignment of each sprocket. Before installing new belt, remove idler pulleys and spring. Check idler pulley bearings for noise or roughness. Inspect spring for proper free length and tension. Standard free length is 2.045" (51.93 mm). Replace idler pulley and/ or spring as necessary. Check camshaft, injection pump and crankshaft timing sprockets for wear or damage. If belt teeth are worn, check timing belt cover gasket for damage and proper installation. Replace components as necessary. Installation (All Models): Install timing belt tensioner, with larger bolt behind water pump, and loosely fasten mounting bolts. Swing tensioner toward the left. Check alignment of timing marks on each pulley. See Fig. 2
NOTE: When tightening idler pulley and timing sprocket mount bolts, do not move idler pulley bracket or apply tension to timing belt.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cyl. Diesel Camry 1984-85 ................ 5.0 Hours ................. 250098 Corolla 1984-85 ................ 2.7 Hours ................. 250098


TIMING BELT
Removal (1984): Disconnect negative battery cable. Remove air cleaner. Drain engine coolant and remove radiator hoses, cooling fan shroud and radiator from vehicle. Remove drive belts, cooling fan and pulley. If equipped with A/C, remove compressor pulley from crankshaft pulley. Using Pulley Holder and Socket (09213-14010 & 09330-00020) or equivalent, remove crankshaft pulley set bolt and washer. Using a puller, remove crankshaft pulley. If equipped with A/ C, remove idler pulley. Remove timing belt cover mount bolts. Remove timing belt cover and belt guide. Disconnect glow plugs by removing 4 screw grommets and glow plug connecting nuts. Disconnect current sensor by removing nut, plate washer, insulator and current connector. Remove glow plug connector and glow plugs. Using crankshaft set bolt, rotate engine and align TDC mark on camshaft timing pulley with top surface of cylinder head on intake manifold side. Using pliers, remove tensioner spring. Loosen tensioner set bolts and remove timing belt. Removal (1985): Disconnect negative battery cable. Remove air cleaner. Drain engine coolant and remove radiator hoses, washer, and radiator reservoir tanks. Remove drive belts, cooling fan and pulley. Remove cruise control actuator (if equipped). Disconnect the accelerator and cruise control cables. Disconnect the actuator vacuum hose. Remove the actuator cover, and the actuator. Disconnect the wiring connector. Remove power steering pump with bracket (if equipped). Remove drive belt and pulley. Remove 3 mounting bolts and PS pump with bracket. Place pump aside and suspend it. Remove alternator with bracket. Remove No. 2 timing belt cover. Set No. 1 cylinder to TDC on compression stroke. Align mark of camshaft pulley with top end of cylinder head. Using Special Service Socket (09213-14010 and 09330-00020) or equivalent, remove crankshaft pulley. Remove No. 1 timing belt cover and belt guide. Jack up engine slightly. Remove RH engine mounting insulator and bracket. Using a screwdriver, remove tension spring. Loosen the No. 1 idler pulley mount bolt. Remove timing belt. If reusing timing belt, scribe a mark on belt, indicating direction of engine rotation. Place match marks on pulleys and timing belt at each position.
Install timing belt onto camshaft timing pulley. Ensure timing belt is securely meshed and not loose. Align marks of injector pump drive pulley and install timing belt onto pulley. Install timing belt over lower idler pulley and under crankshaft timing belt pulley. Ensure timing belt is not twisted or too tight. Install tensioner spring and loosen bolts until tensioner moves by spring tension. Using crankshaft pulley set bolt, turn crankshaft 2 complete revolutions clockwise from TDC to TDC. Always turn crankshaft clockwise. Check that each pulley aligns with marks. If marks DO NOT align, remove timing belt and repeat procedure in previous step. Ensure that each pulley aligns with timing mark. See Fig. 2. After ensuring proper alignment of pulley marks, tighten tensioner pulley set bolts. Reverse remaining removal procedures to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................. 69-75 (94-102) Crankshaft Pulley Washer/Bolt 1984 ..................................................................... 102 (137) 1985 ......................................................................... 72 (98) Injection Pump Drive Pulley Bolts 1984 ............................................................... 43-47 (58-64) 1985 ............................................................... 10-15 (20-28) Nozzle Holder Mount Bolt 1984 ............................................................... 20-22 (27-29) 1985 ............................................................... 51-65 (69-88) Tensioner Pulley Bolts 1984 ......................................................................... 14 (19) 1985 ......................................................................... 27 (37) INCH Lbs. (N.m) Glow Plugs ............................................................... 108 (13)
TOYOTA 1.8L 4-Cylinder Diesel (Cont.)
517
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

Using Toyota tool (09278-54011) or equivalent, hold timing sprocket in place, then remove sprocket retaining bolt and sprocket. Remove No. 1 idler pulley and tension spring. Using Toyota tools (09213-54010 and 09330-00020) or equivalents, remove crankshaft pulley retaining bolt, then pulley. Remove No. 1 timing belt cover and gasket assembly. Remove timing belt and belt guide. Remove No. 2 idler pulley and crankshaft timing sprocket. Installation (1983-86 Camry): Install crankshaft timing sprocket over crankshaft key. See Fig. 2. Install No. 2 idler pulley. Tighten idler pulley retaining bolt. Temporarily install timing belt onto sprockets. Install timing belt guide. Install No. 1 timing belt cover and gasket assembly. Install crankshaft pulley. Pull timing belt upward and align preset mark on No. 1 timing belt cover with crankshaft pulley groove. See Fig. 4. Align camshaft oil seal retainer preset mark with center of small hole on camshaft timing pulley. Install timing belt. Loosen No. 1 idler pulley retaining bolt 1/2 turn and release spring tension on timing belt. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (Celica w/3S-GE Engine): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel and engine undercover. Remove radiator reservoir tank. Remove cruise control actuator and bracket. Remove the power steering oil reservoir bolts and position reservoir aside. Remove accessory drive belts. Remove alternator and bracket. Raise the engine slightly with suitable jack with wooden block between jack and engine. Remove the right engine mount through bolt, then mount. Remove the valve cover. Remove spark plugs. Remove No. 2 timing belt cover with gasket. Set the cylinder No. 1 to TDC by rotating crankshaft pulley until groove is aligned with 0 timing mark. See Fig. 8. Ensure alignment marks of camshaft pulleys and No. 3 timing belt cover are aligned. See Fig. 9. Loosen the spring loaded idler pulley attaching bolt. Pry pulley as far left as possible and temporarily tighten bolt. Remove the timing belt from the camshaft timing pulleys. Hold the camshaft flats with a suitable wrench and remove the camshaft sprocket attaching bolts, sprockets and pins. Mark the intake and exhaust camshaft sprockets for installation reference before removing. Remove the crankshaft pulley attaching bolt, then using suitable puller, remove the crankshaft pulley. Remove No. 1 timing cover, then the timing belt guide from crankshaft sprocket. Remove the timing belt, spring loaded idler pulley, tension spring and fixed idler pulley from engine. Installation (Celica w/ 3S-GE Engine): Install fixed idler pulley. Pry the idler pulley as far to the left as possible, then temporarily tighten attaching bolt. Temporarily install the timing belt on crankshaft sprocket, oil pump sprocket, fixed idler pulley and water pump pulleys. Install the timing belt guide on crankshaft sprocket and timing cover No. 1. Install the crankshaft pulley. Ensure crankshaft pulley groove is still aligned with 0 timing mark. This indicates No.1 cylinder is at TDC of compression stroke. See Fig. 8.
TIMING BELT APPLICATION Application 2.0L 4-Cyl. Camry 1983-86 .......... 3.6 Hrs. ...... 2520870 ........ 250087 1987-91 .......... 3.0 Hrs. ...... 2521990 ........ 250199 Celica 1986 GTS ............. 3.0 Hrs. ............................. 250125 Exc. GTS ..... 2.8 Hrs. ...... 2520870 ........ 250087 1987-88 GTS ............. 3.0 Hrs. ............................. 250125 Exc. GTS ..... 2.8 Hrs. ...... 2521990 ........ 250199 1989 ............... 3.0 Hrs. ...... 2521990 ........ 250199 1990-93 .......... 4.3 Hrs. ............................. 250125 MR2 1991-95 .......... 4.0 Hrs. ............................. 250125 1 - With Air Cond. add .5 hours.


TIMING BELT
Removal (1983-86 Camry): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove fender apron seal. Remove alternator drive belt. Remove cruise control actuator and bracket. Remove power steering oil reservoir tank and drive belt. Raise engine slightly and remove right side engine mount insulator and bracket. Remove No. 2 timing belt cover and gasket assembly. Remove spark plugs. Align oil seal retainer mark with center of small hole on camshaft timing sprocket by turning crankshaft pulley clockwise. See Fig. 1. This will position No. 1 cylinder at 90 BTDC of compression stroke. Loosen No.1 idler pulley retaining bolt and move pulley toward left as far as possible, then temporarily tighten retaining bolt. Remove timing belt from camshaft timing sprocket
On models equipped with 2-hole camshaft flanges, use suitable wrench to align camshaft knock pins and cam lobes as shown. See Fig. 10. On models equipped with 5hole camshaft flanges, use suitable wrench to align camshaft alignment marks as shown. See Fig. 11. Hang the timing belt on camshaft sprocket pulleys with sprocket S markings facing outward. Align the camshaft sprocket alignment marks with No. 3 timing cover match mark and install sprockets. See Fig. 9. On models equipped with 2-hole camshaft flange, ensure camshaft knock pin is aligned with sprocket hole. On models equipped with 5-hole camshaft flange, insert knock pin into any holes in alignment. On 5-hole flange type cams, if knock pin alignment is not exact, camshafts can be rotated slightly to compensate. While holding the camshafts with suitable wrench, install and tighten camshaft sprocket attaching bolts. Loosen the spring loaded idler pulley attaching bolt just enough to allow pulley to move by itself under spring tension. Allow the pulley to take up belt tension. Rotate the crankshaft clockwise 2 complete revolutions. Tighten pulley bolt. Ensure that the timing belt has tension between crankshaft sprocket and intake camshaft sprocket. See Fig. 12. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (1987-91 Camry & 1988-89 Celica w/3S-FE Engine): Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel. Remove undercover. Remove cruise control actuator and bracket (if equipped). Remove accessory drive belts. Remove alternator and bracket. Use a jack to raise engine slightly. Remove right side engine mount through-bolt, and mount.
NOTE: Position a wooden block between jack and engine to prevent damage.
TOYOTA 2.0L 4-Cylinder Except RAV4 (Cont.)
519
Rotate crankshaft clockwise two complete revolutions, from TDC compression stroke to TDC compression stroke, then tighten spring loaded idler pulley. Ensure that timing belt has tension between water pump sprocket and camshaft sprocket. Install upper timing belt cover. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (1990-93 Celica & 1991-95 MR2 With 3S-GTE Engine): Raise and support vehicle, then remove right front wheel (Celica) or right rear wheel (MR2). Remove right engine undercover. Remove radiator reservoir tank. Remove charge air cooler. Remove strut tower-to-firewall braces.
NOTE: Air bag system must be disarmed before working on vehicle. Turn ignition to LOCK. Disconnect negative battery cable. Wait at least 20 seconds before working on vehicle.
Remove spark plugs. Remove upper timing belt cover and gasket. Rotate crankshaft pulley until pulley groove is aligned with 0 indication on timing marks, then ensure camshaft sprocket hole is aligned bearing cap No. 1 alignment mark. See Fig. 14. Loosen spring loaded idler pulley attaching bolt, then pry pulley as far to left as possible. Temporarily tighten attaching bolt. Remove timing belt from camshaft sprocket. Remove crankshaft pulley attaching bolt, then using suitable 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 attaching bolts. Rotate camshaft by turning sprocket attaching bolt to align bearing cap mark and camshaft sprocket. See Fig. 14. Install timing belt on camshaft sprocket. Ensure that belt has tension between crankshaft sprocket, water pump sprocket and camshaft sprocket. Loosen spring loaded idler pulley attaching bolt just enough to allow pulley to move under spring tension. Allow pulley to take up belt tension.
Loosen power steering oil reservoir tank. Remove accessory drive belts. Remove alternator and alternator brackets. Use a suitable jack to raise engine slightly and remove weight from engine mounting on right side. Remove right engine mount insulator and bracket. Remove control cables, electrical connectors, vacuum hoses and coolant hoses from throttle body. Remove throttle body assembly. Remove No. 2 timing belt cover. Remove spark plugs. Place No.1 cylinder at TDC of compression stroke by turning crankshaft pulley to align groove with No.1 timing belt cover 0 mark. Ensure alignment marks on camshaft sprockets and No. 3 timing belt cover are aligned as shown in Fig. 15. If not, turn crankshaft one complete revolution (360) to align marks. Remove timing belt from camshaft timing sprockets. Loosen No.1 idler pulley attaching bolt and shift to left as far as possible. Temporarily tighten pulley attaching bolt, then relieve tension from timing belt. Remove timing belt from camshaft sprocket. Support timing belt so meshing of crankshaft sprocket and timing belt does not shift. Remove sprockets, No. 1 timing belt covers, timing belt guide and timing belt. Install crankshaft sprocket and No. 2 idler pulley. Installation (1990-93 Celica & 1991-95 MR2 With 3S-GTE Engine): Temporarily install No. 1 idler pulley and tension spring. Install pulley attaching bolt. Do not tighten bolt. Install tension spring, then pry toward left as far as it will go and tighten. Temporarily install timing belt onto crankshaft sprocket, oil pump, No. 2 idler pulley and water pump pulley.
Fig. 1: Aligning Oil Seal Retainer Mark With Camshaft Sprocket Hole
520
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
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 turning 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 installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................. 20 (27) Camshaft Timing Sprocket Bolt ........................ 40-43 (54-59) Crankshaft Pulley Bolt .............................................. 80 (109) Engine Mount Bolt ........................................................................... 65 (88) Nut ............................................................................ 38 (52) Through-Bolt ............................................................. 64 (87) Idler Pulley Bolt No. 1 ......................................................................... 31 (42) No. 2 ......................................................................... 31 (42) Oil Pump Pulley .......................................................... 31 (42) Valve Cover Nut .......................................................... 17 (23) INCH Lbs. (N.m) Timing Cover Attaching Bolts ........................................ 78 (9)
Fig. 9: Aligning Camshaft Sprocket Marks With Marks On No. 3 Timing Belt Cover (3S-GE)
Fig. 10: Aligning Camshaft Sprocket With 2-Hole Camshaft Flange (3S-GE)
522
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 2.0L 4-Cylinder RAV4

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl. RAV4 1996-00 With ABS ........... 1 5.3 Hours ................. 250199 Without ABS ...... 1 3.3 Hours ................. 250199 1 - With Air Cond. add .2 hours.
523

For 1996-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles for severe service operating conditions. For 1998 model year, the manufacturer recommends the belt be replaced every 90,000 miles for severe service operating conditions. For 1999-00 models years, the manufacturer recommends the belt be replaced every 90,000 miles or 72 months.
Check that each pulley aligns with timing marks as shown. See Fig. 3. Slowly turn crankshaft pulley 1-7/8 revolutions and align groove with mark at 45 degrees BTDC (for No. 1 cylinder) of No. 1 timing belt cover. See Fig. 5. Tighten No. 1 idler pulley mounting bolt to specification. Place right engine mounting bracket in position but do not install bolts. Install No. 2 timing belt cover. Disconnect engine wire protector between cylinder head cover and No. 3 timing belt cover. Install No. 2 timing belt cover. Install engine wire to No. 2 timing belt cover. Install engine wire protector to mounting bolts of No. 2 timing belt cover. Remove crankshaft pulley. Install engine mounting bracketto-engine bolts and tighten to specification. Install crankshaft pulley, and tighten pulley bolt to specification. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Timing Pulley Bolt ........................................ 40 (54) Crankshaft Pulley Bolt .................................................. 80 (108) Generator Bracket Bolts ............................................. 31 (42) Engine Mount Bracket-To-Engine Bolts .......................... 38 (52) Engine Mount Insulator-To-Body Bolts ........................ 38 (52) Engine Mount Insulator-To-Bracket Nut ...................... 27 (37) No. 1 Idler Pulley Mounting Bolt ...................................... 31 (42) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) Water Pump Bolts ......................................................... 78 (8.8)

TIMING BELT
Removal: Disconnect negative battery cable. Disconnect power steering reservoir and remove reservoir bracket. Disconnect wire harness bracket for Data Link Connector No. 1. Remove generator and generator bracket. Remove ABS actuator. Raise and support vehicle. Remove right front wheel. Remove right engine undercover. Remove power steering drive belt. Slightly jack up engine and remove right engine mounting insulator.
NOTE: Always turn crankshaft clockwise.
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 pulley 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 tension should be 8.5 lbs. (3.85 kg) at length of 1.988. If not as specified, replace spring. Inspect timing belt cover gaskets. Replace if gaskets are cracked or peeling. Installation: Ensure that No. 1 cylinder is set to TDC on compression stroke by temporarily installing No. 1 timing belt cover and crankshaft pulley. Align groove with timing mark 0 on No. 1 timing belt cover. Ensure that camshaft and timing belt match marks are aligned. Remove crankshaft pulley and timing belt cover. Install timing belt. If reusing old belt, ensure rotation direction and mating marks are in correct position. Install timing belt guide on crankshaft with cup side facing out. Install No. 1 timing belt cover, crankshaft pulley, and crankshaft pulley bolt. Loosen No. 1 idler pulley 1/2 turn to tension timing belt. Slowly turn crankshaft pulley 2 revolutions from TDC to TDC.
96B14507
524
TOYOTA 2.0L 4-Cylinder RAV4 (Cont.)
Fig. 5: Locating 45 Degrees BTDC Mark
96B14507
Fig. 2: Removing No. 2 Timing Belt Cover
96H14511
Fig. 6: Aligning Match Marks Of Timing Belt & Camshaft Pulley
96B14507
Fig. 3: Setting No. 1 Cylinder To TDC
96B14507
Fig. 4: Loosening No. 1 Idler Pulley Mounting Bolt
TOYOTA 2.2L 4-Cylinder

TIMING BELT APPLICATION Labor Component Application Time Kit No. 2.2L 4-Cyl. Camry 1992-01 .......... 1 3.0 hrs. .... 2521990 ........ 250199 Camry Solara 1999-01 .......... 1 3.0 hrs. .... 2521990 ........ 250199 Celica 1990-91 .......... 1 3.1 hrs. ..... 2521990 ........ 250199 1992-99 .......... 1 2.4 hrs. ..... 2521990 ........ 250199 Celica GT & GTS 1990-91 .......... 1 2 3.1 hrs. ... 2521990 ........ 250199 1992-93 .......... 1 2 3.1 hrs. ... 2521990 ........ 250199 MR2 1991-95 .......... 1 3.5 hrs. ..... 2521990 ........ 250199 1 - With Air Cond. add .2 hours. On MR2 with turbo and Air Cond., time is 4.5 hours. 2 On all-wheel drive Celica, add 1.2 hours. Belt Part No.
525
CAUTION: If reusing timing belt, mark direction of timing belt rotation on belt. Place mating marks on timing belt at camshaft sprocket and at crankshaft sprocket for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover. See Fig. 2.
Loosen No. 1 idler pulley bolt. See Fig. 1. Move No. 1 idler pulley outward, away from timing belt as far as possible. Temporarily retighten No. 1 idler pulley bolt. Remove timing belt from camshaft sprocket. Using Pulley Holder (SST 09213-54015) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove No. 1 timing belt cover and gasket. Note direction of timing belt guide installation. See Fig. 1. Remove timing belt guide. Loosen No. 1 idler pulley bolt. See Fig. 1. Remove timing belt from crankshaft sprocket. Remove idler pulleys (if necessary).

For 1990-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe service driving conditions. For 1998-01 model years, the manufacturer recommends the belt be replaced every 90,000 miles.

TIMING BELT
Removal: Disconnect negative battery cable. Raise and support vehicle. Remove lower engine cover. On Celica and Camry, remove right front wheel. On all models, lower vehicle. 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 (timing 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. Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing belt end of engine. Ensure timing mark on crankshaft pulley aligns with 0" mark on No. 1 timing belt cover. Ensure hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 2. If hole in camshaft sprocket is not aligned with alignment mark, rotate crankshaft clockwise one full revolution.
526
TOYOTA 2.2L 4-Cylinder (Cont.)
Using crankshaft pulley bolt, rotate crankshaft so timing mark on crankshaft sprocket aligns with timing mark on oil pump housing. See Fig. 4. This will position keyway in crankshaft sprocket at 12 oclock position.
Inspection: Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely. Replace components if damaged or worn. Ensure free length of tension spring is within specification. See TENSION SPRING SPECIFICATIONS table. Measure free length between from inside edges of hooked portion of spring. Do not measure spring coils. See Fig. 3. Measure tension needed to extend tension spring to specified installed length. Replace spring if tension is not within specification. TENSION SPRING SPECIFICATIONS Application Specification Free Length Except 2000-99 Camry ........................... 1.811" (46.00 mm) 2000-99 Camry ...................................... 1.654" (42.00 mm) Tension At Spring Installed Length 1 Camry (1992-95) Green Spring ............................. 7.2-8.3 lbs (3.25-3.75 kg) Silver Spring .......................... 10.5-11.6 lbs. (4.75-5.25 kg) Camry (1996-01) .......................... 7.2-8.3 lbs (3.25-3.75 kg) Camry Solara ............................... 7.2-8.3 lbs (3.25-3.75 kg) Celica & MR2 ............................... 7.2-8.3 lbs. (3.25-3.75 kg)
1
CAUTION: If reusing timing belt, ensure reference marks on timing belt align with reference marks placed on crankshaft and camshaft sprockets. Ensure timing belt is installed in original direction of rotation.
- At 1.988" (50.50 mm)
Revised Timing Belt Tension Spring: For 1992-96 Camry models, the timing belt tension spring was revised. When replacing the timing belt on 1992-96 Camry with 2.2L, tension spring MUST be replaced. The revised tension spring 0(part no. 905-7-17003) is a 13-coil design which replaces the original 10-coil design. This information is from Toyota technical service bulletin EG001-99; January 29, 1999. Installation: Install No. 2 idler pulley (if removed). Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly. Install No. 1 idler pulley and tension spring (if removed). Pry No. 1 idler pulley away from timing belt area as far as possible. Temporarily tighten No. 1 idler pulley bolt. Ensure idler pulley is clean and rotates smoothly.
Ensure all sprockets and idler pulleys are clean. Install timing belt on crankshaft sprocket, oil pump sprocket, No. 1 idler pulley and then No. 2 idler pulley in sequence. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install No. 1 timing belt cover and new gasket. Align crankshaft pulley key groove with key in crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. If reusing timing belt, ensure reference mark on timing belt aligns with upper edge of No. 1 timing belt cover. Rotate camshaft and align hole in camshaft sprocket with alignment mark on camshaft bearing cap. See Fig. 2. Install timing belt on camshaft sprocket. If reusing timing belt, ensure reference mark on timing belt aligns with reference mark on camshaft sprocket. Ensure tension exists on timing belt between crankshaft and camshaft sprockets.
CAUTION: DO NOT rotate crankshaft counterclockwise, as viewed from timing belt end of engine.
Loosen No. 1 idler pulley bolt turn. Rotate crankshaft pulley 2 full revolutions clockwise from TDC to TDC. Ensure timing mark on crankshaft pulley aligns with 0" mark on No. 1 timing belt cover and hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. Rotate crankshaft clockwise 1 and 7/8 revolutions and align crankshaft pulley 0 mark with 45-degree Before Top Dead Center (BTDC) mark on No. 1 timing belt cover. See Fig. 5. Tighten No. 1 idler pulley bolt to specification. See TORQUE SPECIFICATIONS. Install No. 2 timing belt cover and gaskets. Install and tighten spark plugs to specification. To install remaining components, reverse removal procedure. 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 drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 4: Aligning Crankshaft Sprocket Timing Marks

TORQUE SPECIFICATIONS (CAMRY)
527
Fig. 5: Aligning Crankshaft Pulley With 45-Degree BTDC Mark
Application Ft. Lbs. (N.m) Alternator Bracket Bolt ................................................ 31 (42) Camshaft Sprocket Bolt .............................................. 40 (54) Coolant Outlet Bolt ...................................................... 11 (15) Crankshaft Pulley Bolt .............................................. 80 (109) Engine Mounts & Brackets Right (Timing Belt Side) Engine Mount Bracket-To-Cylinder Block Bolt ............................... 38 (52) No. 1 Idler Pulley Bolt .................................................. 31 (42) No. 2 Idler Pulley Bolt .................................................. 31 (42) Oil Pump Sprocket Nut ............................................... 21 (29) Power Steering Pump Bracket Bolt ............................. 32 (43) Power Steering Pump-To-Bracket Bolt ....................... 32 (43) Spark Plug .................................................................. 13 (18) Valve Cover Nut .......................................................... 17 (23) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) Coolant By-Pass Pipe-To-Water Pump Nut ........................................ 78 (8.8) No 3 Timing Belt Cover Bolt ...................................... 69 (7.8) Oil Pan Bolt/Nut ......................................................... 48 (5.4) Oil Pump Body Cover Bolt .......................................... 78(8.8) Oil Pump Pick-Up Tube Bolt/Nut ................................ 48 (5.4) Oil Pump-To-Cylinder Block Bolt ................................ 82 (9.3) Water Pump-To-Water Pump Cover Bolt ................... 82 (9.3) TORQUE SPECIFICATIONS (CELICA) Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................. 18 (24) Alternator Bracket Bolt ................................................ 18 (24) Camshaft Sprocket Bolt .............................................. 40 (54) Crankshaft Pulley Bolt .............................................. 80 (109) Right (Timing Belt Side) Engine Mount Bracket-To-Cylinder Block Bolt .................................. 38 (52) Right (Timing Belt Side) Engine Mount To-Bracket Bolt ........................................................................ 27 (37) Nut ......................................................................... 38 (52) No. 1 Idler Pulley Bolt .................................................. 31 (42) No. 2 Idler Pulley Bolt .................................................. 31 (42) Power Steering Pump Bracket Bolt ............................. 32 (43) Power Steering Pump-To-Bracket Bolt Adjusting Bolt ........................................................... 29 (39) All Others .................................................................. 32 (43) Spark Plug .................................................................. 13 (18) Valve Cover Nut .......................................................... 17 (23) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt ...................................... 69 (7.8) Water Pump-To-Water Pump Cover Bolt ................... 78 (8.8)
Fig. 6: Control Rod & Bracket Bolt Installation Sequence (Camry)
528
Fig. 7: Installing Left (Flywheel Side) Engine Mount Bolts (MR2)
Fig. 8: Water Pump Bolt Removal & Installation Sequence (Celica & MR2)
TORQUE SPECIFICATIONS (MR2) Application Ft. Lbs. (N.m) A/C Compressor Bolt ................................................. 18 (24) Camshaft Sprocket Bolt .............................................. 40 (54) Crankshaft Pulley Bolt .............................................. 80 (109) Left (Flywheel Side) Engine Mount Through-Bolt ............................................................. 58 (79) Bracket Bolt .......................................................................... 1 Right (Timing Belt Side) Engine Mount Support Bracket Bolt/Nut .......................................... 54 (73) Bracket-To-Cylinder Block Bolt .................................. 45 (61) Mounting Bracket Nut ............................................... 38 (52) Through-Bolt ............................................................. 58 (79) Idler Pulley Bracket-To-Cylinder Block Bolt 12-mm Head ............................................................ 20 (27) 14-mm Head ............................................................ 27 (37) Fuel Pulsation Damper .............................................. 25 (34) No. 1 Idler Pulley Bolt .................................................. 31 (42) No. 2 Idler Pulley Bolt .................................................. 31 (42) Spark Plug .................................................................. 13 (18) Valve Cover Nut .......................................................... 17 (23) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt ...................................... 68 (7.8) Water Pump-To-Cylinder Block Bolt ....................................... 2 Water Pump-To-Water Pump Cover Bolt ................... 78 (8.8)
1 2
- Tighten bolts to specification. See Fig. 7 - 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 *2.2L 4-Cylinder Diesel

TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.2L 4-Cyl. Diesel Pickup 1981 ........................ 2.2 Hours ................ 250079 1982 Up To 5/31 ............ 2.2 Hours ................ 250079 From 6/1 ............... 2.2 Hours ................ 250084 1983 ........................ 2.2 Hours ................ 250084 1 - With Air Cond. add .7 hours.
1
529

Check the free length of idler pulley spring. Length of spring should be 1.563" (39.70 mm). Under 8.8 lbs. (4 kg) tension, spring should measure 2.05" (52.0 mm) in length. Check camshaft timing pulley, injection pump pulley and crankshaft pulley for wear or damage. Installation: Before installing timing belt, engine should be cold. Always turn crankshaft clockwise. Install idler pulley loose enough so it may be moved side to side by hand. Check alignment of timing marks on each pulley. See Fig. 2. Injection pump timing is normally retarded. Install timing belt and idler spring. Turn the crankshaft 2 revolutions clockwise from TDC to TDC. While turning crankshaft make sure idler pulley bracket is moving. Ensure that each pulley aligns with marks. See Fig. 3. Tighten timing belt idler pulley bolt. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................. 69-75 (94-102) Camshaft-To-Timing Pulley ............................ 69-75 (94-102) 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 attaching bolt and using puller, remove damper. Remove air cleaner assembly. Drain cooling system. Remove radiator hoses, shroud and radiator as necessary. Identify and remove any wiring, hoses and lines interfering with timing belt cover removal. Remove crankshaft damper bolt. Do not apply tension to timing belt during damper bolt removal. 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. Remove center retaining bolt to remove pulley. Inspection: Check timing belt for wear, cracks, or missing teeth. Replace belt if defective. Before installing a new belt, remove idler pulley and spring. Check idler pulley bearing for smooth operation.
Fig. 1: Exploded View Of Cylinder Head & Timing Belt Components
530
TOYOTA *2.2L 4-Cylinder Diesel (Cont.)
Fig. 3: Realigning Timing Marks
TOYOTA *2.4L 4-Cylinder Diesel

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.4L 4-Cyl. Diesel Pickup 1984-87 ................ 2.2 Hours ................. 250084
531


TIMING BELT
Removal: Disconnect negative battery cable. Drain engine coolant and radiator hoses, fan shroud, and radiator from vehicle. Remove water pump pulley, drive belts, cooling fan and pulley. See Fig. 1.
If equipped with A/C, remove compressor pulley from crankshaft pulley. Using Special Service Tools (09213-54012 and 09330-00020) or equivalent, remove crankshaft pulley set bolt and washer. Using Puller (09213-60017) or equivalent, remove crankshaft pulley. If equipped with A/C , remove idler pulley. On 2L, remove timing belt cover mount bolts, timing belt cover, and belt guide. On 2L-T, remove No. 1 turbocharger water pipe, air cleaner pipe, No. 1 air cleaner hose, and timing cover. Disconnect glow plugs by removing 4 screw grommets and glow plug connecting nuts. Disconnect current sensor by removing nut, plate washer, insulator and current connector. Remove glow plug connector and glow plugs. Using crankshaft set bolt, rotate engine and align TDC mark on camshaft timing pulley with top surface of cylinder head. See Fig. 2. Using pliers, remove tensioner spring. Loosen tensioner set bolts and remove timing belt. Using Pulley Holder (09278-54011), and a wrench, remove camshaft pulley set bolt. Using Puller (09950-20015), remove camshaft pulley. Using Pulley Holder (09278-54011), and a wrench on injection pump drive pulley, remove set bolt on pulley.
Fig 1: Exploded View Of Timing Belt Components
532
TOYOTA *2.4L 4-Cylinder Diesel (Cont.)
Fig 2: Aligning 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 defective, check if injection pump camshaft is locked or if there are nicks on belt side of idler pulley lock. Replace belt and components as needed. Inspect belt for excessive wear on one side only. If damaged, check belt guide and alignment of each pulley. Before installing new belt, remove idler pulleys and spring. Check idler pulley bearings for noise or roughness. Inspect spring for proper free length and tension. Standard free length is 1.563" (39.70 mm). See Fig. 4. Installed tension is 8.8 lbs. at 2.05" (4.0 kg at 52 mm). Replace idler pulley and/or spring as necessary. Check camshaft, injection pump and crankshaft timing sprockets for wear or damage. If there is noticeable wear on belt teeth, check timing belt cover gasket for damage and proper installation. Replace components as necessary. Installation: Install lower idler pulley. Install timing belt tensioner, with large bolt behind water pump, and loosely fasten mounting bolts. Swing tensioner toward the left. Set No. 1 cylinder to TDC of compression stroke and check alignment of timing marks on each pulley. See Fig. 2. If using a new timing belt, note that injection pump timing is normally in the retarded position.
NOTE: When tightening idler pulley and timing sprocket mount bolts, DO NOT move idler pulley bracket or apply tension to timing belt.
Fig. 3: Realigning Timing Marks
Install timing belt onto camshaft timing pulley. Ensure timing belt is securely meshed and not loose. Align marks of injector pump drive pulley and install timing belt onto pulley. Install timing belt over lower idler pulley and under crankshaft timing belt pulley. Ensure timing belt is not twisted or too tight. Install tensioner spring and loosen bolts until tensioner moves by spring tension. Using crankshaft pulley set bolt, turn crankshaft 2 complete revolutions clockwise from TDC to TDC. Check that each pulley aligns with marks. If marks DO NOT align, remove timing belt and follow repeat the procedure in this step.
Ensure that each pulley aligns with timing mark. See Fig. 3. Tighten tensioner pulley set bolts to 14 ft. lbs. (19 N.m). Install glow plugs and tighten to 9 ft. lbs. (13 N.m). Install current sensor, insulator, plate washer and nut. Install 4 glow plug connecting nuts and 4 screw grommets. Align set key on crankshaft with key groove of timing belt guide, and install guide with curved side facing out. Using a new gasket, install belt cover. On 2L-T, install air cleaner pipe and No. 1 air cleaner hose. Connect accelerator cable and PCV hose. Install timing belt cover and No. 1 water pipe. Connect turbocharger water hoses. If equipped with A/C, install idler pulley. Install crankshaft pulley using Driver (09214-60010). Install washer and bolt and tighten bolt to 101 ft. lbs. (137 N.m). Install drive pulley onto crankshaft drive pulley. Install water pump pulley and cooling fan. Install radiator, hoses and fan shroud. Fill engine cooling system and connect negative battery cable. Install drive belts. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Start engine and check for leaks. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Pulley Bolt .................................................. 73 (98) Crankshaft Pulley Bolt ............................................ 101 (137) Glow Plugs ................................................................... 9 (13) Injector Pump Drive Pulley Bolt ................................... 47 (64) Timing Belt Idler Pulley Bolt ........................................ 29 (39) Timing Belt Tensioner Pulley Bolts ............................. 14 (19)
TOYOTA 2.8L 6-Cylinder

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.8L 6-Cyl. Celica Supra 1982-83 A/T ..................... 3.5 Hours ................. 250074 M/T .................... 3.3 Hours ................. 250074 1984-86 A/T ..................... 3.5 Hours ................. 250101 M/T .................... 3.3 Hours ................. 250101 Cressida 1983 ................... 3.1 Hours ................. 250074 1984-88 .............. 3.1 Hours ................. 250101
533
CAUTION: Ensure camshaft timing pulleys are installed in original location. Guide on exhaust side must be toward No. 2 timing cover and intake side guide facing away from No. 2 timing cover. See Fig. 1.
TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Housing Bolt ............................................ 1 16 (22) Camshaft Timing Pulley Bolt ...................................... 51 (69) Crankshaft Pulley Bolt ............................................ 195 (265) Idler Pulley Bolt ........................................................... 36 (49) Oil Pump Drive Pulley Bolt .......................................... 16 (22) Rear Timing Cover Bolt .............................................. 36 (49) Timing Belt Case Bolt 8 mm ........................................................................ 13 (18) 10 mm ...................................................................... 27 (37) INCH Lbs. (N.m) No. 2 Timing Belt Cover ............................................ 108 (12)
1

- Tighten in 3 steps in proper sequence. See Fig. 5.

TIMING BELT
Removal: Disconnect negative battery cable. Drain cooling system. Remove air cleaner, upper radiator hose, fan shroud and air intake connector. Remove all drive belts. Position No. 1 cylinder at TDC of compression stroke. See Fig. 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 operation. 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. Position idler pulley to alternator side of engine as far as possible. 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 rotation and position No. 1 cylinder at TDC of compression stroke. Recheck alignment of match marks. Install timing belt cover and crankshaft pulley. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
Fig. 2: Aligning Camshaft Match Hole
534
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 3.0L 6-Cylinder 7M-GE

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L 6-Cyl. Cressida 1989-91 ................. 3.1 Hours .................. 250126 1992 ...................... 3.1 Hours .................. 250237 Supra 1986-90 ................. 3.3 Hours .................. 250126 1991-92 ................. 3.3 Hours .................. 250237
535

The manufacturer recommends the belt be replaced every 60,000 miles for severe service operating conditions.
Inspect tension spring for damage, and measure spring free length. Replace tension spring if damaged or free length is not 2.216" (56.274 mm). Installation: Install No. 1 idler pulley as far to the left as possible (away from timing belt), and temporarily tighten retaining bolt. Align timing marks on camshaft sprockets with timing mark on No. 4 timing belt cover. See Fig. 2. Install timing belt. Loosen No. 1 idler pulley retaining bolt. Pry No. 1 idler pulley as far to the right as possible (toward timing belt), and temporarily tighten retaining bolt. Install tension spring. Loosen No. 1 idler pulley retaining bolt until idler pulley moves with spring force of tension spring. Temporarily install crankshaft pulley retaining bolt. Using crankshaft pulley retaining bolt, rotate crankshaft clockwise (viewed from front of engine) 2 full revolutions.

TIMING BELT
Removal: Disconnect negative battery cable. Drain cooling system. Remove radiator. Remove all accessory drive belts. Remove power steering pump with hoses attached and secure aside (if equipped). Remove spark plugs. Disconnect hoses from air pipe. Remove coolant outlet and fan. Remove spark plug wire clamps across front of No. 2 timing belt cover. Remove retaining bolts, No. 3 timing belt cover and gaskets. See Fig. 1. Rotate crankshaft so cylinder No. 1 is at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 2. If timing marks are not aligned, rotate crankshaft 360 degrees and recheck alignment. Remove power steering belt pulley. Using Pulley Holder (SST 09213-58011) or equivalent, and Handle (SST 0933000021) or equivalent, hold crankshaft pulley and remove retaining bolt. Using puller, remove crankshaft pulley. Remove fan bracket, No. 1 timing belt cover and gasket. See Fig. 1. Note direction of timing belt guide installation. Mark direction of timing belt rotation. Remove timing belt guide and tension spring. See Fig. 1. Loosen No. 1 idler pulley retaining bolt. Position No. 1 Idler pulley as far to the left as possible (away from timing belt), and temporarily tighten retaining bolt. Remove timing belt. Inspection: Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Inspect idler pulleys and fan for smooth rotation. Replace component if defective.
Ensure all timing marks are properly aligned. See Fig. 2. Tighten No. 1 idler pulley retaining bolt to 27 ft. lbs. (37 N.m). Check timing belt deflection. To remove slack in timing belt, rotate intake and exhaust camshaft timing pulleys inward by applying a turning torque of 14 ft. lbs. (19 N.m). See Fig. 4. Remove crankshaft pulley retaining bolt. Install timing belt guide with cupped side toward front of engine.
CAUTION: Ensure timing belt guide is installed with cupped side toward front of engine and flat side against crankshaft sprocket.
To install remaining components, reverse removal procedure. Apply sealant to coolant outlet before installing. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 80 (109) Coolant By-Pass Outlet Bolt ....................................... 13 (18) Coolant Inlet Nut ......................................................... 14 (19) Crankshaft Pulley Bolt ............................................ 181 (245) Fan Bracket Bolt ......................................................... 30 (41) Idler Pulley Bolt No. 1 Pulley .............................................................. 27 (37) No. 2 Pulley .............................................................. 13 (18) Power Steering Pump Pulley Nut ................................ 32 (43) Spark Plug .................................................................. 13 (18) Tension Spring Bracket Bolt ....................................... 13 (18) INCH Lbs. (N.m) Fan Retaining Nut ........................................................ 48 (5) Timing Belt Cover Bolt No. 1 & 2 Covers ........................................................ 48 (5) No. 3 & 4 Covers ........................................................ 74 (8)
536
TOYOTA 3.0L 6-Cylinder 7M-GE (Cont.)
Fig. 3: Aligning Camshaft Pin Holes & Timing Marks
TOYOTA 3.0L 6-Cylinder 2JZ, 1993-97

TIMING BELT APPLICATION Belt Part No. Application Labor Time 3.0L 6-Cyl. 2JZ Supra 1993-97 ................. 2.7 Hours .................. 250215 1 - With Turbo add .9 hours.
1
537

The manufacturer recommends the belt be replaced every 60,000 miles or 96 months for severe operating conditions.

Removal: Disconnect negative battery cable. Remove battery, and drain cooling system. Place reference mark on fan clutch and water pump for reassembly reference. Remove drive belt, cooling fan, fan clutch and water pump pulley. Remove radiator and lower engine cover. Remove oil filler cap, No. 2 and No. 3 timing belt covers, gasket and drive belt tensioner. See Fig. 1. Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Timing marks on camshaft sprockets must align with timing marks on No. 4 timing belt cover. See Fig. 2. If conditions are not as described, rotate crankshaft clockwise one complete revolution Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner and dust boot. See Fig. 1. Remove timing belt from camshaft sprockets. Using Handle (SST 09330-00021) and Pulley Holder (SST 0921370010) or equivalent, hold crankshaft pulley and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide. Inspection: Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.
Installation: Install idler pulley and plate washer (if removed). Apply Loctite 242 on threads of idler pulley bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. sing crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 2. Install timing belt on crankshaft sprocket. Install timing belt guide with cupped side away from crankshaft sprocket and flat side against timing belt. Install gaskets and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley and tighten pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on Compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Using sprocket holder, rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 2. Install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets. Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 4. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 4. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.
Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate crankshaft counterclockwise. Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. 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 SPECIFICATIONS. Adjust fluid levels and check ignition timing. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bolt/Nut ........................................... 38 (52) Alternator Mount Bolt ................................................... 27 (37) Camshaft Sprocket Bolt .............................................. 59 (80) Crankshaft Pulley Bolt ............................................ 239 (324) Drive Belt Tensioner Bolt ............................................ 15 (20) Fan Clutch-To-Water Pump Nut ................................. 12 (16) Idler Pulley Bolt ........................................................... 25 (34) Timing Belt Tensioner Bolt ......................................... 20 (27) Water Pump Bolt ........................................................ 15 (20) INCH Lbs. (N.m) No. 4 Timing Belt Cover Bolt ...................................... 78 (8.8) Valve Cover Bolt/Nut .................................................. 73 (8.3)
Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3. Replace timing belt tensioner if distance is not .315-.343" (8.00-8.80 mm).
538
TOYOTA 3.0L 6-Cylinder 2JZ, 1993-97 (Cont.)
TOYOTA 3.0L 6-Cylinder 2JZ, 1998

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L 6-Cyl. 2JZ-GE & 2JZ-GTE Supra 1998 ..................... 1 2.7 Hours ................. 250215 1 - With Turbo add .9 hours.
539

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

Removal (Turbo): Disconnect the negative battery cable. Remove battery and battery tray. Raise and support vehicle. Remove lower engine cover. Drain cooling system. Remove No. 2 air tube located below radiator. Remove air intake hose to air intake chamber for access to timing belt covers. Remove air cleaner duct located above radiator. Remove lower fan shroud and radiator assembly. On manual transmission models, remove drive belt tensioner damper, located between drive belt tensioner and stud on front of engine. See Fig. 1. Rotate drive belt tensioner clockwise. Remove drive belt. Place reference mating marks on fan clutch, water pump pulley, and water pump stud for reassembly reference. Remove cooling fan, fan clutch, and water pump pulley. Remove front bracket for power steering pump for access to timing belt covers. It may be necessary to remove pump pulley. Remove oil filler cap and No. 3 timing belt cover. See Fig. 1. Remove No. 2 timing belt cover and gasket. Remove drive belt tensioner.
CAUTION: DO NOT rotate crankshaft counterclockwise. Rotate crankshaft clockwise (as viewed from front of engine).
Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Timing marks on camshaft sprockets must align with timing marks on No. 4 timing belt cover. See Fig. 2. If not, rotate crankshaft clockwise one complete revolution (360 degrees).
CAUTION: 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 transmission 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 direction of timing belt guide installation for reassembly reference (flat side toward timing belt). See Fig. 1. Remove timing belt guide. If reusing timing belt, place mating reference marks on timing belt and crankshaft sprocket. Remove timing belt.
Fig. 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): Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.
Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3. Replace timing belt tensioner if distance is not .315-.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.
Installation (Turbo): Install idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 4. Install timing belt on crankshaft sprocket.
CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft sprocket align, and timing belt is installed in original direction of rotation.
Fig. 4: Aligning Camshaft & Crankshaft Tlming Marks
Install timing belt guide with cupped side away from crankshaft sprocket and flat side against timing belt. Install gaskets and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley and tighten pulley bolt to specification while holding crankshaft. See TORQUE SPECIFICATIONS. On automatic transmission models, reinstall clamps for oil cooler lines near crankshaft pulley. Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover.
Using spanner wrench, rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 2. Clean oil or water off of crankshaft sprocket and install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets.

Using press, apply pressure on rod of timing belt tensioner 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. See Fig. 5. Release press. Install dust boot on timing belt tensioner. Install timing belt tensioner. Alternately tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.

Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. DO NOT rotate crankshaft counterclockwise. Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. See Fig. 2. If timing marks are not aligned, remove timing belt and reinstall. To install remaining components, reverse removal procedure. 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 SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
541
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. Remove 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. Rotate crankshaft clockwise so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Timing marks on camshaft sprockets must align with timing marks on No. 4 timing belt cover. See Fig. 6. If not, rotate crankshaft clockwise one complete revolution (360 degrees).
CAUTION: Crankshaft must be correctly positioned by aligning sub-timing mark with 0 mark on timing belt cover to prevent valves from contacting pistons.
Fig. 7: Aligning Sub-Timing Marks (Non-Turbo)

Fig. 6: Aligning Camshaft Timing Marks (Non-Turbo)
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Rotate crankshaft pulley 60 degrees counterclockwise. Align sub-timing mark with 0 mark on timing belt cover. Perform 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.
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.
Using Handle (SST 09330-00021) and Pulley Holder (SST 09213-70010) or equivalent to hold crankshaft pulley, remove crankshaft pulley bolt. DO NOT allow the crankshaft pulley to rotate. Alternately loosen timing belt tensioner bolts. Remove bolts, timing belt tensioner, and dust boot. See Fig. 1. Remove timing belt from camshaft sprockets. Remove crankshaft pulley using gear puller. Remove No. 1 timing belt cover and gaskets. Note direction of timing belt guide installation for reassembly reference (flat side toward timing belt). See Fig. 1. Remove timing belt guide. If reusing timing belt, place mating reference marks on timing belt and crankshaft sprocket. Remove timing belt. Inspection (Non-Turbo): Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Check idler pulley and drive belt tensioner for smooth rotation. Replace idler pulley or drive belt tensioner if defective. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists.
If necessary, use spanner wrench to rotate camshaft sprockets so timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover. See Fig. 6. Install timing belt on camshaft sprockets. Ensure tension exists on timing belt between camshaft sprockets. Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 5. 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 tensioner. Alternately tighten timing belt tensioner bolts to specification. See TORQUE SPECIFICATIONS.
Hold timing belt tensioner body, and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3. Replace timing belt tensioner if distance is not .315-.346" (8.00-8.80 mm). Installation (Non-Turbo): Install idler pulley and plate washer (if removed). Apply Loctite 242 or equivalent on threads of idler pulley bolt. Install and tighten bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean and rotates smoothly, and idler pulley bracket moves freely. Using crankshaft pulley bolt, rotate crankshaft and align timing mark on crankshaft sprocket with timing mark on oil pump body. See Fig. 7, STEP 3. Clean oil or water off of crankshaft sprocket and install timing belt on crankshaft sprocket and around idler pulley.
CAUTION: If reusing timing belt, ensure reference marks on timing belt and crankshaft sprocket align, and timing belt is installed in original direction of rotation.
Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. Ensure timing marks on camshaft sprockets align with timing marks on No. 4 timing belt cover, and timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. If timing marks are not aligned, remove timing belt and reinstall. Tighten crankshaft pulley bolt to specification. Install No. 2 and No. 3 timing belt covers. To install remaining components, reverse removal procedure. Use care when installing drive belt tensioner bolts to avoid dropping bolts into timing belt cover. Ensure water pump and fan clutch reference marks are aligned. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 60 (81) Crankshaft Pulley Bolt ............................................ 243 (330) Drive Belt Tensioner Bolt ............................................ 15 (21) Drive Belt Tensioner Damper Bolt .................................. 15 (21) Fan Clutch-To-Water Pump Nut ................................. 12 (16) Idler Pulley Bolt ........................................................... 1 26 (35) Power Steering Pump Pulley Bolt Turbo ............................................................................ 32 (43) Power Steering Pump-To-Front Bracket (Non-Turbo) Right Side Bolt ........................................................... 2 29 (39) Left Side Bolt .............................................................. 2 42 (58) Timing Belt Tensioner Bolt ......................................... 20 (27) Water Pump Bolt ........................................................ 15 (21) INCH Lbs. (N.m) Fan-To-Fan Clutch Nuts ................................................ 65 (7.5) No. 1 & No. 2 Timing Belt Cover Bolt ................................ 71 (8) No. 4 Timing Belt Cover Bolt ...................................... 78 (8.8) 1 - Apply Loctite 242 or equivalent to bolt threads. 2 - Right and left side as viewed from rear of engine.
Install timing belt guide with cupped side away from crankshaft sprocket and flat side against timing belt. Install gaskets and No. 1 timing belt cover. Align crankshaft pulley key groove with crankshaft key. Install crankshaft pulley. Ensure sub-timing mark (60 degrees BTDC) of crankshaft pulley is aligned with 0 timing mark of No. 1 timing belt cover. See Fig. 7, STEP 4. Temporarily install crankshaft pulley bolt.
TOYOTA 2.5L & 3.0L V6 1988-97

TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.5L V6 Camry 1988-91 ................. 3.8 Hours .................. 250157 3.0L V6 Avalon 1995-97 ................. 3.0 Hours .................. 250257 Camry 1992-93 ................. 3.9 Hours .................. 250200 1994-97 ................. 3.0 Hours .................. 250257
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TIMING BELT
Removal (2.5L & 1992-93 3.0L V6): Disconnect negative battery cable. Remove cruise control actuator and vacuum pump. Remove power steering reservoir with hoses attached, and secure them aside. Raise and support vehicle. Remove right front wheel. Remove right lower engine cover. Remove all drive belts. Remove top braces on right engine mount at timing belt cover. Slightly raise engine to remove weight from right engine mount. Remove retaining bolts/nuts and right engine mount assembly. Remove spark plugs. Remove retaining bolts, No. 2 timing belt cover, gasket and right engine mount bracket. See Fig. 1. Note bolt length and location of No. 2 timing belt cover bolts for reassembly reference.
CAUTION: If timing belt is to be reused, mark direction of timing belt rotation and location on camshaft sprockets for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover.

544
TOYOTA 2.5L & 3.0L V6 1988-97 (Cont.)
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" (10.0110.49 mm). Installation (2.5L & 1992-93 3.0L V6): Install No. 1 idler pulley (if removed). Apply Loctite 242 on threads of No. 1 idler pulley retaining bolt. Install and tighten retaining bolt to specification. See TORQUE SPECIFICATIONS. Ensure idler pulley is clean, and pulley rotates smoothly. Install timing belt on crankshaft sprocket with installation mark on timing belt aligned with timing mark on crankshaft sprocket. See Fig. 2. Install timing belt guide with cupped side away from crankshaft sprocket. Install No. 1 timing belt cover and gasket. Align crankshaft key with key groove of crankshaft pulley and install crankshaft pulley. Tighten retaining bolt to specification.
CAUTION: If reusing timing belt, ensure timing mark on crankshaft sprocket is aligned with reference mark placed on timing belt, and timing belt is installed in original direction of rotation.
Rotate crankshaft clockwise so No. 1 cylinder is at TDC of compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Ensure timing marks on camshaft sprockets are aligned with timing marks on No. 3 timing belt cover. See Fig. 2. Remove retaining bolts and timing belt tensioner. Install Camshaft Sprocket Holder (SST 09278-54012) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets. Using Pulley Holder (SST 09213-54014) or equivalent, and Handle (SST 0933000021), hold crankshaft pulley, and remove retaining bolt. If timing belt is to be reused, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley is aligned with 0 mark on No.1 timing belt cover. Using puller, remove crankshaft pulley. DO NOT allow crankshaft to rotate. Remove No. 1 timing belt cover and gasket. If timing belt is to be reused, mark direction of belt rotation, and place reference marks on timing belt and crankshaft sprocket for reassembly reference. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide and timing belt. Remove idler pulleys (if necessary). Removal (1994-97 3.0L V6): Disconnect negative battery cable. Remove coolant reservoir. Raise and support vehicle. Remove right side front wheel. Remove right lower engine cover. Remove accessory drive belts. Remove engine stabilizer rod, engine mounting bracket and right engine mount brace, located near timing belt cover. Remove the alternator bracket for access to timing belt covers. Remove No. 2 timing belt cover. See Fig. 1. Use Pulley Holder (SST 09213-54015) or equivalent, and Handle (SST 0933000021) or equivalent, to hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 timing belt cover. See Fig. 1. Remove engine mounting bracket. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). Remove retaining bolts, timing belt tensioner and dust boot. Remove crankshaft pulley bolt from crankshaft. Install camshaft sprocket holder (SST 09278-54012) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets. Inspection (2.5L & 3.0L V6): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely. Replace damaged components. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body. Press rod against solid surface. Replace timing belt tensioner if rod moves.
Install No. 2 idler pulley. Tighten retaining bolt to specification. Ensure idler pulley rotates smoothly. Rotate crankshaft pulley so timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover. Rotate left camshaft so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2. Rotate right camshaft so knock pin hole in camshaft aligns with timing mark on No. 3 timing belt cover. See Fig. 2. If reusing timing belt, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover
Fig. 2: Aligning Timing Marks (2.5L & 1992-93 3.0L)
TOYOTA 2.5L & 3.0L V6 1988-97 (Cont.)

when timing mark on crankshaft pulley is aligned with 0 mark on No. 1 timing belt cover. Using camshaft sprocket holder, slightly rotate left camshaft sprocket clockwise, and install timing belt on camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket. Using camshaft sprocket holder, slightly rotate left camshaft sprocket, and align timing mark on camshaft sprocket with timing mark on No. 3 timing belt cover. Ensure tension exists on timing belt between crankshaft sprocket and left camshaft reference mark on timing belt with timing mark on right camshaft sprocket. Install right camshaft sprocket on camshaft with flange side toward cylinder head. Ensure timing mark on right camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 2.
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Using camshaft sprocket holder, slightly rotate right camshaft sprocket so knock pin hole in camshaft sprocket aligns with knock pin hole in camshaft. Install knock pin in right camshaft. Install right camshaft sprocket retaining bolt, and tighten it to specification. See TORQUE SPECIFICATIONS. Place washer on bottom side of timing belt tensioner. Using press, apply pressure on rod of timing belt tension until rod is retracted, and holes in rod and housing are aligned. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press, and install dust boot on timing belt tensioner. Install timing belt tensioner. Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS. Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise 2 full revolutions from TDC to TDC. Ensure timing marks on camshaft sprockets align with those on No. 3 timing belt cover. See Fig. 2.
Fig. 3: Aligning Timing Marks (1994-97 3.0L)
To install remaining components, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Installation (1994-97 3.0L V6): Install timing belt plate. Install and tighten bolt to specification. Install No. 1 and No. 2 idler pulleys (if removed). Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Using camshaft sprocket holder, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3. Align reference marks on timing belt with dot on crankshaft sprocket and timing marks on camshaft sprocket. Ensure front mark is pointing toward timing belt end of engine.
CAUTION: Ensure reference marks on timing belt align with timing mark on camshaft sprockets and dot on crankshaft sprocket when installing timing belt. Front mark must face toward timing belt end of engine.
Fig. 4: Identifying Timing Belt Reference Marks (1994-97 3.0L)
Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket, No. 2 idler pulley, right camshaft sprocket, and then on No. 1 idler pulley. Using press, apply pressure on rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. See Fig. 6. Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt.
546
TOYOTA 2.5L & 3.0L V6 1988-97 (Cont.)

TORQUE SPECIFICATIONS (2.5L V6) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 80 (109) Crankshaft Pulley Bolt ............................................ 181 (245) Engine Crossmember-To-Body Bolt .......................... 29 (39) Engine Mount Through-Bolt ........................................ 64 (87) Engine Mount-To-Engine Crossmember Bolt .................................................. 54 (73) Idler Pulley Bolt No. 1 Idler Pulley ....................................................... 25 (34) No. 2 Idler Pulley ....................................................... 29 (39) Idler Pulley Support Bolt ............................................. 13 (18) Right (Timing Belt Side) Engine Mount Bolt ........................................................................... 47 (64) Nut Bracket Side .......................................................... 38 (52) Body Side .............................................................. 65 (88) Timing Belt Tensioner Bolt ......................................... 20 (27) Water Pump Bolt ........................................................ 14 (19) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) No. 3 Timing Belt Cover Bolt ......................................... 65 (7) Valve Cover Nut ............................................................ 52 (6) TORQUE SPECIFICATIONS (3.0L V6) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 94 (127) Crankshaft Pulley Bolt ............................................ 159 (215) Front Engine Mount-To-Crossmember Bolt Toyota Motor Corporation Bolt .................................. 59 (80) Toyota Motor Manufacturing Bolt ............................... 49 (66) Front Engine Mount-To-Cylinder Block Bolt .................................................................. 47 (64) Power Steering Pump Bolt .......................................... 31 (42) Power Steering Pump Bracket To-Cylinder Head Bolt .............................................. 32 (43) Pulsation Damper ...................................................... 24 (33) Right Engine Mount Brace Bolt ................................... 23 (31) Stabilizer Bar Link-To Lower Control Arm Nut ............................................. 29 (39) Timing Belt Idler Pulleys No. 1 Idler Pulley Bolt ............................................... 25 (34) No. 2 Idler Pulley Bolt ............................................... 32 (43) Timing Belt Tensioner Bolt ......................................... 20 (27) Wheel Lug Nut .......................................................... 76 (103) INCH Lbs. (N.m) No. 1 & 2 Timing Belt Cover Bolt ................................ 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)
Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification. Using new gaskets, install No. 1 and No. 2 timing belt covers. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
TOYOTA 3.0L V6 1998-01

TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 1MZFE Avalon 1998-01 ................. 3.0 Hours .................. 250257 Camry & Camry Solara 1998-01 ................. 3.0 Hours .................. 250257 Highlander 2001 ...................... 3.8 Hours .................. 250257 Sienna 1998-01 ................. 3.8 Hours .................. 250257
547

Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. On Camry Solara, remove shock tower suspension brace. On all models, remove engine stabilizer rod, engine mounting bracket. Remove right engine mount brace, located near timing belt cover. Remove generator-to-engine bracket for access to timing belt covers. Using Pulley Holder (SST 09213-54015) or equivalent, and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using gear puller, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. Remove engine mounting bracket from front (timing belt end) of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide.

TIMING BELT
Removal (Avalon, Camry & Camry Solara): Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle.
Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Figs. 2 and 3. Ensure timing marks on camshaft sprockets are aligned with timing the mark on No. 3 timing belt cover. See Figs. 2 and 3. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 4. If not, place
548
TOYOTA 3.0L V6 1998-01 (Cont.)
Fig. 2: Aligning Timing Marks (1998)
Fig. 4: Identifying Timing Belt Reference Marks & Front Mark
Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing 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 Fig. 5. Replace timing belt tensioner if distance is not .394.425" (10.01-10.8 mm).

mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. 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 (Avalon, Camry & Camry Solara): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Check water pump for leaks or worn out bearing.
CAUTION: Never hold timing belt tensioner with pushrod facing downward.
Installation (Avalon, Camry & Camry Solara): Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Ensure idler pulleys are clean and rotate smoothly. Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Figs. 2 and 3. Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Figs. 2 and 3.
CAUTION: Clean timing belt sprockets before installing timing belt. Wipe off any oil or water with rag, DO NOT use any cleaning solvents.
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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 direction of timing belt guide installation for reassembly reference. Remove timing belt guide.
Fig. 6: Retracting Tlming Belt Tensloner Rod
Install timing belt on crankshaft sprocket, water pump pulley, left (front of vehicle side) camshaft sprocket, No. 2 idler pulley, right (firewall side) camshaft sprocket, and then on No. 1 idler pulley. If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. Using press, SLOWLY apply about 200-2200 lbs. (1001000 Kg) of pressure on push rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. See Fig. 6. Align holes in housing and push rod. Install hex wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove hex 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 reinstall. Remove crankshaft pulley bolt. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. Using new gaskets, install No. 1 and 2 timing belt covers. Ensure there are no gaps in gasket. Cut off any excess gasket. Install and tighten bolts to specification. Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten fasteners to specification. Connect engine ground strap. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. Removal (Highlander): Raise and support vehicle. Remove right side front wheel. Remove right fender apron seal. Remove accessory drive belts. Lower vehicle. Remove control (torque) rod from timing belt end of engine. Remove engine mount from timing belt end of engine. Remove generator mounting bracket from engine for access to timing belt covers. Using Pulley Holder (SST 09213-54015) or equivalent, and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt.
Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Fig. 3. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). 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 (Highlander): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Inspect water pump for leaks or worn out bearing.
Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner body with pushrod facing upward. Press rod against solid surface. Replace timing belt tensioner if push rod moves.
Installation (Highlander): Install No. 1 and 2 idler pulleys (if removed). Install and tighten bolts to specification. See TORQUE SPECIFICATIONS table. Ensure idler pulleys are clean and rotate smoothly. Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Fig. 3. Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3.
Install timing belt on crankshaft sprocket, water pump pulley, left (front of vehicle side) camshaft sprocket, No. 2 idler pulley, right (firewall side) camshaft sprocket, and then on No. 1 idler pulley. If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. Using press, SLOWLY apply about 200-2200 lbs. (1001000 Kg) of pressure on push rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 6. Align holes in housing and push rod. Install hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner.
550
Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove hex 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. 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 crankshaft sprocket and flat side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. 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 SPECIFICATIONS. Install engine mount and control (torque) rod to engine and body. Connect engine ground strap. Install accessory drive belts. Adjust drive belts to proper 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. Disconnect Data Link Connector 1 (DLC1) from right side engine mounting bracket. Disconnect engine coolant reservoir hose from water outlet. Disconnect ground strap connectors. Remove engine stabilizer rod and engine mounting bracket, located near timing belt cover. Remove generator-to-engine bracket for access to timing belt covers. Using Pulley Holder (SST 09213-54015) or equivalent, and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley. Remove No. 1 and 2 timing belt covers and gaskets. See Fig. 1. Remove engine mounting bracket from front of engine. Note direction of timing belt guide installation for reassembly reference. Remove timing belt guide.
Fig. 7: Exploded View Of Outer Cowl Top Panel (1998-00 Sienna)
Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Figs. 2 and 3. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. See Figs. 2 and 3. If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). If reusing old belt, ensure there are 3 installation marks and front arrow marked on belt. See Fig. 4. If not, place mating mark on belt where it contacts the crankshaft and camshaft sprockets. Also, mark belt with arrow showing direction of rotation. Alternately loosen 2 bolts, and remove timing belt tensioner and dust boot. Do NOT hold tensioner with push rod facing downward. Remove timing belt.
Fig. 8: Exploded View Of Outer Cowl Top Panel (2001 Sienna)

Inspection (Sienna): Inspect timing belt for damaged teeth, cracking or oil contamination. Ensure idler pulleys rotate freely and are not leaking oil. Replace damaged components. Inspect water pump for leaks or worn out bearing.
551
Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing 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 Fig. 5. Replace timing belt tensioner if distance is not .394.425" (10.01-10.8 mm).
Installation (Sienna): Install No. 1 and 2 idler pulleys (if removed). On No. 1 idler pulley bolt, coat threads with Loctite 242 or equivalent. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS table. Ensure idler pulleys are clean and rotate smoothly. Temporarily install crankshaft pulley bolt in crankshaft. If necessary, use crankshaft pulley bolt to rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. See Figs. 2 and 3. Using spanner wrench, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Figs. 2 and 3.
Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover. See Figs. 2 and 3. If all timing marks are not aligned, remove timing belt and reinstall. Remove crankshaft pulley bolt. Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install engine mounting bracket on front of cylinder block. Install and tighten bolts to specification. See TORQUE SPECIFICATIONS. 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. Align crankshaft key with key groove of crankshaft pulley. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install generator bracket. Install engine stabilizer rod and engine mounting bracket, located near timing belt cover. Connect engine ground strap. To install remaining components, reverse removal procedure. Tighten fasteners to specification. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt (Except Highlander) Left Hand (Front End of Vehicle Side) ......................... 92 (125) Right Hand (Firewall Side of Vehicle) ........................... 65 (88) Camshaft Sprocket Bolt (Highlander) ....................... 92 (125) Crankshaft Pulley Bolt ............................................ 159 (215) Engine Mount Bracket-to-Engine Bolt ............................. 21 (28) Engine Control (Torque) Rod Bolt .................................. 47 (64) Generator Adjusting Lock Bolt ........................................ 13 (18) Generator Pivot Bolt Except Avalon ............................................................... 38 (52) Avalon ........................................................................... 41 (56) Power Steering Pump Bolt .......................................... 32 (43) Power Steering Pump Bracket To-Cylinder Head Bolt .............................................. 32 (43) Right Engine Mount Brace Bolt ................................... 23 (31) Shock Tower Brace-to-Shock Tower Nuts Camry Solara .............................................................. 59 (80) Timing Belt Idler Pulleys No. 1 Idler Pulley Bolt .............................................. 1 25 (34) No. 2 Idler Pulley Bolt ............................................... 32 (43) Timing Belt Tensioner Bolt ......................................... 20 (27) Wheel Lug Nut .......................................................... 76 (103) Wiper Arm Nuts Sienna ......................................................................... 15 (20) INCH Lbs. (N.m) No. 1 & 2 Timing Belt Cover Bolt ................................ 75 (8.5) No. 3 Timing Belt Cover Bolt ...................................... 75 (8.5) Timing Belt Plate Bolt ................................................ 71 (8.0) Water Pump Bolt/Nut Except Sienna ............................................................. 71 (8.0) Sienna ........................................................................ 69 (7.8) 1 - Apply Loctite 242 or equivalent to bolt threads.
Install timing belt on crankshaft sprocket, water pump pulley, left (front of vehicle side) camshaft sprocket, No. 2 idler pulley, right (firewall side) camshaft sprocket, and then on No. 1 idler pulley. If reusing old belt, ensure belt installation marks align with camshaft and crankshaft sprocket marks. Ensure front (or rotation direction mark) points in correct direction. Using press, SLOWLY apply about 200-2200 lbs. (1001000 kg) of pressure on push rod of timing belt tension until rod is retracted and holes in rod and housing are aligned. See Fig. 6. Align holes in housing and push rod. Install hexagon wrench through housing and push rod hole to secure push rod. Release press and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specification. See TORQUE SPECIFICATIONS. Remove hex 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.
552
TOYOTA 3.0L V6 3V-ZE

Removal: Disconnect negative battery cable. Drain cooling system. Remove lower engine covers. Remove radiator. Remove all accessory drive belts. Remove power steering pump with hoses attached and secure aside (if equipped). Remove spark plugs. Disconnect hoses from air pipe.
NOTE If separating fluid coupling from fan bracket, place reference mark on fluid coupling and fan bracket for reassembly reference.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.0L V6 Pickup 1988-92 ................. 4.1 Hours .................. 250154 1993-95 ................. 4.1 Hours .................. 250240 T100 1993-94 ................. 4.1 Hours .................. 250240 4Runner 1988-92 ................. 4.1 Hours .................. 250154 1993-95 ............... 4.1 Hours .................. 250240

The manufacturer recommends the belt be replaced every 60,000 miles for severe operating conditions.
Remove coolant outlet. See Fig. 1. Remove fan. Remove spark plug wire clamps across front of No. 2 timing belt cover. Remove studs for coolant outlet from No. 2 idler pulley. Remove bolts, No. 2 timing belt cover and gaskets. See Fig. 1.
TOYOTA 3.0L V6 3V-ZE (Cont.)

CAUTION: If reusing timing belt, mark direction of timing belt rotation and ensure reference marks are on timing belt. See Fig. 2. If reference marks are not apparent, place reference mark on timing belt and all sprockets for reassembly reference. Also place reference mark on timing belt at upper edge of No. 1 timing belt cover with cylinder No. 1 at TDC on compression stroke. See Fig. 2.
553
Install timing belt on crankshaft sprocket with reference mark on timing belt aligned with reference mark (dot) on crankshaft sprocket. See Fig. 2. Install timing belt on water pump.
Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on right side when viewed from rear of engine. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Ensure timing marks on camshaft sprockets align with timing marks on No. 3 timing belt cover. See Fig. 3. If timing marks are not aligned, rotate crankshaft clockwise one complete revolution and recheck alignment. Remove bolts and timing belt tensioner with dust boot. Remove bolts/nuts, fan bracket and gasket. See Fig. 1. Install Camshaft Sprocket Holder (SST 09278-54012) or equivalent, in holes on front of right camshaft sprocket. Slightly rotate right camshaft sprocket clockwise to release tension on timing belt between camshaft sprockets. Remove timing belt from camshaft sprockets. Remove power steering belt pulley. Using Pulley Holder (SST 0921358012) and Handle (SST 09330-00021) or equivalent, hold crankshaft pulley. Remove crankshaft pulley bolt.
CAUTION: If reusing timing belt, ensure timing belt is installed in original direction of rotation and reference mark on timing belt aligns with reference mark (dot) on crankshaft sprocket.
NOTE: If reusing timing belt, ensure reference mark placed on timing belt aligns with upper edge of No. 1 timing belt cover when timing mark on crankshaft pulley aligns with 0 mark on No. 1 timing belt cover.
Using puller, remove crankshaft pulley. Remove bolts, No. 1 timing belt cover and gasket. Note direction of timing belt guide installation for reassembly reference. See Fig. 1. Remove timing belt guide. If reusing timing belt, mark direction of timing belt rotation. Ensure reference mark exists on timing belt at reference mark (dot) on crankshaft sprocket. See Fig. 2. If reference mark does not exist, install reference mark on timing belt in alignment with timing mark (dot) on crankshaft 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: Inspect timing belt for damaged teeth, cracking or oil contamination. Replace timing belt if damaged or contaminated. Inspect timing belt tensioner for oil leakage. Replace timing belt tensioner if oil leakage exists. Hold timing belt tensioner housing and press rod against solid surface. Replace timing belt tensioner if rod moves. Measure timing belt tensioner rod protrusion from end of 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 SPECIFICATIONS. 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.
Install timing belt guide with cupped side away from crankshaft sprocket and flat side against timing belt. Install No. 1 timing belt cover and gasket. Align groove of crankshaft pulley with crankshaft key. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See TORQUE SPECIFICATIONS. Install power steering belt pulley on crankshaft pulley. Rotate crankshaft so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with 0 mark on timing belt cover. Rotate left camshaft so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3. Rotate right camshaft so pin hole in camshaft aligns with timing mark on No. 3 timing belt cover. Pull timing belt outward (toward outside of cylinder block) at area near sprocket on water pump. Ensure reference mark on timing belt aligns with upper edge of No. 1 timing belt cover when crankshaft pulley timing mark is aligned with 0 mark on No. 1 timing belt cover. See Fig. 2. Using camshaft sprocket holder, slightly rotate left camshaft sprocket clockwise. Install timing belt on left camshaft sprocket. Ensure reference mark on timing belt aligns with timing mark on camshaft sprocket. See Fig. 2. Using camshaft sprocket holder, slightly rotate left camshaft sprocket and align timing mark on camshaft sprocket with timing mark on No. 3 timing belt cover. See Fig. 3. Ensure tension exists on timing belt between crankshaft sprocket and left camshaft sprocket.
Fig. 2: Identifying Timing Belt Reference Marks
554
TOYOTA 3.0L V6 3V-ZE (Cont.)
Align reference mark on timing belt with timing mark on right camshaft sprocket. See Fig. 2. Ensure timing mark on right camshaft sprocket aligns with timing mark on No. 3 timing belt cover. See Fig. 3. Using new gasket, install fan bracket. Install and tighten bolt/nuts to specification. See TORQUE SPECIFICATIONS. Using press, apply pressure on rod of timing belt tension 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. See Fig. 5. Release press. Install dust boot on end of timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts. See TORQUE SPECIFICATIONS.
Install No. 2 idler pulley gasket. See Fig. 1. Install No. 2 timing belt cover and gaskets. Install crankshaft pulley. To install remaining components, reverse removal procedure. Apply sealant on coolant outlet before installing. Tighten all bolts/nuts to specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Alternator Bracket-To-Cylinder Head Bolt ................... 27 (37) Camshaft Sprocket Bolt ............................................ 80 (109) Crankshaft Pulley Bolt ........................................ 181 (245) Spark Plug .................................................................. 13 (18) Timing Belt Tensioner Bolt ......................................... 20 (27) INCH Lbs. (N.m) Camshaft Housing Rear Cover Bolt .......................... 43 (4.9) Fan Retaining Nut ..................................................... 48 (5.4) No. 3 Timing Belt Cover Bolt ...................................... 73 (8.3) No. 4 Timing Belt Cover Bolt ...................................... 73 (8.3) Valve Cover Bolt ......................................................... 48 (5.4)
Remove hexagon wrench from timing belt tensioner. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure crankshaft pulley timing mark aligns with 0 mark on No. 1 timing belt cover. Ensure timing marks on camshaft sprockets align with timing 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 3.4L V6
TIMING BELT APPLICATION Application Labor Time Belt Part No. 3.4L V6 Tacoma 1995-01 ................ 1 2.4 Hours ................. 250271 T100 1995-98 ................ 1 2.4 Hours ................. 250271 Tundra 2000-01 ................ 1 2.8 Hours ................. 250271 4Runner 1996-01 ................ 1 2.4 Hours ................. 250271 1 - With Air Cond. add .4 hours.
555
Inspection: Inspect idler pulley for oil leakage. Inspect idle pulley bearing for smoothness. Replace if defective.
NOTE: DO NOT hold tensioner with push rod facing downward.
Inspect timing belt tensioner for oil leakage. Hold tensioner (push rod facing upward) with both hands and pushing push rod against a hard surface. If push rod moves, replace tensioner. Measure protrusion of push rod. If protrusion is not .394-.425" (10.0-10.8 mm), replace tensioner. See Fig. 4.
NOTE: Only wipe timing belt pulleys and sprockets clean. Do NOT use any cleaning agents or solvents.

1990-97 model years, the manufacturer recommends the belt be replaced every 60,000 miles under severe driving conditions. For 1998-01 model years, the manufacturer recommends the belt be replaced every 90,000 miles.
Installation: Ensure No. 1 cylinder is at TDC of compression stroke by aligning crankshaft sprocket with mark on oil pump body. See Fig. 5. Ensure camshaft sprockets are still aligned at TDC positions. See Fig. 6.
NOTE: Install timing belt when engine is cold.

TIMING BELT
Removal: Remove lower engine cover (if equipped). Drain cooling system. Disconnect upper radiator hose. Remove accessory drive belts. Disconnect 2 power steering hoses from the air intake chamber and resonator. Remove power steering pump driver belt. Remove power steering pump with hoses attached and hang out of way. Remove A/C compressor with hoses attached and hang out of way. Loosen cooling fan with fluid coupling and fan pulleys. Remove lower fan shroud. Remove fan and fan pulleys. Remove A/C compressor bracket from engine. Remove engine oil dipstick and tube. Disconnect electrical connectors and clamps from upper timing belt cover. Remove upper timing belt cover. See Fig. 2. Remove power steering pump adjusting strut. Remove fan bracket.
NOTE: Always turn crankshaft clockwise as viewed from timing belt end of engine.
Ensure No. 1 cylinder is set at TDC of compression stroke (crankshaft pulley groove aligned with zero mark on lower timing belt cover). Use Pulley Holder (SST 09213-54015) or equivalent to hold crankshaft pulley. Remove crankshaft pulley bolt. Use gear puller to remove crankshaft pulley. Remove lower timing belt cover. Noting installed position for reassembly reference, remove timing belt guide. Check that the crankshaft sprocket timing mark is aligned with mark on oil pump body. Check that camshaft sprocket timing marks are aligned with timing marks on back cover. See Fig. 1. If marks are not aligned, temporarily install crankshaft pulley. Turn crankshaft one revolution in direction of rotation (clockwise). Recheck alignment of timing marks. If reusing timing belt, check that there are 3 installation marks and a front mark on belt. See Fig. 3. If marks are missing, place 3 new marks on belt to match position of belt on camshaft and crankshaft pulleys. Also place front facing arrow on belt. Remove timing belt tensioner. DO NOT hold tensioner with push rod facing downward. Remove timing belt.
Install timing belt on left (drivers side) camshaft pulley, No. 2 idler pulley, right (passengers side) camshaft pulley, water pump pulley, crankshaft pulley and No. 1 idler pulley. If reusing old belt, ensure all reference marks are aligned. Using a press, SLOWLY press in tensioner push rod with pressure of 200-2205 lbs. (100-1000 N.m). Align holes of push rod and housing and insert a 1.27 mm hexagon wrench. Release pressure on push rod. See Fig. 7. Install dust boot on tensioner. Install tensioner and alternately tighten 2 bolts to specification. See TORQUE SPECIFICATIONS table. Remove hexagon wrench from tensioner. Ensure timing marks of crankshaft timing pulley and oil pump body are aligned and check camshaft timing marks. See Fig. 1. Install timing belt guide with cup facing outward. Install lower timing belt guide with new gaskets. Install crankshaft pulley. Install crankshaft pulley bolt and tighten to specification. Turn crankshaft clockwise 2 revolutions, from TDC to TDC. Ensure V notch (TDC mark) on crankshaft pulley aligns with 0 mark on lower timing belt cover. Ensure camshaft timing marks are still aligned with marks on rear cover. Install fan bracket. Install power steering adjusting strut. Install upper timing belt cover with new gasket. Install generator drive belt. Install oil dipstick tube. Install A/C com-
556
TOYOTA 3.4L V6 (Cont.)
TOYOTA 3.4L V6 (Cont.)
557
Fig. 3: Timing Belt Installation Marks
Fig. 7: Retracting Timing Belt Tensioner Push Rod
pressor bracket and A/C compressor. Install power steering 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. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS table. Fill cooling system and bleed air from system. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS
Fig. 4: Measuring Tensioner Push Rod Protrusion
Application Ft. Lbs. (N.m) A/C Compressor-to-Bracket ......................................... 18 (25) A/C Compressor Bracket-to-Engine ........................... 35 (47) Camshaft Sprocket Bolt ............................................ 81 (110) Crankshaft Pulley Bolt 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) Timing Belt Tensioner Bolt ......................................... 20 (27) Water Pump Bolt ............................................................ 14 (20) INCH Lbs. (N.m) Fan Retaining Nut ..................................................... 48 (5.4) Lower Timing Belt Cover Bolt ....................................... 80 (9) Upper Timing Belt Cover Bolt ....................................... 80 (9) Oil Dipstick Tube ............................................................ 71 (8)
558
VOLKSWAGEN 1.5L, 1.6L & 1.7L 4-Cylinder

termediate shaft sprocket aligns with V notch on crankshaft pulley. See Figs. 1 and 2. Use care not to move any sprocket. Fit belt on bottom first and then at top. There should be no slack between sprockets. Tighten tensioner so belt can just be twisted 90 degrees halfway between camshaft and intermediate sprockets. Tighten adjuster lock nut. Reverse removal procedure for remaining components. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Bolts .............................................. 15 (20) Crankshaft Sprocket Bolt ............................................ 59 (80) Intermediate Sprocket Bolt 1 ....................................... 59 (80) Timing Belt Tensioner Lock Nut ................................. 33 (45) Water Pump Bolts ...................................................... 15 (20) Water Pump Pulley Bolts ............................................ 15 (20)
1
TIMING BELT APPLICATION Application 1.5L 4-Cyl. Dasher 1974-75 .......... 1.8 Hrs. ...... Rabbit 1975-79 .......... 1.8 Hrs. ...... Scirocco 1978 ............... 1.8 Hrs. ...... 1.6L 4-Cyl. Dasher 1976-80 .......... 1.8 Hrs. ...... Jetta 1980 ............... 1.8 Hrs. ...... Pickup 1980 ............... 1.8 Hrs. ...... Rabbit 1980 ............... 1.8 Hrs. ...... Scirocco 1976-80 .......... 1.8 Hrs. ...... 1.7L 4-Cyl. Jetta 1981-84 .......... 1.8 Hrs. ...... Quantum 1982-83 .......... 1.8 Hrs. ...... Rabbit 1981-84 .......... 1.8 Hrs. ...... Rabbit Pickup 1981-83 .......... 1.8 Hrs. ...... Scirocco 1981-83 .......... 1.8 Hrs. ......
2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017
- Use Loctite.
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 engine. Installation: Rotate camshaft sprocket until index punch mark on camshaft sprocket is lined up with top surface of valve cover mounting flange on spark plug side of head. Rotate crankshaft and intermediate shaft until index punch mark on in-
Fig. 2: Aligning Camshaft With Cylinder Head Flange
559 VOLKSWAGEN *1.5L & 1.6L 4-Cylinder Diesel & Turbo Diesel TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.5L 4-Cyl. Diesel Dasher 1979-80 ..................... 1.5 Hours .............. 250043 Rabbit 1977-80 ..................... 2.8 Hours .............. 250043 Rabbit Pickup 1980 .......................... 2.8 Hours .............. 250043 1.6L 4-Cyl. Diesel & Turbo Diesel Dasher 1981 .......................... 1.5 Hours ............. 250043 Golf 1985-87 ..................... 2.8 Hours .............. 250043 1988-92 (Canadian) .. 2.2 Hours .............. 250043 Jetta 1981-86 ..................... 2.8 Hours .............. 250043 1986 (Canadian) ....... 2.8 Hours .............. 250043 1989-92 ..................... 2.2 Hours .............. 250043 1988-92 (Canadian) .. 2.2 Hours .............. 250043 Quantum 1982-86 ..................... 2.0 Hours .............. 250043 Rabbit 1981-84 ..................... 1.5 Hours .............. 250043 Rabbit Pickup 1981-83 ..................... 2.8 Hours .............. 250043 Vanagon 1982 .......................... 2.8 Hours .............. 250043
Removal: Disconnect negative battery cable. Loosen alternator and remove drive belt. Remove crankshaft drive belt pulley. Remove air cleaner and ducting. Remove timing belt and cylinder head cover. Remove timing plug on top of bell housing. Rotate engine to bring No. 1 cylinder to TDC. Check that TDC mark on flywheel is aligned with reference. Using Setting Bar (2065A for Vanagon, 2065 for other models) or equivalent, lock camshaft in position. See Fig. 1. Align tool by turning camshaft until one end of tool touches cylinder head. Measure gap at other end with feeler gauge. Insert feeler gauges of 1/2 thickness measured between tool and cylinder head at each end of tool. Lock injection pump sprocket at TDC with Special Pin (2064) or equivalent. Loosen belt tensioner and remove timing belt from sprockets.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed.

Installation: Ensure that flywheel is still aligned with TDC mark. With camshaft and injection pump locked in place, loosen camshaft sprocket bolt 1/2 turn. Lightly tap camshaft gear loose from camshaft. Install drive belt so there is no slack between camshaft sprocket and injection pump and injection pump and crankshaft sprocket. Tighten tension adjuster to keep belt firmly in place. Remove injection pump locking pin. Adjust belt tension by turning tensioner until scale reads 12-13 on Tension Gauge (210) or equivalent. See Fig. 2. Tighten camshaft sprocket bolt and tensioner adjuster lock nut. Remove lock from camshaft. Turn crankshaft 2 revolutions in direction of engine rotation. Using a rubber hammer, strike belt once between camshaft sprocket and injection pump sprocket. Recheck belt tension and install remaining components in reverse order of removal. Check injection pump timing. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 33 (45) Crankshaft Pulley Bolts .............................................. 15 (20) Crankshaft Sprocket Bolt Except Vanagon ...................................................... 81 (110) Vanagon .............................................................. 110 (150) Intermediate Sprocket Bolt .......................................... 33 (45) Timing Belt Tensioner Lock Nut ................................. 33 (45) Water Pump Pulley Bolt .............................................. 15 (20)

TIMING BELT
NOTE: Sprockets do not have to be removed to replace drive 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 *1.8L 4-Cylinder Beetle, 1999-01

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cylinder DOHC Beetle (APH & AWV Engines) 1999-01 ................. 2.7 Hours .................. 250306
561

The manufacturer suggests the timing belt AND tensioner be replaced at 105,000 mile intervals.
Courtesy of Volkswagen United States, Inc.

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 serpentine 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 serpentine drive belt. Remove serpentine drive belt tensioner.
NOTE: On vehicles without headlight cleaning system, Connecting Rod Support (3090) can also be used to secure tensioner.
Fig. 2: Releasing Serpentine Drive Belt Tension
Fig. 3: Setting Crankshaft To TDC (Manual Transmission)
Rotate crankshaft so that No. 1 cylinder is at TDC of compression 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 engine bracket from engine block. See Fig. 6. If reusing old timing belt, mark timing belt with arrow to indicate original direction of rotation.
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 Locking Pin (T40011) or drill bit can be inserted through the tensioner body, locking the tensioner in place. Remove timing belt. Turn crankshaft back just slightly to ensure that crankshaft is not at TDC for any cylinder.
NOTE: When turning camshaft, crankshaft must not be at TDC or there is a potential for valves to contact pistons. Install timing belt when engine is cold or lukewarm.
Fig. 8: Locating Engine Bracket-To-Block Bolts
Installation: Ensure crankshaft is still at TDC of compression stroke for No. 1 cylinder. Align timing marks on camshaft sprocket with mark on cylinder head cover. See Fig. 5. Install timing belt around crankshaft sprocket. If installing used belt, ensure it is installed in original direction of rotation. Install lower timing belt guard. Install crankshaft pulley and tighten bolts to specification. See TORQUE SPECIFICATIONS. Place timing belt on water pump, tensioner pulley and camshaft sprocket. Remove Locking Pin (T40011) or drill bit. Unscrew Tensioning Bolt (T10092). See Fig. 6.
Turn crankshaft 2 revolutions and check that camshaft and crankshaft marks align properly. See Fig. 5. Install middle and upper timing belt covers. Tighten bolts to specification. See TORQUE SPECIFICATIONS. Install engine mount bracket to block. Install engine mount to engine bracket and body using NEW bolts. Adjust engine mount clearance. See Fig. 9. Remove engine support bridge or floor jack. Install 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. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS.
VOLKSWAGEN *1.8L 4-Cylinder Beetle, 1999-01 (Cont.)

563
Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .................................................. 59 (80) Crankshaft Pulley Bolt ................................................... 18 (25) Crankshaft Sprocket Center Bolt 1 Step 1 ........................................................................... 66 (90) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) Engine Mount Bracket-To-Engine ................................... 33 (45) Engine Mount-To-Body 1 Step 1 ........................................................................... 30 (40) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) Engine Mount-To-Engine Bracket 1 Step 1 ........................................................................... 44 (60) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) Serpentine Drive Belt Tensioner Bolt ............................ 18 (25) Timing Belt Cover Bolt ................................................... 15 (20) Timing Belt Idler Pulley Bolt ............................................ 15 (20) Timing Belt Tensioner Mount Bolt ................................... 11 (15) Timing Belt Tensioner Pulley Bolt ............................... 18 (25) Water Pump Bolt ............................................................ 11 (15) 1 Replace bolts if loosened or removed.
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.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cylinder DOHC (AEB & ATW Engines) Passat 1998-00 152 Tooth Belt ... 3.1 Hours .................. 250291 153 Tooth Belt ... 3.1 Hours .................. 250317

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.
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 carrier-to-side panel bolts. Insert Lock Carrier Guide (3369) into hole on drivers side of vehicle. Slide lock carrier forward on lock carrier guides. On vehicles with A/C, mark direction of rotation on belt, and remove A/C drive belt. On all vehicles, rotate accessory drive belt tensioner clockwise to remove tension from belt. Mark belt with rotation direction and remove accessory drive belt. See Fig. 1. Remove accessory drive belt tensioner pulley and lever. Turn crankshaft to TDC of compression stroke on No. 1 cylinder. See Fig. 2. Remove crankshaft pulley. It is NOT necessary to remove center crankshaft pulley center bolt. Remove upper and lower timing belt covers. Loosen timing belt tensioner lever bolt. If reusing timing belt, mark belt with arrow to indicate direction of rotation. Remove timing belt.
NOTE: When turning camshaft, crankshaft must not be at TDC or there is a potential for valves to contact pistons. Install timing belt when engine is cold or lukewarm.
Installation: Align timing marks on camshaft sprocket with mark on cylinder head cover. See Fig. 2. Ensure crankshaft is still at TDC position. Install timing belt around crankshaft sprocket. Temporarily install crankshaft pulley to ensure crankshaft is still at TDC of compression stroke for No. 1 cylinder. Place timing belt on intermediate shaft sprocket, tensioner pulley and camshaft sprocket. To tension timing belt, use spanner wrench to rotate tensioner pulley clockwise until tensioner piston No. 1 is fully extended, and tensioner piston No. 2 lifts about .040 (1 mm). See Fig. 3. Tighten tensioner pulley bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft 2 revolutions. Make sure camshaft and crankshaft timing marks are aligned.
VOLKSWAGEN *1.8L 4-Cylinder Passat, 1998-2000 (Cont.)
565
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 specification. See TORQUE SPECIFICATIONS. Install accessory drive belt tensioner. Install accessory drive belt. Install the A/C compressor drive belt (if equipped). Ensure used belts are installed in original direction of rotation. Install lock carrier in original location. Install bumper and bumper cover. TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m) Accessory Drive Belt Tensioner Bolt .............................. 18 (25) A/C Drive Belt Tensioner Bolt ......................................... 22 (30) Bumper Carrier-To-Impact Damper Vertical Bolt ................................................................... 15 (20) Camshaft Sprocket Bolt .................................................. 59 (80) Crankshaft Pulley Bolt ................................................... 18 (25) Impact Damper-To-Lock Carrier Bolt ............................. 68 (50) Lock Carrier Front Support Bolt ......................................................... 37 (50) Timing Belt Tensioner Pulley Bolt ............................... 18 (25) INCH Lbs. (N.m) Bumper Guide-To-Side Panel Bolt ................................... 18 (2) Lock Carrier-To-Side Panel Bolt ....................................... 71 (8) Timing Belt Cover Bolt ................................................... 89 (10) Timing Belt Tensioner Bolt ......................................... 89 (10)
Fig. 5: Exploded View Of Bumper Assembly
566
VOLKSWAGEN *1.8L 4-Cylinder Passat, 2000-01
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cylinder DOHC (AUG & AWM Engines) Passat 2000-01 152 Tooth Belt ... 3.1 Hours .................. 250291 153 Tooth Belt ... 3.1 Hours .................. 250317

For 2000-01 model year, the manufacturer suggests the timing 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 harnesses. Separate hood release lever from bumper cover. Remove front bumper cover. See Fig. 1. Remove bumper beam. Remove air intake duct from air cleaner housing. Remove support bolts from lock carrier assembly. See Fig. 3. Install Support Tool (3369) through lock carrier to body. Remove oil cooler from lock carrier assembly. Move lock carrier forward on support tools.
Fig. 2: Removing Front Bumper Cover (From October, 2000)
For vehicles manufacturered from October, 2000, remove bumper cover from bumper carrier. See Fig. 2. Remove noise insulation panel from under engine compartment. Remove air intake duct at lock carrier. Remove bolts from front of bumper carrier. See Fig. 4. Install guide rods on right and left sides. Pull lock carrier forward about 4 (10 cm) on guide rods into service position. 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: DO NOT hang condenser or oil cooler from their lines.
CAUTION: Vibration damper outer bolts and center bolt are torqueto-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 housing. Insert Tensioning Bolt (T10092) into timing belt tensioner bracket. See Fig. 7. Turn tensioning bolt just enough so that holes in tensioner piston rod and housing align. Insert Locking Pin (T40011) into holes to secure tensioner in place. 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 *1.8L 4-Cylinder Passat, 2000-01 (Cont.)
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. Turn crankshaft 2 revolutions in normal direction of rotation. 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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Bumper Carrier-To-Impact Absorber Vertical Bolt ................................................................... 15 (20) Camshaft Sprocket Bolt .................................................. 50 (65) Crankshaft Pulley Center Bolt 1 Step 1 ........................................................................... 66 (90) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) Idler Pulley Bolt .............................................................. 18 (25) Impact Damper-To-Lock Carrier Bolt (From Oct. 2000) ......................................... 68 (50) Lock Carrier Front Support Bolt ......................................................... 37 (50) Timing Belt Tensioner Bolt ............................................ 11 (15) Serpentine Drive Belt Tensioner Bolt ............................ 18 (25) Timing Belt Tensioner Pulley Bolt ............................... 20 (27) Water Pump Bolt ............................................................ 11 (15) INCH Lbs. (N.m) Bumper Guide-To-Side Panel Bolt ................................... 18 (2) Lock Carrier-To-Side Panel Bolt ....................................... 71 (8) Timing Belt Cover Bolt 1 ..................................................................................... 89 (10) Vibration Damper Bolt 1 Step 1 ........................................................................... 89 (10) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) 1 Replace bolt if loosened or removed.
Fig. 3: Moving Lock Carrier To Service Position (Up To September, 2000)
Fig. 4: Moving Lock Carrier To Service Position (From October, 2000) NOTE: When turning camshaft, crankshaft must not be at TDC or there is a potential for valves to contact pistons. Install timing belt when engine is cold or lukewarm.
Installation: Align timing marks on camshaft sprocket with mark on cylinder 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 specification. See TORQUE SPECIFICATIONS. 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 (Cont.)
Fig. 7: Installing Timing Belt Tensioner Locking Pin
VOLKSWAGEN 1.8L 4-Cylinder SOHC, 1983-93

TIMING BELT APPLICATION Labor Application Time 1.8L 4-Cyl. SOHC Cabriolet 1985-93 .......... 1.8 Hrs. ...... Corrado 1990-92 .......... 1.8 Hrs. ...... Fox 1987-93 .......... 1.8 Hrs. ...... Golf 1985-92 .......... 1.8 Hrs. ...... Golf (Canadian) 1993-95 .......... 1.8 Hrs. ...... GTI 1985-92 .......... 1.8 Hrs. ...... Jetta 1984-92 .......... 1.8 Hrs. ...... Jetta (Canadian) 1993-95 .......... 1.8 Hrs. ...... Passat (Canadian) 1992-94 .......... 1.8 Hrs. ...... Quantum 1985 ............... 1.8 Hrs. ...... Rabbit 1983-84 .......... 1.8 Hrs. ...... Scirocco 1983-89 .......... 1.8 Hrs. ...... Component Kit No. Belt Part No.
569
2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017 2520170 ........ 250017
With intermediate shaft/ignition rotor positioned, rotate crankshaft and align mark on crankshaft pulley with mark on intermediate shaft sprocket. Position camshaft sprocket mark even with valve cover surface. See Fig. 3. Install timing belt. Rotate tensioner clockwise to tighten belt and install lock nut. Proper deflection is achieved when longest span of belt between sprockets can be twisted 90 degrees. See Fig. 4. By hand, rotate crankshaft 2 turns and check timing mark alignment. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Bracket-To-Engine Bolt ........................................ 22 (30) Crankshaft Timing Sprocket Bolt ................................ 66 (90) Intermediate Shaft Sprocket Bolt ................................. 59 (80) Lower Pulley Bolt ........................................................ 15 (20) Timing Belt Tensioner Nut .......................................... 33 (45) Water Pump Pulley Bolt .............................................. 15 (20) INCH Lbs. (N.m) Valve Cover Retaining Nut .......................................... 89 (10) Water Pump-To-Housing ........................................... 89 (10)


TIMING BELT
Removal: Disconnect negative battery cable. Match mark all components to ensure reassembly in original position. See Fig. 1. DO NOT turn crankshaft with belt removed. Valve damage may result. Remove upper drive belt cover, drive belt, and pulley. Remove timing belt guide, if equipped. Loosen belt tensioner. Remove vibration damper. Remove lower belt cover. Remove timing belt. Installation: Align flywheel/flexplate 0 mark with pointer. This is TDC. Remove distributor cap and check position of ignition rotor. Rotate intermediate shaft and position ignition rotor at No. 1 cylinder mark on housing. See Fig. 2.
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 *1.8L & 2.0L 4-Cylinder DOHC

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cyl. - DOHC Cabriolet 1985-89 ................. 1.8 Hours .................. 250292 Golf & GTI 1985-89 ................. 1.8 Hours .................. 250292 Jetta 1985-89 ................. 1.8 Hours .................. 250292 Scirocco (Canadian) 1988-89 ................. 1.8 Hours .................. 250292 Scirocco 1985-88 ................. 1.8 Hours .................. 250292 2.0L 4-Cyl. - DOHC GTI 1990-92 ................. 1.8 Hours .................. 250292 Jetta 1990-92 ................. 1.8 Hours .................. 250292 Passat 1990-92 ................. 1.8 Hours .................. 250292
571


TIMING BELT
Removal: Disconnect negative battery cable. Match mark all components to ensure reassembly to original position. Remove accessory drive belts. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Remove fan belt and water pump pulleys. See Fig. 1. Remove timing belt covers. Remove tensioner pulley. Remove timing belt. 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 Tension Scale (VW 210) or equivalent, reads 13-14. Rotate crankshaft 2 revolutions and check timing mark alignment. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges.
572
VOLKSWAGEN 1.8L & 2.0L 4-Cylinder DOHC (Cont.)

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Crankshaft Pulley Nut ................................................. 15 (20) Crankshaft Sprocket Bolt 16-Valve ................................................................ 148 (200) Intermediate Shaft Sprocket Bolt 16-Valve .................................................................... 48 (65) Timing Belt Tensioner Pulley Nut ............................... 33 (45) Water Pump Pulley ..................................................... 15 (20) INCH Lbs. (N.m) Upper & Lower Timing Belt Cover Bolt ......................... 53 (6) Water Pump-To-Housing ........................................... 84 (10)
Fig. 4: Proper Timing Belt Tension
VOLKSWAGEN *1.9L 4-Cylinder Turbo Diesel, 1993-98

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.9L 4-Cylinder Turbo Diesel Golf (Engine Code AAZ, AHU & 1Z) 1 1993-95 ................. 2.8 Hours .................. 250242 1996-97 ................. 2.2 Hours .................. 250242 Jetta (Engine Code AAZ, AHU & 1Z) 1 1993-95 ................. 2.8 Hours .................. 250242 1996-98 ................. 2.2 Hours .................. 250242 Passat (Engine Code AAZ, AHH & 1Z) 1 1994-99 ................. 2.2 Hours .................. 250242 1 - Code is stamped on pad on engine block between diesel injection pump and exhaust manifold. Engine code is also included on vehicle data plate and timing belt cover.
573
mension between setting bar and one side of cylinder head. Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of same dimension between other end of bar and cylinder head. Lock injection pump in place using Lock Pin (2064). See Fig. 5. Loosen timing belt tensioner. Remove crankshaft vibration damper. Remove the lower timing belt cover. See Fig. 3. If reusing old timing belt, mark belt with arrow to indication original direction of rotation. Move timing belt tensioner, and remove timing belt. Installation (Golf & Jetta w/AAZ Engine, Up To Sept., 1994): Ensure TDC mark on flywheel and transmission mating flange are still aligned. See Fig. 2.
NOTE: Use spanner wrench to hold camshaft sprocket while loosening center bolt. Do not use camshaft setting bar to hold camshaft sprocket.

The manufacturer recommends the belt AND tensioner be replaced at 60,000 mile intervals.

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. Remove 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. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Flywheel TDC mark must be aligned to mark on transmission mating flange. See Fig. 2. Lock camshaft in place with Setting Bar (2065A) installed on rear of camshaft. See Fig. 4. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. Divide this feeler gauge dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head diTensioner Tool (3299)
Loosen camshaft sprocket bolt about 1/2 turn. Insert pin punch through hole in rear of timing belt cover until it contacts rear of camshaft sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft sprocket on camshaft taper. With Camshaft Setting Bar (2065A) in place on rear of camshaft and crankshaft at TDC, install timing belt on engine. If reusing old belt, ensure belt is installed in original direction of rotation. Remove Lock Pin (2064) from injection pump sprocket.
Fig. 2: Locating TDC Mark On Flywheel/Flexplate

95B59106 Courtesy of Volkswagen United States, Inc.
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 tension belt. Install Tension Tool (VW210) set to 12 to 13. Measure tension midway between camshaft sprocket and injection pump sprocket. Tighten lock nut on timing belt tensioner to 33 ft. lbs. (45 N.m). On models with semiautomatic timing belt tensioner, install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft. lbs. (20 N.m). On all models, tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. Remove setting bar from camshaft. Turn crankshaft 2 revolutions in normal direction of rotation. Recheck timing belt tension.
Fig. 5: Locking Diesel Fuel Injection Pump Sprocket (AHU & 1Z Engines; AAZ Engines Up To Sept. 1994)
On models with semiautomatic tensioner, apply thumb pressure to timing belt. Notched and raised portions of timing belt tensioner must move apart. Release thumb pressure on belt. Tensioner must back to its original position (raised and notched portions aligned). If not, replace tensioner. On all models, install timing belt covers. Install vibration damper and belt pulleys (if removed). Install accessory drive belts. To prevent damage to serpentine belt, install in original direction of rotation.
575 VOLKSWAGEN *1.9L 4-Cylinder Turbo Diesel, 1993-98 (Cont.)
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 pulley. On all models, remove crankshaft vibration damper. Remove the lower timing belt cover. See Fig. 3. If reusing old timing belt, mark belt with arrow to indication original direction of rotation. Move timing belt tensioner, 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.
Fig. 7: Adjusting Timing Belt Tension (Semi-Automatic Timing Belt Tensioner)
Install valve cover. On engine code AAZ, check fuel injection delivery. Consult service information for procedure.
CAUTION: Timing belt replacement for Passat (1Z engine) requires using factory scan tool VAG 1551/1552 to check injection pump start of delivery after timing belt is installed.
Removal (Golf, Jetta & Passat w/AHU & 1Z Engines; w/AAZ Engine, From Oct., 1994): On models with tensioner, install Tensioner Tool (3299) and rotate clockwise. Mark serpentine belt with arrow to indicate rotation direction, and remove belt. See Fig. 1. Remove 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. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. Flywheel TDC mark must be aligned to mark on transmission mating flange. Lock camshaft in place with Setting Bar (2065A) installed on rear of camshaft. See Fig. 4. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. Divide this feeler gauge dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and one side of cylinder head.
Loosen camshaft sprocket bolt about 1/2 turn. Insert pin punch through hole in rear of timing belt cover until it contacts rear of camshaft sprocket. LIGHTLY tap pin punch with hammer to loosen camshaft sprocket on camshaft taper. With Camshaft Setting Bar (2065A) in place on rear of camshaft and crankshaft at TDC, install timing belt on engine. If reusing old belt, ensure belt is installed in original direction of rotation. Install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft. lbs. (20 N.m). Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. Tighten injection pump sprocket mounting bolt(s). Remove setting bar from camshaft. Remove lock pin from injection pump. Rotate crankshaft 2 revolutions in normal direction of rotation. Set No. 1 cylinder to TDC of compression stroke. On models with semiautomatic tensioner, apply thumb pressure to timing belt. Notched and raised portions of timing belt tensioner must move apart. Release thumb pressure on belt. Tensioner must back to its original position (raised and notched portions aligned). If not, replace tensioner.
576
On engine codes AHU and 1Z, ensure injection pump sprocket can be locked using Lock Pin (2064). See Fig. 5. On engine code AAZ, ensure injection pump sprocket can be locked using Lock Pin (3359). See Fig. 8. If injection pump cannot be locked using correct lock pin, loosen injection pump sprocket mounting bolt(s), and turn sprocket until lock pin can be inserted in place. Tighten mounting bolt(s). Install timing belt covers. Install vibration damper and belt pulleys (if removed). Install valve cover. Install accessory drive belts. To prevent damage to serpentine belt, install in original direction of rotation. 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 harnesses. Separate hood release lever from bumper cover. Remove front bumper cover. See Fig. 9. Remove bumper beam. Remove air intake duct from air cleaner housing. Remove support bolts from lock carrier assembly. See Fig. 10. Install Support Tool (3369) through lock carrier to body. Remove oil cooler from lock carrier assembly. Move lock carrier forward on support tools. Mark serpentine drive belt with arrow to indicate direction of rotation. Rotate tensioner counterclockwise, and remove serpentine drive belt. Remove upper timing belt cover. See Fig. 2. Lock camshaft in place with Setting Bar (2065A) installed on rear of camshaft. See Fig. 4. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. Divide this feeler gauge dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and one side of cylinder head. Remove timing belt tensioner. Lock injection pump in place using lock pin. See Fig. 8. Loosen injection pump sprocket mounting bolts. Remove crankshaft vibration damper. Remove lower 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 (1998 Passat w/AHH Engine): Ensure TDC mark on flywheel and transmission mating flange are still aligned. See Fig. 2.
Fig. 9: Exploded View Of Bumper Assembly (1998 Passat)
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.
With Camshaft Setting Bar (2065A) in place on rear of camshaft and crankshaft at TDC, install timing belt on engine. If reusing old belt, ensure belt is installed in original direction of rotation. Install idler pulley and tighten center nut to 15 ft. lbs. (20 N.m). Using Tension Pin Wrench (Matra V159), turn tensioner clockwise until notch aligns with raised portion of tensioner. See Fig. 7. Tighten tensioner lock nut to 15 ft. lbs. (20 N.m). Tighten camshaft sprocket bolt. See TORQUE SPECIFICATIONS. Tighten injection pump sprocket mounting bolts. Remove setting bar from camshaft. Remove lock pin from injection pump. Rotate crankshaft 2 revolutions in normal direction of rotation. Set No. 1 cylinder to TDC of compression stroke. Apply thumb pressure to timing belt. Notched and raised portions of timing belt tensioner must move apart. Release thumb pressure on belt. Tensioner must back to its original position (raised and notched portions aligned). If not, replace tensioner. Ensure injection pump sprocket can be locked using Lock Pin (3359). See Fig. 8. If injection pump cannot be locked using correct lock pin, loosen injection pump sprocket mounting bolt(s), and turn sprocket until lock pin can be inserted in place. Tighten mounting bolts. Install timing belt covers. Install vibration damper. Install valve cover. To prevent damage to serpentine belt, install in original direction of rotation.

TORQUE SPECIFICATIONS (GOLF & JETTA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 33 (45) Crankshaft Pulley Bolt ................................................ 18 (25) Crankshaft Sprocket Center Bolt 1 Step 1 ........................................................................... 66 (90) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) 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)
Fig. 10: Exploded View Of Lock Carrier Assembly (1998 Passat)
Application Ft. Lbs. (N.m) Bumper Beam-To-Impact Absorber Bolt (1998) .................................................... 15 (20) Camshaft Sprocket Bolt .............................................. 33 (45) Crankshaft Pulley Bolt ................................................ 18 (25) Crankshaft Sprocket Center Bolt 1 Step 1 ........................................................................... 66 (90) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) Injection Pump Sprocket Mounting Bolts 1 Step 1 .......................................................................... 15 (20 ) Step 2 ........................................... Plus 1/4 Turn (90 Degrees) 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

Fig. 11: Injection Pump Mounting Bracket (1994-97 Golf, Jetta & Passat w/AAZ & 1Z Engines)
TIMING BELT RUNS TOWARD OUTSIDE, WEARS OUT, JUMPS OFF SPROCKET OR CRACKS
Place lock carrier in original position on body. Install front bumper assembly. Check injection pump start of delivery. Consult service information for procedure using VAG 1551/1552 factory scan tool.
1994-97 Golf, Jetta & Passat (AAZ & 1Z Engines): If this condition exists, replace timing belt and semiautomatic tensioner (part No. 028 109 243F). BEFORE installing new timing belt, clean all timing belt sprockets. Install new belt. Before installing vibration damper, start and run engine at idle for a few seconds. Turn off engine Belt must not protrude past edge of crankshaft sprocket. If it does, remove diesel injection pump. Loosen 3 injection pump bracket mount bolts. Tighten bolts to 18 ft. lbs. (25 N.m) while pressing mount down at A and lifting mount at B. See Fig. 11. Start and run engine at idle for a few seconds. Turn off engine. Belt must not protrude past edge of crankshaft sprocket.
NOTE: This information is from Volkswagen technical service bulletin Group 15, No. 97-01; June 4, 1997.
578
VOLKSWAGEN *1.9L 4-Cylinder Turbo Diesel, 1998-01

NOTE: The 3 diesel injection pump bolts are torque-to-yield type. Manufacturer recommends replacing bolts during final assembly.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.8L 4-Cylinder Turbo Diesel Beetle (Engine Code ALH) 1 1998-01 ................. 4.0 Hours .................. 250301 Golf (Engine Code ALH) 1 1999-01 ................. 2.7 Hours .................. 250301 Jetta (Engine Code ALH) 1 1999-01 ................. 2.7 Hours .................. 250301 1 - Code is stamped on pad on engine block between diesel injection pump and exhaust manifold. Engine code is also included on vehicle data plate and timing belt cover.
Loosen, but do not remove, the 3 diesel injection pump sprocket mounting bolts. Manufacturer recommends replacing these torque-to-yield bolts during final assembly. Support engine weight from above or below with floor jack.
NOTE: On Beetle models, engine mount bolts are torque-to-yield type. Manufacturer recommends replacing bolts if they are loosened or removed.

The manufacturer suggests the belt AND tensioner be replaced at 40,000 mile intervals for automatic transmission model, and 60,000 mile intervals on manual transmission models.
Remove engine mount from timing belt end of engine. Remove 4 crankshaft pulley bolts and remove crankshaft pulley (it is not necessary to remove center bolt). Remove timing belt covers. If reusing old timing belt, mark belt with arrow to indication original direction of rotation. Loosen, but do not remove, timing belt tensioner nut, and remove timing belt.
CAUTION: DO NOT turn camshaft or crankshaft with drive belt removed. NOTE: Timing belt installation procedure requires using a factory scan tester (VAG 1551/1552) to adjust injection pump timing

TIMING BELT REMOVAL
NOTE: Timing belt installation procedure requires using a factory scan tester (VAG 1551/1552) to adjust injection pump timing.
Golf & Jetta: Remove upper engine cover. Remove right sound damper cover. Rotate serpentine belt tensioner clockwise to relieve belt tension, and remove serpentine belt. Remove serpentine belt tensioner.
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. Remove brake booster vacuum pump. Remove pipe between charge air cooler and turbocharger. Remove right side insulation tray. Rotate tensioner clockwise, and remove serpentine drive belt. If reusing serpentine drive belt, mark belt with direction of rotation. Rotate crankshaft so that No. 1 cylinder is at TDC of compression 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 between other end of setting bar and cylinder head. Divide this dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of same dimension between other end of bar and cylinder head. 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
Lock camshaft in place with Camshaft Setting Bar (3418) installed on rear of camshaft. See Fig. 2. Center setting bar by turning camshaft so one side of setting bar contacts cylinder head. Using feeler gauge, measure distance between other end of setting bar and cylinder head. Divide this dimension in half. Place a feeler gauge corresponding to half the bar-to-cylinder head dimension between setting bar and cylinder head. Turn camshaft until setting bar contacts feeler gauge. Place second feeler gauge of same dimension between other end of bar and cylinder head. Lock injection pump in place using Lock Pin (3359). See Fig. 3.
CAUTION: DO NOT loosen diesel injection pump center hub nut. This will alter injection pump basic setting.
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. Remove 4 crankshaft pulley bolts and remove crankshaft pulley (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.
NOTE: Use spanner wrench to hold camshaft sprocket while loosening center bolt. DO NOT use camshaft setting bar to hold camshaft sprocket.
Fig. 3: Locking Diesel Fuel Injection Pump 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 timing belt cover. Remove engine valve cover. Remove tube between charge air cooler and intake manifold. Rotate crankshaft so that No. 1 cylinder is at TDC of compression stroke. TDC mark can be viewed through access hole in engine-to-transmission mating flange. See Fig. 1.
Fig. 5: Adjusting Timing Belt Tension (Golf & Jetta With Automatic Transaxle)
580
Install timing belt onto crankshaft sprocket, idler pulley, water pump, injection pump sprocket, and tensioner pulley. If installing 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 exceeded, tension must be fully released, and then readjusted. Tighten center lock nut on tensioner pulley. On all models, ensure tensioner is correctly installed in rear timing belt cover. See Fig. 6. Ensure TDC marks on flywheel are still aligned. Tighten camshaft sprocket center bolt to specification. See TORQUE SPECIFICATIONS.
TORQUE SPECIFICATIONS (BEETLE) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 33 (45) Crankshaft Pulley Bolt ................................................ 18 (25) Diesel Injection Pump Sprocket 1 Bolts .................................................... 15 (20 ) + 90 Degrees Engine Mount Bracket-to-Engine Bolt ...................................................... 1 30 (40) + 90 Degrees Engine Mount-To-Bracket Bolt ...................................................... 1 44 (60) + 90 Degrees Idler Pulley Bolt ........................................................... 15 (20) Timing Belt Tensioner Pulley Nut ............................... 15 (20) Water Pump Bolts ...................................................... 11 (15) INCH. Lbs. (N.m) Timing Belt Cover Bolt .................................................... 89 (10) Valve Cover Nut .............................................................. 89 (10)
1
NOTE: Timing belt installation procedure requires using a factory scan tester (VAG 1551/1552) to adjust injection pump timing.
Install NEW torque-to-yield mounting bolts in diesel injection pump sprocket. Tighten injection pump bolts to 15 ft. lbs. (20 N.m). Before final tightening injection pump mounting bolts, perform start of injection procedure (dynamic timing) using factory scan tester (VAG 1551/1552). Final tighten injection pump sprocket mounting bolts about 90 degrees. If not already done, remove camshaft setting bar from rear of camshaft. Remove lock pin from injection pump. Rotate crankshaft 2 complete revolutions. Place crankshaft at TDC and ensure belt timing is correct. Ensure timing belt tensioner pulley marks are still aligned. Install engine mount bracket to engine block. Install timing belt covers. Install crankshaft pulley. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS. Check fuel lines for leaks. Adjust drive belts to proper tension. On Beetle models, check injection pump start of delivery with scan tool.
Replace with new torque-to-yield bolts on installation.
TORQUE SPECIFICATIONS (GOLF & JETTA) Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 33 (45) Crankshaft Pulley Bolt ................................................ 18 (25) Diesel Injection Pump Sprocket 1 Bolts .................................................... 15 (20 ) + 90 Degrees Engine Mount Bracket-to-Engine Bolt ............................ 33 (45) Idler Pulley Bolt ............................................................ 15 (20) Serpentine Drive Belt Tensioner .................................... 18 (25) Timing Belt Tensioner Pulley Nut ............................... 15 (20) Vacuum Pump Bolt ....................................................... 15 (20) Water Pump Bolts ........................................................ 16 (22) INCH. Lbs. (N.m) Timing Belt Cover Bolt .................................................... 89 (10) Valve Cover Nut .............................................................. 89 (10)
1
Replace with new torque-to-yield bolts on installation.
VOLKSWAGEN *2.0L 4-Cylinder ABA Engine

NOTE: Engine code (ABA) is stamped into machined pad on front of cylinder block above crankcase breather, near cylinder head mating surface.
581
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl., ABA Engine Cabrio 1995-01 ................. 1.9 Hours .................. 250262 Golf (Canadian) 1995 ...................... 1.9 Hours .................. 250262 Golf 1993-99 ................. 1.9 Hours .................. 250262 GTI (Canadian) 1993-95 ................. 1.9 Hours .................. 250262 GTI 1996-99 ................. 1.9 Hours .................. 250262 Jetta 1993-99 ................. 1.9 Hours .................. 250262 Passat 1993-96 ................. 1.9 Hours .................. 250262
Install timing belt around crankshaft, intermediate shaft, tensioner, and camshaft sprockets. Loosen timing belt tensioner center nut. Using spanner wrench, rotate tensioner pulley clockwise to tension belt. Belt tension is correct when it is possible to rotate belt 90 degrees with thumb and forefinger, half-way between camshaft and intermediate shaft sprockets. See Fig. 4.


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 necessary to remove center bolt). Remove water pump pulley. Remove upper and lower timing belt covers.
NOTE: DO NOT turn crankshaft with belt removed. Valve damage may result.
If reusing timing belt, mark belt with arrow to indicate original direction of rotation.
CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed.
Place crankshaft at TDC by aligning flywheel (M/T) or drive plate (A/T) TDC marks. See Fig. 2. Ensure camshaft timing mark is aligned with mark on belt guard. See Fig. 3. Loosen belt tensioner. Remove timing belt. Installation: Ensure crankshaft is still at TDC position. See Fig. 2. Remove distributor cap. Rotate intermediate shaft counterclockwise 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.
Fig. 2: Aligning Crankshaft & Distributor Timing Marks
582
VOLKSWAGEN *2.0L 4-Cylinder ABA Engine (Cont.)
While holding tensioner pulley stationary, tighten tensioner pulley center nut to specification. Rotate crankshaft 2 revolutions and recheck check belt tension. Adjust tension as necessary. Recheck all timing marks again. Install timing belt covers. Install drive belt tensioner bracket. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 59 (80) Crankshaft Pulley Bolt ................................................. 18 (25) Crankshaft Sprocket Center Bolt .......................................... 1 66 (90) + 90 Degrees Drive Belt Tensioner Bracket Bolt .................................. 15 (20) Intermediate Shaft Sprocket Bolt ................................. 59 (80) Timing Belt Tensioner Center Nut ................................ 33 (45) Water Pump Pulley Bolt .............................................. 18 (25) INCH Lbs. (N.m) Valve Cover Retaining Nut .......................................... 89 (10)
1
- Replace torque-to-yield bolt on installation.
VOLKSWAGEN *2.0L 4-Cylinder AEG Engine

NOTE: Engine code (AEG) is stamped into machined pad on front of cylinder block above crankcase breather, near cylinder head mating surface.
583
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.0L 4-Cyl., AEG Engine Beetle 1998-01 ................. 2.7 Hours .................. 250296 Cabrio 1999 ..................... 1 1.9 Hours ................. 250296 Golf 1999 ..................... 1 1.9 Hours ................. 250296 1999-00 ................ 2 3.1 Hours ................. 250296 GTI 1999 ..................... 1 1.9 Hours ................. 250296 Jetta 1999 ................... 1 1.9 Hours ................. 250296 1999-00 ................ 2 3.1 Hours ................. 250296 1 Early 1999 model. 8th character of VIN is H. 2 Late 1999 model. 8th character of VIN is M for Cabrio and Jetta; 8th character of VIN is J for Golf.
On all models, remove engine mount from timing belt end of engine. Remove crankshaft pulley from crankshaft sprocket. It is NOT necessary to remove center bolt (center bolt is torque-to-yield type that must be replaced if removed). Remove timing belt covers. Remove engine support from front of engine. See Fig. 1.
CAUTION: To prevent valves from contacting piston, DO NOT rotate camshaft or crankshaft with timing belt removed.

For 1998-00 model years, although the manufacturer does not recommend a specific scheduled maintenance interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals. For 2001 model year, the manufacturer recommends the belt be replaced at 105,000 mile intervals.
If reusing old belt, mark belt with arrow to indicate original direction of rotation. Rotate timing belt tensioner away from belt and remove timing belt. Installation: Ensure crankshaft and camshaft timing marks are still aligned. See Figs. 2 and 3. Install timing belt around crankshaft and water pump sprockets. Install engine support on front of engine block. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS. Install timing belt lower and center covers. Install crankshaft pulley and tighten bolts to specification. Install engine mount-to-body and engine support. Remove floor jack or engine support bar from engine. Install timing belt on camshaft sprocket and timing belt tensioner. Make sure there is no slack in timing belt. To tension timing belt, engine must be at most warm to the touch. Rotate tensioner pulley counterclockwise until tensioner arrow is aligned with cut-out on cylinder head. See Fig. 4.

TIMING BELT
Removal: Remove right hand insulation tray from engine compartment. Remove engine cover. Rotate serpentine belt tensioner clockwise to relieve belt tension. Remove serpentine belt. Remove serpentine belt tensioner assembly. See Fig. 1. Turn crankshaft to TDC position. See Fig. 2. On Golf and Jetta, align TDC marks visible in bellhousing access hole. See Fig. 3. On all models, remove upper timing belt cover. Ensure camshaft sprocket timing mark aligns with mark on rear cover. See Fig. 2. Support engine from above or below with floor jack to take engine weight off of mounts. Remove coolant reservoir and set aside. On Golf and Jetta, remove power steering reservoir (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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt ............................................ 74 (100) Crankshaft Pulley Bolt 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) Timing Belt Tensioner Center Nut ................................ 15 (20) Water Pump Bolt ........................................................ 11 (15) INCH Lbs. (N.m) Timing Belt Cover Bolt ................................................ 89 (10) Valve Cover Retaining Nut .......................................... 89 (10)
1
- Replace torque-to-yield bolt on installation.
Fig. 3: Locating TDC Mark On Transaxle (Golf & Jetta)
VOLKSWAGEN *2.8L V6
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.8L V6, 30-Valve Passat 1998-01 ................. 3.1 Hours .................. 250297
585

The manufacturer suggests the belt be replaced at 90,000 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 cooling fan is LEFT-HAND threaded. Use a 17 mm box wrench to turn serpentine belt tensioner counterclockwise. Relieve belt tension and remove serpentine 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. 1. 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 sealing 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 direction of rotation on accessory drive belt or timing belt. Damage may result if belts are installed in opposite direction of rotation.
Fig. 2: Locating Camshaft Sprocket Holes
Remove crankshaft vibration damper from crankshaft. It is NOT necessary to remove center bolt. If center bolt is removed, manufacturer recommends using NEW bolt on reassembly. Remove serpentine belt idler pulley. Remove lower timing belt guard (if equipped). Remove timing 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 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. 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 tension. Tighten camshaft sprocket bolts to specification. Remove camshaft locator bar. Remove crankshaft holder. Install sealing plug. Install timing belt cover. Install crankshaft pulley. Install serpentine drive belt To complete installation, reverse removal procedure. When installing crankshaft pulley, ensure notches in pulley are aligned with locating lugs in crankshaft. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 40 (55) Crankshaft Pulley Center Bolt ................................... 1 148 (200) + 180 Degrees Crankshaft Pulley-To-Crankshaft Hex Bolt .................... 18 (25) Lock Carrier-To-Body Bolts ........................................... 37 (50) Timing Belt Idler Pulley Bolt ........................................... 33 (45) Timing Belt Tensioner Center Bolt .............................. 15 (20) INCH Lbs. (N.m) Lock Carrier-To-Body Torx bolts ...................................... 89 (10) Timing Belt Tensioner Bolt/Nut ................................... 89 (10) Water Pump Bolt ......................................................... 89 (10) 1 If removed, manufacturer recommends using NEW bolt.
Fig. 3: Installing Crankshaft Holding Tool

VOLVO *1.9L 4-Cylinder Turbo

TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.9L 4-Cyl. Turbo S40 & V40 2000-01 Up To Engine VIN 1219110 ............ 1 2.4 Hours ................. 250252 From Engine VIN 1219111 ............ 1 2.4 Hours ................. 250311 1 - With Air Cond. add .5 hours.
587

For 2000-01 model years, the manufacturer recommends the timing belt and belt tensioner be replaced every 105,000 miles.
Courtesy of Volvo Cars of North America
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 turning 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 remove the screw and the cover. See Fig. 2. Use an appropriate engine lifting tool to support the weight of the engine at timing belt end of engine. Remove engine mount bolts and nuts on timing end of engine. Remove engine mount. See Figs. 3 and 7.
Fig. 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.)
Fig. 5: Locating Engine Bracket Bolts
Fig. 7: Locating Engine Mount (2001)
Fig. 6: Locating Upper Rear Timing Belt Cover
589
Fig. 8: Locating Snow Cap & Bolts
Fig. 10: Installing New Timing Belt
Fig. 9: Installing New Tensioner
Remove lower timing gear cover by releasing the bottom cover and moving it backwards. See Fig. 4. On 2000 models, engine bracket may have to be removed for clearance to remove belt. See Fig. 5. On all models, remove right front wheel. Turn crankshaft clockwise until camshaft sprocket timing marks align with, inner timing gear cover, and crankshaft sprocket aligns with the oil pump housing. See Fig. 6.
Loosen timing belt tensioner pulley bolt. See Fig. 11. Holding tensioner pulley bolt stationary, rotate pulley eccentric clockwise with a 6 mm Allen wrench. Remove timing belt from tensioner pulley, camshaft sprockets and water pump. 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 engine compartment. Ensure camshaft and crankshaft timing marks are still aligned. Position new timing belt tensioner, and finger tighten bolt A. See Fig. 9. Turn eccentric from tensioner in lowest position. Install timing belt in correct sequence. See Fig. 10. Install upper rear timing cover on engine (do not tighten).
NOTE: Timing belt tension MUST be adjusted when the engine is cold. Around 68F (20C) is the best temperature.
590

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 moving tensioner. See Fig. 11. Recheck adjustment by pressing pin A clockwise and counterclockwise to check. Rotate crankshaft two complete revolutions and check that markings on crankshaft pulley and timing gears align with marks on timing gear cover. Ensure indicator pin A is in middle. Readjust if necessary. See Fig. 12. After readjustment, always turn crankshaft 2 complete revolutions to check if tensioner indicator returns to correct position.
NOTE: Timing belt tensioner indicator will be in different positions depending on engine temperature. At very low or high temperatures, tensioner indicator will be to the left or right of center. See Fig. 13.

Install engine bracket (if removed), timing belt covers, and snow cap.
591
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. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Engine Bracket-To-Engine Block Bolt Step 1 ........................................................................... 26 (35) Step 2 ..................................................... Plus 75 Degree Turn Engine Mount (2000) To-Body Through-Bolt .................................................. 72 (98) To-Engine Bolt ............................................................. 50 (67) Engine Mount (2001) To-Body Nut ................................................................. 37 (50) To-Engine Bolt ............................................................. 50 (67) Idler Pulley Bolt .............................................................. 18 (24) Timing Belt Tensioner Pulley Bolt ............................... 15 (20) Water Pump Bolt ............................................................ 13 (17) Wheel Lug Nut ............................................................. 81 (110) INCH. Lbs. (N.m) Power Steering Hose Bolt .............................................. 89 (10) Snow Cap Bolt ............................................................ 89 (10) Timing Belt Cover Front ........................................................................... 106 (12) Upper ........................................................................... 89 (10)
Fig. 13: Timing Belt Tension Positions
592
VOLVO *2.1L & *2.3L 4-Cylinder B21 & B23

Belt Part No. TIMING BELT REMOVAL
Removal: Disconnect negative battery cable. Remove fan shroud and accessory drive belts. Remove timing belt cover. Rotate crankshaft until timing marks are aligned. See Fig. 1. Loosen belt tensioner and pull belt outward until tensioner spring is compressed. Tighten tensioner nut. Remove timing belt. Installation: Ensure that timing marks are still aligned. See Fig. 1. Install belt around crankshaft and intermediate shaft so that lines on belt are aligned with timing mark on crankshaft. Install belt over camshaft pulley and tensioner roller. Loosen tensioner nut to release spring tension. Tighten tensioner nut. To complete installation, reverse removal procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket ..................................................... 37 (50) Crankshaft Sprocket ................................................. 22 (166) Drive Belt Tensioner Nut ............................................. 37 (50) Fan Bolt ...................................................................... 33 (45) Intermediate Shaft Sprocket ....................................... 37 (50)
TIMING BELT APPLICATION Labor Component Kit No. Application Time 1 2.1L 4-Cyl. B21 242, 244 & 245 1976-79 .......... 1.3 Hrs. ...... 2520320 ........ 250032 DL, GL, GLT 1980-83 .......... 1.3 Hrs. ...... 2520320 ........ 250032 DL (Canadian) 1983 ............... 1.3 Hrs. ...... 2520320 ........ 250032 GLT 1981-83 .......... 1.3 Hrs. ...... 2520320 ........ 250032 Turbo 1984-85 .......... 1.3 Hrs. ...... 2520320 ........ 250032 2.3L 4-Cyl. B23 DL & GL 1982-85 .......... 2.0 Hrs. ...... 2520320 ........ 250032 GLE (Canadian) 1984 ............... 2.0 Hrs. ...... 2520320 ........ 250032 GLT (Canadian) 1983 ............... 2.0 Hrs. ...... 2520320 ........ 250032 760 GLE 1984 ............... 2.2 Hrs. ...... 2520320 ........ 250032 1 - With Air Cond. add .5 hours.

On 1976-85 be replaced On 1986-88 be replaced engines, the manufacturer recommends the belt every 40,000 miles. engines, the manufacturer recommends the belt every 50,000 miles.
Fig. 1: Timing Marks For Crankshaft, Intermediate Shaft & Camshaft
VOLVO *2.3L 4-Cylinder B230, B230F, B230FT

TIMING BELT APPLICATION Belt Labor Component Part Kit No. No. Application Time1 2.3L 4-Cyl. SOHC Coupe 1991 ............... 2.0 Hrs. ...... 2520320 ........ 250032 240 Series 1986-92 .......... 2.0 Hrs. ...... 2520320 ........ 250032 1993 ............... 2.0 Hrs. ............................. 250234 740 Series 1986-92 .......... 2.2 Hrs. ...... 2520320 ........ 250032 760 Series 1985-90 .......... 2.2 Hrs. ...... 2520320 ........ 250032 780 Series 1989-90 .......... 2.2 Hrs. ...... 2520320 ........ 250032 940 Series 1991-92 .......... 2.2 Hrs. ...... 2520320 ........ 250032 1993-95 .......... 2.2 Hrs. ............................. 250234 1 - With Air Cond. add .5 hours. NOTE: A timing belt component kit is available for this application. See page I for information on component kits.
593
Place mark on timing belt to indicate direction of belt rotation. Loosen belt tensioner nut one turn. Pull on timing belt to compress belt tensioner spring. Tighten belt tensioner nut. Install a 3 mm drill bit through hole of belt tensioner bolt to lock belt tensioner spring in place. Remove timing belt from camshaft sprocket. Inspection: Check belt teeth for cracks, damage or oil contamination. Inspect all sprockets for damage. Check belt tensioner for roughness in rotation. Replace components if damaged. Installation: Install belt tensioner if previously removed. Ensure all timing marks align. See Fig. 1. Outer side of timing belt has 2 lines, which should fit toward crankshaft marks. Install belt over crankshaft sprocket first, then over intermediate shaft. Stretch belt on tension side and fit over camshaft sprocket. Slide back of belt onto belt tensioner. Loosen bolt on belt tensioner to apply spring tension against drive belt. Tighten belt tensioner nut. Ensure timing marks align. To install remaining components, reverse removal procedure.
CAUTION: Readjust timing belt when engine reaches normal operating temperature.

The manufacturer recommends the belt be replaced every 50,000 miles, except for 1994 and later B230FT engines with EGR. On these engines, the manufacturer recommends the timing belt be replaced at 100,000 mile intervals.
Warm engine to normal operating temperature. Remove plug from front timing belt cover. Loosen belt tensioner bolt one turn and allow for belt tensioner spring to apply pressure on timing belt. This readjusts timing belt to allow for belt stretch. Tighten belt tensioner nut. Install rubber plug. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Sprocket Bolt .............................................. 37 (50) Crankshaft Pulley Bolt 1 Step 1 ....................................................................... 44 (60) Step 2 ............................................... Additional 60 degrees Intermediate Shaft Sprocket Bolt ................................. 38 (51)
1

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.
- Apply light coat of oil to bolts before installation.
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 Crankshaft Holder (5284) or equivalent, on crankshaft pulley and belt tensioner stud. Install nut on stud. Remove crankshaft center bolt, crankshaft pulley and lower timing belt cover. Ensure timing marks are aligned. See Fig. 1.
NOTE: If reusing timing belt, mark direction of rotation for installation reference. Fig. 1: Aligning Timing Marks
594
VOLVO *2.3L 4-Cylinder B234

1
TIMING BELT APPLICATION Belt Part No. Application Labor Time 2.3L 4-Cyl. B234 740 Series (Canadian) 1986-88 Balance Shaft ........... 2 ......................... 250174 Camshaft ............ 2.5 Hours .................. 250173 1989 (With Automatic Tensioner) Balance Shaft ........... 2 ......................... 250174 Camshaft ............ 2.5 Hours .................. 250198 1989 (With Manual Tensioner) Balance Shaft ........... 2 ......................... 250174 Camshaft ............ 2.5 Hours .................. 250173 1990 Balance Shaft ........... 2 ......................... 250174 Camshaft ............ 2.5 Hours .................. 250173 940 Series (Canadian) 1991-92 Balance Shaft ........... 2 ......................... 250174 Camshaft ............ 2.5 Hours .................. 250198 1 - With Air Cond. add .5 hours. 2 Balance shaft labor included in camshaft.


TIMING BELT
CAUTION: Ensure timing marks align before removing timing belt. DO NOT rotate crankshaft or camshaft with timing belt removed, as it is possible valves may contact pistons.
Removal: Disconnect negative battery cable. Remove radiator fan and pulley. Remove fan shroud and servo pump. Remove A/C compressor drive belts, if equipped. Remove timing cover attaching bolts, then all three covers starting with top cover. Rotate crankshaft until No. 1 cylinder is at TDC position. Check that marks on camshaft pulleys align with those on transmission mounting plate. Marking on belt guide plate on crankshaft should be opposite TDC marking on cylinder block. See Fig. 1. Loosen tensioner lock nut, then compress tensioner spring. Tighten tensioner lock nut and remove camshaft timing belt. Do not turn crankshaft and camshafts while timing belt is removed. Remove balance shaft belt idler pulley. Loosen locknut and remove balance shaft belt. See Fig. 2. Installation: Check that balance shaft marking aligns with markings on transmission mounting plate. See Fig. 3. Ensure that crankshaft marking is opposite TDC marking on cylinder head. Install balance shaft belt under crankshaft pulley assembly. Ensure that blue dot (marking B) is opposite bottom TDC marking on belt guide plate at bottom of crankshaft. See Fig. 4.
Install balance shaft belt around left (upper) balance shaft with marking C opposite marking on pulley. See Fig. 4. Install balance shaft belt on right (lower) balance shaft with marking A opposite marking on pulley. Install balance shaft belt around tensioner. Ensure that markings are still aligned. Tighten balance shaft belt tensioner, using an Allen key inserted in adjusting hole in tensioner. See Fig. 5. Carefully rotate crankshaft a few degrees on either side of TDC position to ensure that balance shaft belt engages properly in pulleys. Return crankshaft to TDC position. Ensure that adjusting hole in balance shaft belt tensioner is below 3 oclock position when tightening locking bolt. Torque locking bolt to 29.5 ft. Ibs. (40.5 N.m), using an Allen key inserted in adjusting hole as counter hold. See Fig. 5. Check balance shaft belt tension using Volvo Gauge Tool (No. 998 8500) or equivalent. Position gauge above idler. See Fig. 7. Balance shaft belt tension should be within 1 to 4 unit range. Align double line marking on camshaft timing belt with top marking on belt guide plate. See Fig. 6. Ensure that single line markings align with pulley markings. Place camshaft timing belt around oil pump drive pulley, then install belt onto left hand idler. Ensure that timing marks are aligned properly and No. 1 cylinder is at TDC position. Rotate crankshaft clockwise until pulley markings align with those on transmission mounting plate. See Fig. 8. Rotate crankshaft clockwise until pulley markings are 1 1/2 teeth past markings on housing. Tighten camshaft timing belt tensioner lock nut. Start engine and allow to reach normal operating temperature, then shut engine off. To check balance timing belt tension, start engine and allow to reach normal operating temperatures. Turn engine off. Position gauge above location of dismantled idler. Belt tension should be within 4.7 to 5.1 unit range. If belt tension is low, rotate tensioner slightly clockwise, then rotate crankshaft clockwise one revolution. Belt tension should be within 4.7 to 5.1 unit range. If belt tension is high, repeat procedure. Install idler pulley and timing covers. To check timing belt tension, rotate crankshaft until No.1 cylinder is at TDC position, then position Volvo Belt Gauge Tool (No. 998 8500) or equivalent, between exhaust camshaft pulley and idler. Belt tension should be within 5.3 to 5.7 unit range. See Fig. 9. Torque tensioner lock nut to 37 ft. Ibs. (51 N.m). Replace protective cap in measuring zone. See Fig. 10. Torque tensioner lock nut to 37 ft. lbs. (51 N.m). Replace protective cap. If belt tension reading is outside above range, remove protective cap, then loosen tensioner locknut. Position Volvo Gauge (998 8500) or equivalent in measuring zone. See Fig. 10. If belt tension is low, move roller to adjust belt tension to 5.8 to 6.2 units. If belt tension is high, adjust to obtain a reading of 4.8 to 5.2 units. Torque tensioner lock nut to 37 ft. Ibs. (51 N.m), and rotate crankshaft clockwise. Measure belt tension. Belt tension should be 5.3 to 5.7 unit range. Torque tensioner lock nut to 37 ft. Ibs. (51 N.m). Remove protective cap, then loosen tensioner. To complete installation, reverse procedure. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Tensioner Locking Bolt ............................................ 29.5 (40) Tensioner Lock Nut ................................................. 37.0 (49)
VOLVO *2.3L 4-Cylinder B234 (Cont.)
595
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
Fig. 7: Checking Balance Shaft Belt Tension Fig. 5: Adjusting Tensioner
Fig. 8: Rotating Crankshaft
597
Fig. 9: Checking Belt Tension
Fig. 10: Adjusting Belt Tension
598
VOLVO *2.3L & 2.4L 5-Cylinder

TIMING BELT
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L 5-Cyl. Turbo C70, S70 & V70 1998-01, Up To Engine VIN 1266127 ............. 1 2.4 Hours ................. 250252 1998-01, From Engine VIN 1266128 ............. 1 2.4 Hours ................. 250311 S60 2001, Up To Engine VIN 1266127 ............. 1 2.0 Hours ................. 250252 2001, From Engine VIN 1266128 ............. 1 2.0 Hours ................. 250311 2.4L 5-Cyl. C70, S70 & V70 1998-01, Up To Engine VIN 1266127 ............. 1 2.4 Hours ................. 250252 1998-01, From Engine VIN 1266128 ............. 1 2.4 Hours ................. 250311 S60 2001, Up To Engine VIN 1266127 ............. 1 2.0 Hours ................. 250252 1998-01, From Engine VIN 1266128 ............. 1 2.0 Hours ................. 250311 1 - With Air Cond. add .5 hours.
Removal: Remove key from ignition switch. On S60 models, remove the cross brace between the front shock towers. On all models, remove upper timing belt cover. Remove power steering pump reservoir with hoses attached and set aside. Remove coolant reservoir and set aside. Remove accessory drive belt. Remove front timing belt cover. Raise and support vehicle. Remove right front wheel. Remove nut from fender liner cover. Remove upper timing belt cover. Turn crankshaft clockwise (as viewed from timing belt end of engine) to align the timing marks on the crankshaft pulley and camshaft sprockets. See Fig. 1. Turn crankshaft an additional 1/4 turn clockwise, and then back again until the timing marks align. Loosen timing belt tensioner pulley center bolt. Holding center bolt, turn the tensioner eccentric clockwise with a 6 mm Allen wrench. Turn eccentric until the hole for the Allen wrench is at the 10 oclock position.
CAUTION: Vibration damper pulley bolts are torque-to-yield type. If vibration damper pulley bolts are removed so that Counterhold (999 5433) or equivalent can be installed, pulley bolts MUST be replaced.

For 1998 model year, the manufacturer recommends the belt be replaced every 70,000 miles. For 1999-01 model years, the manufacturer recommends the belt be replaced every 105,000 miles. In addition, manufacturer recommends replacing timing belt tensioner on 2001 C70.
Raise and support vehicle. Holding vibration damper stationary with Counterhold (999 5433) or equivalent, remove vibration damper center bolt. Remove vibration damper. Lower vehicle. Remove timing belt. Inspection: Spin tensioner and idler pulleys and listen for bearing noise. Ensure pulley surfaces in contact with belt are clean and smooth. Installation: If timing belt tensioner was remove, ensure tensioner fork is installed with fork centered over rib on engine block.
VOLVO *2.3L & 2.4L 5-Cylinder (Cont.)
599
Place timing belt around crankshaft pulley. Install vibration damper. Install vibration damper center bolt. Hold vibration damper stationary with Counterhold (999 5433) or equivalent, and tighten center bolt to specification. See TORQUE SPECIFICATIONS. Install NEW vibration damper pulley bolts (if removed). Place timing belt around idler pulley, intake camshaft pulley, exhaust camshaft pulley, water pump and timing belt tensioner.
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 crankshaft timing marks. Ensure the timing belt tensioner indicator is within the correct area. Turn crankshaft 2 revolutions in normal direction of rotation. Ensure camshaft and crankshaft sprocket timing marks are still aligned. Ensure timing belt tensioner indicator is in the correct position for engine temperature. Install front and upper timing belt covers. Install accessory drive belt. Install power steering reservoir. Check power steering fluid level. Refill, if necessary. Install coolant reservoir. Install fender liner cover. Install front wheel. On S60 models, install shock tower brace. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Shock Tower Brace (S60) Engine Bracket Bolt .................................................... 37 (50) Shock Tower Bolt ....................................................... 59 (80) Timing Belt Idler Pulley Bolt ............................. 17-18 (24-25) Timing Belt Tensioner Bolt ......................................... 15 (20) Vibration Damper Center Bolt .................................... 133 (180) Vibration Damper Pulley Bolts 1 Step 1 ........................................................................... 18 (25) Step 2 ........................................................... Plus 30 Degrees Water Pump Bolt ............................................................ 13 (17) Wheel Lug Nut ........................................................... 100 (130) INCH Lbs. (N.m) Front Timing Belt Cover Bolt ..................................... 106 (12) Upper Timing Belt Cover Bolt ........................................... 71 (8) 1 Always replace bolts if loosened or removed.
NOTE: Timing belt tension MUST be adjusted when the engine is cold. Around 68F (20C) is the best temperature.
Slowly turn crankshaft clockwise (as viewed from timing belt end of engine) until the timing belt is tensioned. The belt should be tight between the intake camshaft sprocket, idler pulley and crankshaft sprocket. Hold timing belt tensioner pulley bolt secure and turn tensioner eccentric counterclockwise until the tensioner needle passes to the right of center position. See Fig. 3. Turn tensioner eccentric back until the needle reaches the marked position corresponding to engine temperature. At 68F (20C), the needle must be centered in the window.
600
VOLVO *2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder
Remove right front wheel and release wheel arch liner to gain access to vibration damper. Remove vibration damper guard. Turn crankshaft clockwise until all timing marks are aligned. See Fig. 1. Remove tensioner upper mounting bolt and loosen tensioner lower bolt. Twist tensioner to free pulley. Remove lower bolt, tensioner, upper timing belt cover. If reusing old timing belt, mark belt with arrow to indicate rotation direction. Remove timing belt. Removal (6-Cylinder): Remove auxiliary drive belt, front transmission cover splash guard under engine, vibration damper guard, and ignition coil cover. Turn crankshaft clockwise until timing marks on camshaft pulleys/transmission plate and crankshaft pulley/oil pump housing are aligned. See Fig. 1. Remove upper transmission cover. Remove tensioner upper mounting bolt and loosen lower mounting bolt. Twist tensioner to free plunger/pulley. If reusing old timing belt, mark belt with arrow to indicate rotation direction. Remove lower bolt, tensioner, and timing belt.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.3L 5-Cyl. Turbo 850 1994 ..................... 1 2.4 Hours ............... 2 250217 1994 ..................... 1 2.4 Hours ............... 3 250252 1995-97 ................ 1 2.4 Hours ................ 250252 850 (Canadian) 1996 ..................... 1 2.4 Hours ................. 250252 2.4L 5-Cyl. 850 1993 ..................... 1 2.4 Hours ............... 2 250217 1993 ................... 1 2.4 Hours ............... 3 250252 1994-97 ................ 1 2.4 Hours ................. 250252 850 (Canadian) 1995 ..................... 1 2.4 Hours ............... 2 250217 1995 ..................... 1 2.4 Hours ............... 3 250269 2.9L 6-Cyl. S90 & V90 1997-98 ................ 1 2.2 Hours ................. 250270 960 1992-93 ................ 1 2.2 Hours ................. 250217 1994 ................... 1 2.2 Hours ................. 250252 1995-97 ................ 1 2.2 Hours ................. 250270 1 - With Air Cond. add .5 hours. With shimmed Air Cond. belt add .5 hours. 2 Through engine number 131034. 3 From engine number 131035.
Inspection: Spin tensioner and idler pulleys and listen for bearing noise. See Fig. 2. Ensure pulley surfaces in contact with belt are clean and smooth. Check tensioner pulley arm and idler pulley mountings, and tighten bolts as necessary. See TORQUE SPECIFICATIONS. Check tensioner for signs of leakage, no resistance when depressed, or a plunger that cannot be depressed.

On 1992 960 models, the manufacturer recommends the belt be replaced every 30,000 mile intervals, starting at the first 40,000 mile service. On 1993 960 models, the manufacturer recommends the belt be replaced at 30,000 mile intervals, starting at the first 30,000 mile service. On 1994 960 models, the manufacturer recommends the belt to be replaced every 50,000 miles. On 1993 850 models, with engine number 131034 and earlier, the manufacturer suggests the belt be replaced every 50,000 miles. On 1994 850 models, and 1993 850 models from engine number 131035, the manufacturer recommends the belt be replaced every 70,000 miles. On ALL 1995-98 models, the manufacturer recommends the belt be replaced every 70,000 miles.

TIMING BELT
Removal (5-Cylinder): Disconnect negative battery cable. Remove spark plug cover and 2 fuel line clips. Lift out expansion tank and place on top of engine. Remove front timing belt cover. Remove auxiliary drive belt.
601 VOLVO *2.3L & 2.4L 5-Cylinder & 2.9L 6-Cylinder (Cont.)
Installation: Compress tensioner and tighten center nut. Wait until compression has taken place and insert a 2 mm locking pin in plunger. Install tensioner and tighten mounting bolts to specification. Place timing belt around crankshaft pulley and right idler. Place belt over camshaft pulleys. Position belt around water 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 pulleys are aligned. See Fig. 1. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Cover Bolt .................................................. 13 (17) Camshaft Pulley Bolt .................................................. 15 (20) Spark Plug .................................................................. 18 (25) Timing Belt Pulley Bolt ................................................ 30 (40) Timing Belt Tensioner Bolt ......................................... 18 (25) Vibration Damper Center Nut 5-Cylinder ................................................................. 133 (180) 6-Cylinder ................................................................. 221 (300) Vibration Damper-To-Crankshaft Bolt 5-Cylinder Step 1 ........................................................................ 18 (25) Step 2 .................................................. Plus 30 Degree Turn 6-Cylinder Step 1 ........................................................................ 26 (35) Step 2 .................................................. Plus 50 Degree Turn Water Pump Bolt ........................................................ 13 (17) Wheel Lug Nut ............................................................. 81 (110)
Fig 2: Checking Tensioner & Idler Pulleys
602
VOLVO *2.4L 6-Cylinder Diesel
Remove center bolt from idler pulley. Using Idler Pulley Removal Tool (5202) or equivalent, remove idler pulley. Replace and tap new idler pulley into position. Using Spanner Wrench Tool (5199) or equivalent, hold front camshaft drive gear in place and remove center retaining bolt. See Fig. 2.
TIMING BELT APPLICATION Application Labor Time Belt Part No. 2.4L 6-Cyl. Diesel DL 1982 Camshaft ............ 13.6 Hours ................. 250083 Injection Pump ... 1.9 Hours .................. 250082 GL 1982-84 Camshaft ............ 13.6 Hours ................. 250083 Injection Pump ... 1.9 Hours .................. 250082 740 Series 1985-86 Camshaft ............ 13.6 Hours ................. 250083 Injection Pump ... 1.9 Hours .................. 250082 760 GLE 1983-84 Camshaft ............ 13.6 Hours ................. 250083 Injection Pump ... 1.9 Hours .................. 250082 760 Series 1985 Camshaft ............ 13.6 Hours ................. 250083 Injection Pump ... 1.9 Hours .................. 250082 1 - With Air Cond. add .5 hours.
NOTE: Idler pulley must be replaced when replacing timing gear belt. Use Puller (5202) to remove pulley. NOTE: Camshaft MUST NOT rotate or damage to valves and pistons may result.

Tap gear loose from camshaft tapered end. Remove injection pump drive belt by loosening retaining bracket bolts. Tighten one screw to hold pump in upper position. Use Spanner Wrench Tool (5199) or equivalent to hold rear camshaft sprocket and Wrench (5201) or equivalent to remove center retaining bolt. Tap gear loose from camshaft. See Fig. 2. Installation: Check that No. 1 cylinder is at TDC, timing mark on flywheel is at 0 and camshaft lobes for No. 1 cylinder are facing up with equally large angles in comparison with cylinder head. See Fig. 1. Place Camshaft Lock Gauge Tool (5190) or equivalent in camshaft groove at rear of cylinder head. Place a .008" (.2 mm) feeler gauge under left side of Camshaft Locking Gauge Tool (5190) or equivalent. See Fig. 3. Install timing gear belt and damper pulley. Replace 4 damper pulley bolts and torque to 15 ft. lbs. (20 N.m).
NOTE: Feeler gauge placed under Camshaft Lock Gauge Tool (5190) or equivalent is to compensate for timing gear clearance.

TIMING BELT
Removal: Disconnect negative battery cable. Remove splash guard, cooling fan, spacer, and pulley. Remove fan and power steering pump belts, power steering pump and expansion tank cap. Drain and remove radiator. Disconnect battery ground cable. Remove valve cover and front and rear timing belt covers. Using a 1 1/16" (27 mm) socket on damper pulley bolt, set No. 1 cylinder at TDC (timing mark on flywheel at 0). Loosen water pump and idler pulley bolts to remove timing belt from camshaft gear. See Fig. 1. Using Damper Pulley Wrench (5187) or equivalent, and Damper Pulley Bolt Tool (5188) or equivalent, remove damper pulley bolt. Using a (6 mm) socket, remove 4 screws from damper pulley and pulley (it may be necessary to tap pulley from shaft). Remove lower belt shield and timing gear belt.
Using Damper Pulley Wrench Tools (5187 and 5188) or equivalent, install and torque center bolt (use sealing agent on center bolt threads) of damper pulley to 255 ft. lbs. (350 N.m). Install front timing gear belt and camshaft timing gear (ensuring camshaft does not turn). Torque to 33 ft. lbs. (45 N.m) after setting timing marks. Remove Camshaft Gauge Locking Tool (5190) and feeler gauge from rear of camshaft. Install rear camshaft gear and injection pump belt. Set injection pump timing. See Fig. 4. Position Belt Tension Gauge Tool (5197) or equivalent on timing and injection pump belt, set gauge to .50" (12.5 mm). Place tension on belt until mark on plunger is flush with gauge sleeve and tighten bolts. Using coolant pump to adjust timing gear belt tension, place tension on belt until mark on plunger is flush with gauge sleeve. Install valve cover and new gaskets. Install front and rear timing gear covers. Install lower belt shield. Reverse removal procedure to complete installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Gear Bolt Front ......................................................................... 33 (45) Rear ....................................................................... 74 (100) Crankshaft Pulley Nut ............................................. 258 (350) Injector Pump Gear .................................................... 33 (45)
VOLVO *2.4L 6-Cylinder Diesel (Cont.)
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 & *1.3L 4-Cylinder
TIMING BELT APPLICATION Application Labor Time Belt Part No. 1.1L 4-Cyl. GV Series 1986-89 ................. 2.5 Hours .................. 250018 1.3L 4-Cyl. GV Series 1987 ...................... 2.5 Hours .................. 250018

The manufacturer recommends inspection of the timing belt every 15,000 miles. Although the manufacturer does not recommend a specific scheduled replacement interval, belt manufacturers suggest the belt be replaced at 60,000 mile intervals.

TIMING BELT
Removal: Disconnect negative battery cable. Position No. 1 cylinder at TDC of compression stroke. Disconnect positive battery cable. Remove accessory drive belt. Remove cooling fan and shroud. Remove crankshaft pulley. Remove timing belt covers. Align camshaft sprocket with timing mark. See Fig. 1. Loosen tensioner lock nut and move tensioner pulley toward engine mount. Tighten nut to secure tensioner in slack position. Remove and discard timing belt.
CAUTION: Timing belts cannot be reused. DO NOT readjust belt tension following initial installation of a new belt.
Fig. 1: Camshaft-To-Crankshaft Alignment
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 tension. 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 installation. Adjust drive belts to proper tension. See page A-60 for belt tension ranges. TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) Camshaft Housing Bolts ............................................ 14 (19) Camshaft Sprocket Bolt .............................................. 61 (83) Crankshaft Pulley Nut ............................................. 101 (137) Tensioner Pulley Support Nut ..................................... 33 (45)

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ALPHABETICAL MODEL LISTING

ALPHABETICAL MODEL LISTING (Cont.)

250120 250017 250017 250017 2520170 2520170 2520170

50,000 60,000 1 60,000 1 60,000 1

250212 250164 250212 250164 250212

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

215 215 217 217 217

ALPHABETICAL MODEL LISTING (Cont.)

ALPHABETICAL MODEL LISTING (Cont.)

Yes Yes Yes Yes Yes Yes Yes

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

Yes Yes Yes

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

ALPHABETICAL MODEL LISTING (Cont.)

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

325 Series 1987-88 1989-91 1984-88 525i 1989-95 528e 1982-88

250131 250106 250131 250131 250106 250131 250131 250106

Yes Yes Yes Yes Yes Yes Yes Yes

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

Skyhawk 1982-86 1987-88

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

250037 250039 250037 250039 250061 250076 250192 250273

Yes Yes Yes Yes Yes

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

221 221 221 221 221 226 238 238

ALPHABETICAL MODEL LISTING (Cont.)

250075 250075 250212 250164 250212

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

323 323 217 217 217

1995-99 2000 1995-00 Concorde 1998-99 2000 1993-94 1995-97 2000

ALPHABETICAL MODEL LISTING (Cont.)

Yes Yes Yes Yes Yes Yes Yes Yes Yes

2521530 2521390 2520710

Lanos 1999-01 Nubira 1999-01

ALPHABETICAL MODEL LISTING (Cont.)

250178 250181 250182

Yes Yes Yes

60,000 60,000 60,000

152 154 154

DATSUN (SEE NISSAN) DODGE

2520710 2521530 2521530 Yes Yes Yes Yes

2520170 2520710 Yes Yes Yes

Yes Yes 2521280 2521910 Yes Yes

ALPHABETICAL MODEL LISTING (Cont.)

2521530 2521390 2521530 2521390 2520710 2521530

ALPHABETICAL MODEL LISTING (Cont.)

Yes Yes Yes

Yes Yes Yes Yes