GM Prizm/Nova 1985-1993 Repair Guide

Timing Belt Covers

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REMOVAL & INSTALLATION



1985-88 VIN Code 4 Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the right side splash shield under the engine.
  4.  
  5. Loosen the water pump pulley bolts and remove the alternator belt. Remove the power steering drive belt if so equipped.
  6.  
  7. Remove the bolts and remove the water pump pulley.
  8.  
  9. Loosen the air conditioning idler pulley mounting bolt. Loosen the adjusting nut and then remove the air conditioning drive belt if so equipped. Remove the idler pulley.
  10.  
  11. Rotate the crankshaft clockwise and set the engine to TDC/compression on No. 1 cylinder. Loosen the crankshaft pulley mounting bolt and remove the crank pulley.
  12.  

Before removing the pulley, check that the rockers on the No. 1 cylinder are loose and that the timing marks on the crankshaft align at the zero setting. If the rockers are not loose, rotate the crankshaft 1 full revolution, stopping again at the zero point.

  1. Remove the mounting bolts and the No. 1 (upper) cover.
  2.  
  3. Remove the 4 bolts and remove the center engine mount.
  4.  
  5. Place a block of wood on a floor jack and position it under the motor. Raise the engine slightly, remove 2 bolts and then remove the right engine mount.
  6.  
  7. Lower the engine and then remove the No. 2 (lower) and the No. 3 (center) covers with their gaskets.
  8.  
  9. When reinstalling, make certain that the gaskets and their mating surfaces are clean and free from dirt and oil. The gasket itself must be free of cuts and deformations and must fit securely in the grooves of the covers.
  10.  



Click image to see an enlarged view

Fig. Fig. 1: Timing belt and related components - 1985-88 VIN Code 4 engine

  1. Install the No. 3 cover with its gasket, then install the No. 2 cover and its gasket. Before tightening the bolts fully, check that the gaskets have not fallen out of place.
  2.  
  3. Raise the engine slightly and install the right engine mount.
  4.  
  5. Lower the engine into place and install the center engine mount. Tighten the bolts to 29 ft. lbs.
  6.  
  7. Install the upper timing belt cover.
  8.  
  9. Install the crankshaft pulley; tighten the bolt to 87 ft. lbs.
  10.  
  11. Install the water pump pulley and tighten the bolts finger tight.
  12.  
  13. Reinstall the idler pulley for the air conditioning belt. Install the belt and adjust it by turning the adjustor into position.
  14.  
  15. Tighten the water pump pulley bolts.
  16.  
  17. Install the power steering drive belt if so equipped.
  18.  
  19. Install the splash shield.
  20.  
  21. Connect the negative battery cable.
  22.  

1988 VIN Code 5 Engine

See Figures 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Elevate the vehicle and safely support it on jackstands.
  4.  
  5. Remove the right front wheel.
  6.  
  7. Remove the splash shield from under the car.
  8.  
  9. Drain the coolant into clean containers. Close the draincocks when the system is empty.
  10.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Lower the car to the ground. Disconnect the accelerator cable and, if equipped, the cruise control cable.
  2.  
  3. Remove the cruise control actuator if so equipped.
  4.  
  5. Carefully remove the ignition coil.
  6.  
  7. Disconnect the radiator hose at the water outlet.
  8.  
  9. Remove the power steering drive belt and the alternator drive belt.
  10.  



Click image to see an enlarged view

Fig. Fig. 2: Timing belt, cover and related components - 1988 VIN Code 5 engine and 1991-92 VIN Code 6 engine

  1. Remove the spark plugs.
  2.  
  3. Rotate the crankshaft clockwise and set the engine to TDC/compression on No. 1 cylinder. Align the crankshaft marks at zero; look through the oil filler hole and make sure the small hole in the end of the camshaft can be seen.
  4.  
  5. Raise and safely support the vehicle. Disconnect the center engine mount.
  6.  
  7. Lower the vehicle to the ground.
  8.  
  9. Support the engine either from above or below. Disconnect the right engine mount from the engine.
  10.  
  11. Raise the engine and remove the mount.
  12.  
  13. Remove the water pump pulley.
  14.  
  15. Remove the crankshaft pulley. The use of a counterholding tool such as J-8614-01 or equivalent, is highly recommended.
  16.  
  17. Remove the ten bolts and remove the timing belt covers with their gaskets.
  18.  


WARNING
The bolts are different lengths; they must be returned to their correct location at reassembly. Label or diagram the bolts during removal.

  1. When reinstalling, make certain that the gaskets and their mating surfaces are clean and free from dirt and oil. The gasket itself must be free of cuts and deformations and must fit securely in the grooves of the covers.
  2.  
  3. Reinstall the covers and their gaskets and the 10 bolts in their proper positions.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Timing cover bolts must be installed in the correct locations. Bolt lengths shown are in millimeters (mm) - 1988 VIN Code 5 engine

  1. Install the crankshaft pulley, again using the counterholding tool. Tighten the bolt to 101 ft. lbs.
  2.  
  3. Install the water pump pulley.
  4.  
  5. Install the right engine mount. Tighten the through bolt to 58 ft. lbs.
  6.  
  7. Reinstall the spark plugs and their wires.
  8.  
  9. Install the alternator drive belt and the power steering drive belt. Adjust the belts to the correct tension.
  10.  
  11. Connect the radiator hose to the water outlet port.
  12.  
  13. Install the ignition coil.
  14.  
  15. Install the cruise control actuator and the cruise control cable if so equipped.
  16.  
  17. Connect the accelerator cable.
  18.  
  19. Refill the cooling system with the correct amount of anti-freeze and water.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and check for leaks. Allow the engine to warm up and check the work areas carefully for seepage.
  24.  
  25. Install the splash shield under the car.
  26.  
  27. Install the right front wheel.
  28.  

1989-90 VIN Code 6, 1990 VIN Code 5 and All 1991-92 Engines

See Figures 2 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Elevate the vehicle and safely support it on jackstands.
  4.  
  5. Remove the right splash shield under the car.
  6.  
  7. Lower the vehicle. Remove the wiring harness from the upper timing belt cover.
  8.  
  9. Depending on equipment, loosen the air conditioner compressor, the power steering pump and the alternator on their adjusting bolts. Remove the drive belts.
  10.  
  11. Remove the crankshaft pulley. The use of a counterholding tool such as J 8614-01 or similar is highly recommended.
  12.  
  13. Remove the valve cover.
  14.  
  15. Remove the windshield washer reservoir.
  16.  
  17. Elevate and safely support the vehicle.
  18.  
  19. Support the engine either from above (Tool 28467-A or chain hoist) or below (floor jack and wood block) and remove the through bolt at the right engine mount.
  20.  
  21. Remove the protectors on the mount nuts and studs for the center and rear transaxle mounts.
  22.  
  23. Remove the 2 rear transaxle mount-to-main crossmember nuts. Remove the 2 center transaxle mount-to-center crossmember nuts.
  24.  
  25. Carefully elevate the engine enough to gain access to the water pump pulley.
  26.  
  27. Remove the water pump pulley. Lower the engine to its normal position.
  28.  
  29. Remove the lower center and upper timing covers.
  30.  



Click image to see an enlarged view

Fig. Fig. 4: Timing covers, belt and related components - 1989-90 VIN Code 6 engine and 1991-92 VIN Code 5 engine

To install:
  1. If further work is to be done, the car may be lowered to the ground but the engine must remain supported until the mount(s) are reinstalled.
  2.  
  3. When reinstalling, make certain that the gaskets and their mating surfaces are clean and free from dirt and oil. The gasket itself must be free of cuts and deformations and must fit securely in the grooves of the covers.
  4.  
  5. Install the covers and the bolts; tighten the bolts to 3.6 ft. lbs. (44 INCH lbs.)
  6.  
  7. Elevate the engine and install the water pump pulley.
  8.  
  9. Lower the engine to its normal position. Install the through bolt in the right engine mount and tighten it to 64 ft. lbs. With the bolt secure, the engine lifting apparatus may be removed.
  10.  
  11. Install the valve cover.
  12.  
  13. Install the crankshaft pulley and tighten its bolt to 87 ft. lbs.
  14.  
  15. Reinstall the air conditioning compressor, the power steering pump and the alternator. Install their belts and adjust them to the correct tension.
  16.  
  17. Reconnect the wiring harness to the upper timing belt cover.
  18.  
  19. Raise the vehicle and safely support it on jackstands.
  20.  
  21. Install the 2 nuts on the center transaxle mount and the rear transaxle mount. Tighten all the nuts to 45 ft. lbs.
  22.  
  23. Install the protectors on the nuts and studs.
  24.  
  25. Install the splashshield under the car.
  26.  
  27. Lower the vehicle to the ground.
  28.  
  29. Install the windshield washer reservoir and connect the negative battery cable.
  30.  

1993 All Engines

For removal and installation procedure of the front timing belt covers on all 1993 models, please refer to Timing Belt, Tensioner and Gears procedure, outlined in this section.

 
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