Hyundai Coupes/Sedans 1986-1993 Repair Guide

Timing Belt and Tensioner

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ADJUSTMENT



1468cc and 1495cc Engines

See Figures 1 and 2

  1. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 1: Loosening the tensioner bolts (1 and 2) temporarily to set the belt tension. Tighten the No. 2 bolt first then the No. 1, otherwise the tensioner will move



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Fig. Fig. 2: Checking the belt tension

  1. Remove the timing belt covers.
  2.  
  3. Loosen the tensioner lower mounting bolt first, then the uppermost bolt.
  4.  
  5. Check to insure that the timing marks are in correct alignment and secure, tightening the uppermost bolt first.
  6.  
  7. Rotate the crankshaft 1 revolution in operating direction (clockwise), and realign the timing marks. Loosen the tensioner lower mounting bolt first, then the uppermost bolt.
  8.  
  9. Retighten the attaching bolts, uppermost first, to 14-20 ft. lbs. (20-27 Nm).
  10.  
  11. Apply a moderate pressure to the tension side of the timing belt and measure the belt deflection. The inner (cog) side of the belt should be depressed to the center of the tensioner mounting bolt head. If the deflection point is correct, the tension adjustment of the timing belt is correct.
  12.  
  13. If a tension gauge is used, measure the tension in the middle of the tension side span. The desired reading is 32-47 lbs.
  14.  
  15. Install the timing belt covers and all related components.
  16.  
  17. Reconnect the negative battery cable.
  18.  

2351cc Engine

See Figures 3, 4 and 5

  1. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 3: Tensioner "B" installation-1596cc, 1796cc, 1997cc and 2351cc engines



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Fig. Fig. 4: Adjusting tensioner "B"-1596cc, 1796cc, 1997cc and 2351cc engines



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Fig. Fig. 5: Checking the deflection of timing belt "B"-1596cc, 1796cc, 1997cc and 2351cc engines

  1. Remove the upper and lower timing belt covers.
  2.  
  3. Check the tensioners for a smooth rate of movement and leaking seal. Replace any tensioner that binds or shows grease leakage through the seal.
  4.  
  5. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke. Do not rotate the crankshaft in a counterclockwise direction as this can cause improper timing belt tension.
  6.  
  7. Loosen the timing belt tensioner bolt and nut, using a 14mm socket wrench.
  8.  
  9. Rotate the crankshaft and camshaft sprocket clockwise 2 teeth. Do not turn the engine counterclockwise. Momentarily apply slight pressure behind the tensioner to assure tensioner is not sticking and then release pressure. After tension has equalized, tighten the tensioner mounting bolt (lower side) first, and then tighten the upper mounting nut. Be sure to tighten the mounting hardware in that order. If the nut it tightened first, the tensioner will rotate with the nut and the belt will be loose.
  10.  
  11. Check to ensure proper tension of the belt by measuring its deflection. The standard value is 0.200-0.276 in. (5-7mm) with moderate pressure applied to the center of the timing belt.
  12.  
  13. Install the upper and lower timing belt covers.
  14.  
  15. Install the crankshaft pulley.
  16.  
  17. Install the water pump drive belt and pulley. Connect the negative battery cable.
  18.  

1596cc, 1796cc and 1997cc Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt covers.
  4.  
  5. Adjust the silent shaft (inner) belt tension first. Loosen the idler pulley center bolt so the pulley can be moved.
  6.  
  7. Move the pulley by hand so the long side of the belt deflects about 1 / 4 in.
  8.  
  9. Hold the pulley tightly so the pulley cannot rotate when the bolt is tightened. Tighten the bolt to 15 ft. lbs. (20 Nm) and recheck the amount of deflection.
  10.  
  11. To adjust the timing (outer) belt, turn the crankshaft 1 / 4 turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
  12.  
  13. Loosen the center bolt. Using tool MD998752 or equivalent and a torque wrench, apply a torque of 1.88-2.03 ft. lbs. (2.6-2.8 Nm). If the body of the vehicle interferes with the special tool and the torque wrench, use a jack and slightly raise the engine assembly. Holding the tensioner pulley, tighten the center bolt.
  14.  
  15. Screw special tool MD998738 or exact equivalent into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto tensioner, if wire was not previously removed. Then remove the special tool.
  16.  
  17. Rotate the crankshaft 2 complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto tensioner protrusion (the distance between the tensioner arm and auto tensioner body) to ensure that it is within 0.15-0.18 in. (3.8-4.5mm). If out of specification, repeat Step 1-4 until the specified value is obtained.
  18.  
  19. If the timing belt tension adjustment is being performed with the engine mounted in the vehicle, and clearance between the tensioner arm and the auto tensioner body cannot be measured, the following alternative method can be used:
    1. Screw in special tool MD998738 or equivalent, until its end makes contact with the tensioner arm.
    2.  
    3. After the special tool makes contact with the arm, screw it in some more to retract the auto tensioner pushrod while counting the number of turns the tool makes until the tensioner arm is brought into contact with the auto tensioner body. Make sure the number of turns the special tool makes conforms with the standard value of 2 1 / 2 -3 turns.
    4.  
    5. Install the rubber plug to the timing belt rear cover.
    6.  

  20.  
  21. Install the timing belt covers and all related items.
  22.  
  23. Connect the negative battery cable.
  24.  

2972cc Engine
  1. Disconnect the negative battery cable.
  2.  
  3. If equipped with air conditioning, remove the compressor drive belt.
  4.  
  5. Remove the access cover located in the lower timing belt cover.
  6.  
  7. Loosen the timing belt tensioner mounting bolt 1-2 turns.
  8.  
  9. Rotate the engine clockwise 2 revolutions.
  10.  
  11. Tighten the timing belt tensioner mounting bolt.
  12.  
  13. Install the access cover and the air compressor drive belt.
  14.  
  15. Reconnect the negative battery cable.
  16.  

REMOVAL & INSTALLATION



1468cc and 1495cc Engines

See Figures 6 and 7

  1. Disconnect the negative battery cable. Remove the timing belt cover.
  2.  
  3. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke. Loosen the tensioning bolt, it runs in the slotted portion of the tensioner, and the pivot bolt on the timing belt tensioner. Move the tensioner as far as it will go toward the water pump. Tighten the adjusting bolt. Mark the timing belt with an arrow showing direction of rotation if the belt is to be reused.
  4.  
  5. Remove the timing belt.
  6.  
  7. Remove the camshaft sprocket as required.
  8.  
  9. Remove the crankshaft sprocket bolts and remove the crankshaft sprocket and flange, noting the direction of installation for each. Remove the timing belt tensioner.
  10.  
  11. Inspect the belt thoroughly. The back surface must be pliable and rough. If it is hard and glossy, the belt should be replaced. Any cracks in the belt backing or teeth or missing teeth mean the belt must be replaced. The canvas cover should be intact on all the teeth. If rubber is exposed anywhere, the belt should be replaced.
  12.  
  13. Inspect the tensioner for grease leaking from the grease seal and any roughness in rotation. Replace a tensioner for either defect.
  14.  
  15. The sprockets should be inspected and replaced, if there is any sign of damaged teeth or cracking. Do not immerse sprockets in solvent, as solvent that has soaked into the metal may cause deterioration of the timing belt later. Do not clean the tensioner in solvent either, as this may wash the grease out of the bearing.
  16.  

To install:
  1. Install the flange and crankshaft sprocket. The flange must go on first with the chamfered area outward. The sprocket is installed with the boss forward and the studs for the fan belt pulley outward. Install and torque the crankshaft sprocket bolt to 51-72 ft. lbs. (69-98 Nm). Install the camshaft sprocket and bolt, torquing it to 47-54 ft. lbs. (64-74 Nm) on 1468cc engines and 58-72 ft. lbs. (80-100 Nm) on 1495cc engines.
  2.  



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Fig. Fig. 6: Timing belt as installed, note the alignment of the timing marks-1468cc and 1495cc engines



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Fig. Fig. 7: Sprocket alignment for timing belt installation-1468cc and 1495cc engines

  1. Align the timing marks of the camshaft sprocket. Check that the crankshaft timing marks are still in alignment (the locating pin on the front of the crankshaft sprocket is aligned with a mark on the front case).
  2.  
  3. Mount the tensioner, spring and spacer with the bottom end of the spring free. Then, install the bolts and tighten the adjusting bolt slightly with the tensioner moved as far as possible away from the water pump. Install the free end of the spring into the locating tang on the front case. Position the belt over the crankshaft sprocket and then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel. Turn the camshaft sprocket in the opposite of its normal direction of rotation until the straight side of the belt is tight and make sure the timing marks align. If not, shift the belt 1 tooth at a time in the appropriate direction until this occurs.
  4.  
  5. Loosen the tensioner mounting bolts so the tensioner works, without the interference of any friction, under spring pressure. Make sure the belt follows the curve of the camshaft pulley so the teeth are engaged all the way around.
  6.  
  7. Correct the path of the belt, if necessary. Torque the tensioner adjusting bolt to 15-18 ft. lbs. (20-26 Nm). Then, torque the tensioner pivot bolt to the same figure. Bolts must be torqued, in order, or tension won't be correct.
  8.  
  9. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension as before. Torque the bolts in order. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward it. The belt should move toward the pump until the teeth are about 1 / 4 of the way across the head of the tensioner adjusting bolt. Retension the belt, if necessary.
  10.  
  11. Install the timing belt covers.
  12.  
  13. Install the crankshaft pulley, making sure the pin on the crankshaft sprocket fits through the hole in the rear surface of the pulley. Install the bolts and torque to 7.5-8.5 ft. lbs. (9-12 Nm). Connect the negative battery cable.
  14.  

2351cc Engine

See Figures 8 through 13

An 8mm diameter metal bar is needed for this procedure.

  1. Disconnect the negative battery cable. Remove the water pump drive belt and pulley.
  2.  



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Fig. Fig. 8: Timing covers and timing belt assemblies-2351cc engine



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Fig. Fig. 9: Holding the silent shaft in position with an 8mm bar-2351cc engine



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Fig. Fig. 10: Right counterbalance shaft alignment-2351cc engine



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Fig. Fig. 11: Timing belt installation-2351cc engine

  1. Remove the crank adapter and crankshaft pulley.
  2.  



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Fig. Fig. 12: Right counterbalance shaft seal installation-2351cc engine



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Fig. Fig. 13: Removing tensioner "B"-2351cc engine

  1. Remove the upper and lower timing belt covers.
  2.  
  3. Move the tensioner fully in the direction of the water pump and temporarily secure it there.
  4.  
  5. If the timing belt is to be reused, make a paint mark on the belt to indicate the direction of rotation. Slip the belt from the sprockets.
  6.  
  7. Remove the camshaft sprocket bolt and pull the sprocket from the camshaft.
  8.  
  9. Remove the crankshaft sprocket bolt and pull the crankshaft sprocket and flange from the crankshaft.
  10.  
  11. Remove the plug on the left side of the block and insert an 8mm diameter metal bar in the opening to keep the silent shaft in position.
  12.  
  13. Remove the oil pump sprocket retaining nut and remove the oil pump sprocket.
  14.  
  15. Loosen the right silent shaft sprocket mounting bolt until it can be turned by hand.
  16.  
  17. Remove the belt tensioner and remove the timing belt.
  18.  

Do not attempt to turn the silent shaft sprocket or loosen its bolt while the belt is off.

  1. Remove the silent shaft belt sprocket from the crankshaft.
  2.  
  3. Check the belt for wear, damage or glossing. Replace it if any cracks, damage, brittleness or excessive wear are found.
  4.  
  5. Check the tensioners for a smooth rate of movement.
  6.  
  7. Replace any tensioner that shows grease leakage through the seal.
  8.  

To install:
  1. Install the silent shaft belt sprocket on the crankshaft, with the flat face toward the engine.
  2.  
  3. Apply light engine oil on the outer face of the spacer and install the spacer on the right silent shaft. The side with the rounded shoulder faces the engine.
  4.  
  5. Install the sprocket on the right silent shaft and install the bolt but do not tighten completely at this time.
  6.  

Align the silent shaft and oil pump sprockets using the timing marks. If the 8mm metal bar can not be inserted into the hole 2.36 inch (60mm), the oil pump sprocket will have to turned 1 full rotation until the bar can be inserted to the full length. The above step assures that the oil pump sprocket and silent shafts are in correct orientation. This step must not be skipped or a vibration may develop during engine operation.

  1. Install the silent shaft belt and adjust the tension, by moving the tensioner into contact with the belt, tight enough to remove all slack. Tighten the tensioner bolt to 21 ft. lbs. (28 Nm).
  2.  
  3. Tighten the silent shaft sprocket bolt to 28 ft. lbs. (36 Nm).
  4.  
  5. Install the flange and crankshaft sprocket on the crankshaft. The flange conforms to the front of the silent shaft sprocket and the timing belt sprocket is installed with the flat face toward the engine.
  6.  

The flange must be installed correctly or a broken belt will result.

  1. Install the washer and bolt in the crankshaft and torque it to 94 ft. lbs. (130 Nm).
  2.  
  3. Install the camshaft sprocket and bolt and torque the bolt to 72 ft. lbs. (96 Nm).
  4.  
  5. Install the timing belt tensioner, spacer and spring.
  6.  
  7. Align the timing mark on each sprocket with the corresponding mark on the front case.
  8.  
  9. Install the timing belt on the sprockets and move the tensioner against the belt with sufficient force to allow a deflection of 5-7mm along its longest straight run.
  10.  
  11. Tighten the tensioner bolt to 21 ft. lbs. (28 Nm).
  12.  
  13. Install the upper and lower covers, the crankshaft pulley and the crank adapter. Tighten the bolts to 21 ft. lbs. (28 Nm).
  14.  
  15. Remove the 8mm bar and install the plug. Connect the negative battery cable.
  16.  

1596cc, 1796cc and 1997cc Engines

See Figures 14 through 20

The 1596cc engine is not equipped with silent shafts. Disregard all instructions pertaining to silent shafts if working on that engine.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing belt upper and lower covers.
  4.  
  5. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke. At this time the timing marks on the camshaft sprocket and the upper surface of the cylinder head should coincide, and the dowel pin of the camshaft sprocket should be at the upper side.
  6.  

Always rotate the crankshaft in a clockwise direction. Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused.

  1. Remove the auto tensioner and remove the outermost timing belt.
  2.  
  3. Remove the timing belt tensioner pulley, tensioner arm, idler pulley, oil pump sprocket, special washer, flange and spacer.
  4.  
  5. Remove the silent shaft (inner) belt tensioner and remove the inner belt.
  6.  

To install:
  1. Align the timing marks on the crankshaft sprocket and the silent shaft sprocket. Fit the inner timing belt over the crankshaft and silent shaft sprocket. Ensure that there is no slack in the belt.
  2.  



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Fig. Fig. 14: Timing belt and cover assemblies-1596cc engine



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Fig. Fig. 15: Timing belt and cover assemblies-1796cc and 1997cc engines



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Fig. Fig. 16: Timing mark alignment for proper belt installation-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 17: Note the direction of the belt if it is going to be re-used-1596cc, 1796cc and 1997cc engines

  1. While holding the inner timing belt tensioner with your fingers, adjust the timing belt tension by applying a force towards the center of the belt, until the tension side of the belt is taut. Tighten the tensioner bolt.
  2.  

When tightening the bolt of the tensioner, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.

  1. Check belt for proper tension by depressing the belt on its long side with your finger and noting the belt deflection. The desired reading is 0.20-0.28 in. (5-7mm). If tension is not correct, readjust and check belt deflection.
  2.  
  3. Install the flange, crankshaft and washer to the crankshaft. The flange on the crankshaft sprocket must be installed towards the inner timing belt sprocket. Tighten bolt to 80-94 ft. lbs. (110-130 Nm).
  4.  
  5. To install the oil pump sprocket, insert a Phillips screwdriver with a shaft 0.31 in. (8mm) in diameter into the plug hole in the left side of the cylinder block to hold the left silent shaft. Tighten the nut to 36-43 ft. lbs. (50-60 Nm).
  6.  



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Fig. Fig. 18: Rotate the camshaft using a wrench on the flats of the cam-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 19: Installing the timing belt tensioner-1596cc, 1796cc and 1997cc engines



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Fig. Fig. 20: Proper camshaft sprocket alignment-1596cc, 1796cc and 1997cc engines

  1. Using a wrench, hold the camshaft at its hexagon between journal No. 2 and 3 and tighten bolt to 58-72 ft. lbs. (80-100 Nm). If no hexagon is present between journal No. 2 and 3, hold the sprocket stationary with a spanner wrench while tightening the retainer bolt.
  2.  
  3. Carefully push the auto tensioner rod in until the set hole in the rod is aligned with the hole in the cylinder. Place a wire into the hole to retain the rod.
  4.  
  5. Install the tensioner pulley onto the tensioner arm. Locate the pinhole in the tensioner pulley shaft to the left of the center bolt. Then, tighten the center bolt finger-tight.
  6.  
  7. When installing the timing belt, turn the 2 camshaft sprockets so their dowel pins are located on top. Align the timing marks facing each other with the top surface of the cylinder head. When you let go of the exhaust camshaft sprocket, it will rotate 1 tooth in the counterclockwise direction. This should be taken into account when installing the timing belts on the sprocket.
  8.  

Both camshaft sprockets are used for the intake and exhaust camshafts and are provided with 2 timing marks. When the sprocket is mounted on the exhaust camshaft, use the timing mark on the right with the dowel pin hole on top. For the intake camshaft sprocket, use the 1 on the left with the dowel pin hole on top.

  1. Align the crankshaft sprocket and oil pump sprocket timing marks.
  2.  
  3. After alignment of the oil pump sprocket timing marks, remove the plug on the cylinder block and insert a Phillips screw driver with a shaft diameter of 0.31 in. (8mm) through the hole. If the shaft can be inserted 2.4 in. deep, the silent shaft is in the correct position. If the shaft of the tool can only be inserted 0.8-1.0 in. (20-25mm) deep, turn the oil pump sprocket 1 turn and realign the marks. Reinsert the tool making sure it is inserted 2.4 in. deep. Keep the tool inserted in hole for the remainder of this procedure.
  4.  

The above step assures that the oil pump socket is in correct orientation to the silent shafts. This step must not be skipped or a vibration may develop during engine operation.

  1. Install the timing belt as follows:
    1. Install the timing belt around the intake camshaft sprocket and retain it with 2 spring clips or binder clips.
    2.  
    3. Install the timing belt around the exhaust sprocket, aligning the timing marks with the cylinder head top surface using 2 wrenches. Retain the belt with 2 spring clips.
    4.  
    5. Install the timing belt around the idler pulley, oil pump sprocket, crankshaft sprocket and the tensioner pulley. Remove the 2 spring clips.
    6.  
    7. Lift upward on the tensioner pulley in a clockwise direction and tighten the center bolt. Make sure all timing marks are aligned.
    8.  
    9. Rotate the crankshaft 1 / 4 turn counterclockwise. Then, turn in clockwise until the timing marks are aligned again.
    10.  

  2.  
  3. To adjust the timing (outer) belt, turn the crankshaft 1 / 4 turn counterclockwise, then turn it clockwise to move No. 1 cylinder to TDC.
  4.  
  5. Loosen the center bolt. Using tool MD998738 or equivalent and a torque wrench, apply a torque of 1.88-2.03 ft. lbs. (2.6-2.8 Nm). Tighten the center bolt.
  6.  
  7. Screw the special tool into the engine left support bracket until its end makes contact with the tensioner arm. At this point, screw the special tool in some more and remove the set wire attached to the auto tensioner, if the wire was not previously removed. Then remove the special tool.
  8.  
  9. Rotate the crankshaft 2 complete turns clockwise and let it sit for approximately 15 minutes. Then, measure the auto tensioner protrusion (the distance between the tensioner arm and auto tensioner body) to ensure that it is within 0.15-0.18 in. (3.8-4.5mm). If out of specification, repeat Step 1-4 until the specified value is obtained.
  10.  
  11. If the timing belt tension adjustment is being performed with the engine mounted in the vehicle, and clearance between the tensioner arm and the auto tensioner body cannot be measured, the following alternative method can be used:
    1. Screw in special tool MD998738 or equivalent, until its end makes contact with the tensioner arm.
    2.  
    3. After the special tool makes contact with the arm, screw it in some more to retract the auto tensioner pushrod while counting the number of turns the tool makes until the tensioner arm is brought into contact with the auto tensioner body. Make sure the number of turns the special tool makes conforms with the standard value of 2 1 / 2 -3 turns.
    4.  
    5. Install the rubber plug to the timing belt rear cover.
    6.  

  12.  
  13. Install the timing belt covers and all related items.
  14.  
  15. Connect the negative battery cable.
  16.  

2972cc Engine

See Figures 21 and 22

  1. Disconnect the negative battery cable.
  2.  



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Fig. Fig. 21: Timing belt components and arrangement-2972cc engine



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Fig. Fig. 22: Timing belt tensioner spring installation-2972cc engine

  1. To remove the air conditioning compressor belt, loosen the adjustment pulley locknut, turn the screw counterclockwise to reduce the drive belt tension and remove the belt.
  2.  
  3. To remove the serpentine drive belt, insert a 1 / 2 in. breaker bar into the square hole of the tensioner pulley, rotate it counterclockwise to reduce the drive belt tension and remove the belt.
  4.  
  5. Remove the air conditioning compressor and the air compressor bracket, power steering pump and alternator from the mounts and support them to the side. Remove power steering pump/alternator automatic belt tensioner bolt and the tensioner.
  6.  
  7. Raise the vehicle and support safely. Remove the right inner fender splash shield.
  8.  
  9. Remove the crankshaft pulley bolt and the pulley/damper assembly from the crankshaft.
  10.  
  11. Lower the vehicle and place a floor jack under the engine to support it.
  12.  
  13. Separate the front engine mount insulator from the bracket. Raise the engine slightly and remove the mount bracket.
  14.  
  15. Remove the timing belt cover bolts and the upper and lower covers from the engine.
  16.  
  17. Turn the crankshaft until the timing marks on the camshaft sprocket and cylinder head are aligned.
  18.  
  19. Loosen the tensioning bolt, it runs in the slotted portion of the tensioner, and the pivot bolt on the timing belt tensioner.
  20.  
  21. Move the tensioner counterclockwise as far as it will go. Tighten the adjusting bolt.
  22.  
  23. Mark the timing belt with an arrow showing direction of rotation.
  24.  
  25. Remove the timing belt from the camshaft sprocket.
  26.  
  27. Remove the crankshaft pulley. Then, remove the timing belt. Remove the timing belt tensioner. Remove the retainer bolts from the timing sprockets and remove as required.
  28.  
  29. Inspect the belt thoroughly. The back surface must be pliable and rough. If it is hard and glossy, the belt should be replaced. Any cracks in the belt backing or teeth or missing teeth mean the belt must be replaced. The canvas cover should be intact on all the teeth. If rubber is exposed anywhere, the belt should be replaced.
  30.  
  31. Inspect the tensioner for grease leaking from the grease seal and any roughness in rotation. Replace a tensioner for either defect.
  32.  
  33. The sprockets should be inspected and replaced if there is any sign of damaged teeth or cracking anywhere.
  34.  
  35. Do not immerse sprockets in solvent, as solvent that has soaked into the metal may cause deterioration of the timing belt later.
  36.  
  37. Do not clean the tensioner in solvent either, as this may wash the grease out of the bearing.
  38.  

To install:
  1. Align the timing marks of the camshaft sprocket. Check that the crankshaft timing marks are still in alignment, the locating pin on the front of the crankshaft sprocket is aligned with a mark on the front case.
  2.  
  3. Mount the tensioner, spring and spacer with the bottom end of the spring free. Then, install the bolts and tighten the adjusting bolt slightly with the tensioner moved as far as possible away from the water pump. Install the free end of the spring into the locating tang on the front case. Position the belt over the crankshaft sprocket and then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel. Turn the camshaft sprocket in the opposite of its normal direction of rotation until the straight side of the belt is tight and make sure the timing marks align. If not, shift the belt 1 tooth at a time in the appropriate direction until this occurs.
  4.  
  5. Loosen the tensioner mounting bolts so the tensioner works, without the interference of any friction, under spring pressure. Make sure the belt follows the curve of the camshaft pulley so the teeth are engaged all the way around.
  6.  
  7. Correct the path of the belt, if necessary. Torque the tensioner adjusting bolt to 16-21 ft. lbs. (22-29 Nm). Then, torque the tensioner pivot bolt to the same figure. Bolts must be torqued in that order, or tension won't be correct.
  8.  
  9. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt. Then loosen both tensioner attaching bolts and let the tensioner position itself under spring tension as before. Finally, torque the bolts in the proper order exactly as before. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward it. The belt should move toward the pump until the teeth are about 1 / 4 of the way across the head of the tensioner adjusting bolt. Retension the belt, if necessary.
  10.  
  11. Install the timing belt covers.
  12.  
  13. Install the crankshaft pulley, making sure the pin on the crankshaft sprocket fits through the hole in the rear surface of the pulley. Install the retaining bolt and torque to 108-116 ft. lbs. (147-157 Nm).
  14.  
  15. Install the engine mount bracket and secure with the mounting hardware.
  16.  
  17. Install the pulley damper assembly to the crankshaft. Torque the bolt to 110 ft. lbs. (149 Nm). Install the splash shield.
  18.  
  19. Install the power steering pump/alternator automatic belt tensioner.
  20.  
  21. Install the air conditioning compressor bracket, compressor, power steering pump and alternator.
  22.  
  23. Install the accessory drive belt.
  24.  
  25. Connect the negative battery cable and check all disturbed components for proper operation.
  26.  

 
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