Hyundai Coupes/Sedans 1994-1998 Repair Guide

Timing Belt and Sprockets

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CAUTION
Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.

REMOVAL & INSTALLATION



See Figures 1 through 10



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Fig. Fig. 1: On some models, to gain access to the bottom of the engine, you must remove the engine undercover



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Fig. Fig. 2: It is sometimes easier to loosen the crankshaft pulley bolt with the accessory belts installed



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Fig. Fig. 3: Remove the crankshaft pulley bolt....



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Fig. Fig. 4: ....the crankshaft pulley spacer....



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Fig. Fig. 5: ....and then the crankshaft pulley



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Fig. Fig. 6: Removing the lower timing belt cover allows access to the crankshaft sprocket and timing belt tensioner



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Fig. Fig. 7: After loosening the tensioner, remove the timing belt....



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Fig. Fig. 8: ....the crankshaft sprocket....



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Fig. Fig. 9: ....and the crankshaft sprocket flange



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Fig. Fig. 10: This tensioner is secured by two bolts. One bolt goes through the spring, the other in the slotted area

1.5L (VIN E) and 1.5L (VIN J) Engines

See Figures 11, 12, 13, 14 and 15



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Fig. Fig. 11: Timing belt components-1.5L (VIN E) and 1.5L (VIN J) engines



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Fig. Fig. 12: Properly align the timing marks prior to installing the timing belt-1.5L (VIN E),1.5L (VIN J) and 1.5L (VIN K) engines



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Fig. Fig. 13: Use a pry bar to properly position the timing belt tensioner spring-1.5L (VIN E),1.5L (VIN J) and 1.5L (VIN K) engines



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Fig. Fig. 14: When tightening the tensioner bolts, first tighten the adjuster bolt and then the pivot bolt-1.5L (VIN E),1.5L (VIN J) and 1.5L (VIN K) engines



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Fig. Fig. 15: Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward the water pump. The belt should move toward the pump until the teeth are about 1/2 of the way across the head of the tensioner adjusting bolt-1.5L (VIN E),1.5L (VIN J) and 1.5L (VIN K) engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the crankshaft and water pump pulleys.
  6.  
  7. Remove the timing belt cover.
  8.  
  9. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke.
  10.  
  11. Loosen the tensioning bolt 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.
  12.  
  13. Mark the timing belt with an arrow showing direction of rotation.
  14.  
  15. Remove the timing belt.
  16.  
  17. Remove the camshaft sprocket as required.
  18.  
  19. Remove the crankshaft sprocket and flange.
  20.  

Note the direction of installation for the crankshaft sprocket and flange.

  1. Remove the timing belt tensioner.
  2.  

To install:
  1. Install the flange and crankshaft sprocket. Tighten bolts to 51-72 ft. lbs. (69-98 Nm).
  2.  

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.

  1. Install the camshaft sprocket. Tighten bolt to 47-54 ft. lbs. (64-74 Nm) on 1.5L (VIN J) engines and 58-72 ft. lbs. (80-100 Nm) on 1.5L (VIN E) engines.
  2.  
  3. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
  4.  
  5. Install the timing belt tensioner, spring and spacer with the bottom end of the spring free. Tighten the adjusting bolt slightly with the tensioner moved as far as possible away from the water pump.
  6.  
  7. Install the free end of the spring into the locating tang on the front case.
  8.  
  9. Position the timing belt over the crankshaft sprocket and then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel.
  10.  
  11. 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.
  12.  

If timing marks do not align, shift the belt 1 tooth at a time in the appropriate direction..

  1. 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. Correct the path of the belt, if necessary.
  2.  
  3. Tighten the tensioner adjusting bolt, then the tensioner pivot bolt to 15-18 ft. lbs. (20-26 Nm).
  4.  

Bolts must be torqued in the stated order or tension won't be correct.

  1. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt.
  2.  
  3. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension. Retighten the bolts.
  4.  
  5. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward the water pump. The belt should move toward the pump until the teeth are about 1/2 of the way across the head of the tensioner adjusting bolt. Retension the belt, if necessary.
  6.  
  7. Install the timing belt covers.
  8.  
  9. Install the crankshaft pulley, making sure the pin on the crankshaft sprocket fits through the hole in the rear surface of the pulley.
  10.  
  11. Install the water pump pulley.
  12.  
  13. Install and tension the accessory drive belts.
  14.  
  15. Connect the negative battery cable.
  16.  

1.5L (VIN K) Engine

See Figure 16



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Fig. Fig. 16: Timing belt components-1.5L (VIN K) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the coolant pump and crankshaft pulleys.
  6.  
  7. Remove the timing belt cover.
  8.  
  9. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke.
  10.  
  11. Move the timing belt tensioner toward the water pump and temporarily secure it.
  12.  
  13. Remove the camshaft sprocket.
  14.  
  15. Mark the timing belt with an arrow showing direction of rotation.
  16.  
  17. Remove the timing belt.
  18.  
  19. Remove the crankshaft sprocket and flange.
  20.  

Note the direction of installation for the crankshaft sprocket and flange.

  1. Remove the timing belt tensioner.
  2.  

To install:
  1. Install the flange and crankshaft sprocket. Tighten crankshaft sprocket bolt to 110-118 ft. lbs. (150-160 Nm).
  2.  

Pay special attention to the mounting direction of the crankshaft sprocket. The flange should face the engine.

  1. Install camshaft sprocket. Tighten bolts to 59-73 ft. lbs. (80-100 Nm).
  2.  
  3. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
  4.  
  5. Install the timing belt tensioner spring and spacer. Temporarily tighten the tensioner bolt. Install the bottom end of the spring against the front case.
  6.  
  7. Install the timing belt on the crankshaft sprocket.
  8.  
  9. Position the timing belt over the crankshaft sprocket and then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel.
  10.  
  11. 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.
  12.  

If timing marks do not align, shift the belt 1 tooth at a time in the appropriate direction..

  1. 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. Correct the path of the belt, if necessary.
  2.  
  3. Tighten the tensioner adjusting bolt, then the tensioner pivot bolt to 15-18 ft. lbs. (20-26 Nm).
  4.  

Bolts must be torqued in the stated order or tension won't be correct.

  1. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt.
  2.  
  3. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension. Retighten the bolts
  4.  
  5. Check belt tension by putting a finger on the water pump side of the tensioner wheel and pull the belt toward the water pump. The belt should move toward the pump until the teeth are about 1/2 of the way across the head of the tensioner adjusting bolt. Retension the belt, if necessary.
  6.  
  7. Install the timing belt covers.
  8.  
  9. Install the crankshaft pulley, making sure the pin on the crankshaft sprocket fits through the hole in the rear surface of the pulley.
  10.  
  11. Install the water pump pulley.
  12.  
  13. Install and tension the accessory drive belts.
  14.  
  15. Connect the negative battery cable.
  16.  

1996-98 1.8L (VIN M) and 2.0L (VIN F)Engines

See Figures 17 and 18



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Fig. Fig. 17: The timing belt is held in place by a tensioner and an idler pulley-1996-98 1.8L (VIN M) and 2.0L (VIN F) engines



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Fig. Fig. 18: Properly align the timing marks prior to installing the timing belt-1996-98 1.8L (VIN M) and 2.0L (VIN F) engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the crankshaft and water pump pulleys.
  6.  
  7. Remove the timing belt cover.
  8.  
  9. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at TDC of the compression stroke.
  10.  
  11. Remove the timing belt tensioner and idler pulley.
  12.  
  13. Mark the timing belt with an arrow showing direction of rotation.
  14.  
  15. Remove the timing belt.
  16.  
  17. Remove the camshaft sprocket.
  18.  
  19. Remove the crankshaft sprocket and flange.
  20.  

Note the direction of installation for the crankshaft sprocket and flange.

To install:
  1. Install the flange and crankshaft sprocket.
  2.  

Pay special attention to the mounting direction of the crankshaft sprocket. The flange should face the engine.

  1. Install camshaft sprocket. Tighten bolts to 74-89 ft. lbs. (100-120 Nm).
  2.  
  3. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
  4.  
  5. Install the timing belt tensioner.
  6.  
  7. Install the idler pulley, if equipped. Tighten bolt to 32-41 ft. lbs. (43-55 Nm).
  8.  
  9. Position the timing belt over the camshaft sprocket and then over the crankshaft sprocket.
  10.  
  11. Tension the timing belt and tighten the tensioner pulley bolt to 32-41 ft. lbs. (43-55 Nm). When properly tensioned, the timing belt should deflect 0.16-0.24 in. (4-6 mm) when a force of 5 lbs is placed on the longest span of the belt.
  12.  
  13. Turn the crankshaft sprocket one turn clockwise and realign the crankshaft sprocket timing mark.
  14.  
  15. Recheck the belt tension and adjust as necessary.
  16.  
  17. Install the timing belt covers.
  18.  
  19. Install the crankshaft pulley, making sure the pin on the crankshaft sprocket fits through the hole in the rear surface of the pulley. Tighten pulley bolt to 125-133 ft. lbs. (170-180 Nm).
  20.  
  21. Install the water pump pulley.
  22.  
  23. Install and tension the accessory drive belts.
  24.  
  25. Connect the negative battery cable.
  26.  

1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) Engines

See Figures 19 through 27



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Fig. Fig. 19: Timing belt components-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 20: Insert a screwdriver with a 0.32 in. (8 mm) diameter shaft into the left side cylinder block plug hole. The screwdriver will hold the counter balance shaft stable during timing belt service-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 21: Tightening the oil pump sprocket bolt after installing the timing belt tensioner "B", timing belt "B" and the crankshaft sprocket "B"-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 22: Oil pump and crankshaft sprocket "B" timing mark locations-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 23: Check belt for proper timing belt "B" 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) -1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 24: Use a soft jawed vice to compress the timing belt tensioner until holes "A" and "B" align....-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 25: ....then insert a wire to hold the tensioner piston in place-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 26: Timing mark locations-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines



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Fig. Fig. 27: Special tools used to adjust timing belt tension-1.6L (VIN R), 2.0L (VIN P) and 1994-95 1.8L (VIN M) engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the crankshaft pulley, water pump pulley and drive belts.
  4.  
  5. Remove the timing belt upper and lower covers.
  6.  

Always rotate the crankshaft in a clockwise direction.

  1. 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.
  2.  
  3. Remove the timing belt tensioner.
  4.  
  5. Mark the timing belt indicating the direction of rotation.
  6.  
  7. Remove the timing belt.
  8.  
  9. Remove the camshaft sprockets.
  10.  
  11. Insert a screwdriver with a 0.32 in. (8 mm) diameter shaft into the left side cylinder block plug hole. The screwdriver will hold the counter balance shaft stable while removing the oil pump sprocket retaining nut.
  12.  
  13. Remove the oil pump sprocket.
  14.  
  15. Loosen the right counter balance shaft sprocket bolt.
  16.  
  17. Remove the timing belt tensioner "B".
  18.  
  19. Remove the timing belt "B".
  20.  
  21. Remove the crankshaft sprocket "B".
  22.  

To install:
  1. Install the crankshaft sprocket "B".
  2.  

Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken belt could result.

  1. Lightly lubricate the outer surface of the spacer with engine oil and install with the chamfer toward the engine.
  2.  
  3. Install counter balance shaft sprocket and tighten flange bolt finger tight.
  4.  
  5. Align timing mark on each sprocket with corresponding timing mark on front case.
  6.  
  7. Install the timing belt "B".
  8.  

When installing timing belt "B", ensure tension side has no slack.

  1. Install the timing belt tensioner "B" with the center of the pulley on the left side of the mounting bolt and with pulley flange facing front of engine.
  2.  
  3. Lift the timing belt tensioner "B" to tighten the timing belt "B" so that its tension side will be pulled tight.
  4.  
  5. Tighten the bolt to secure tensioner "B".
  6.  

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 to ensure the timing marks are in alignment.
  2.  
  3. 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).
  4.  
  5. Install the flange, crankshaft sprocket 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).
  6.  
  7. Insert a screwdriver with a 0.32 in. (8 mm) diameter shaft into the left side cylinder block plug hole. The screwdriver will hold the counter balance shaft stable while removing the oil pump sprocket retaining nut.
  8.  
  9. Install the oil pump sprocket and tighten the nut to 36-43 ft. lbs. (50-60 Nm).
  10.  
  11. Install the camshaft sprocket and tighten the bolt to 56-72 ft. lbs. (80-100 Nm).
  12.  
  13. 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.
  14.  
  15. Install the timing belt tensioner.
  16.  
  17. Install the tensioner pulley onto the tensioner arm. Locate the pinhole in the tensioner pulley shaft to the left of the center bolt. Tighten the center bolt finger-tight.
  18.  
  19. Turn the two 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.
  20.  

Both camshaft sprockets are used for the intake and exhaust camshafts and are provided with two 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. Insert a screwdriver with a 0.32 in. (8 mm) diameter shaft into the left side cylinder block plug 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.
  4.  

Keep the tool inserted in hole for the remainder of this procedure. 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 around the tensioner pulley and crankshaft sprocket. Hold the belt with your left hand.
  2.  
  3. Pulling the belt with your right hand, install it around the oil pump sprocket.
  4.  
  5. Install the belt around the idler pulley and intake camshaft sprocket.
  6.  
  7. Turn the exhaust camshaft sprocket one tooth clockwise to align it timing mark with the cylinder head top surface. Pulling the belt with both hands, install it around the exhaust camshaft sprocket.
  8.  
  9. Gently raise the tensioner pulley so that the belt does not sag and temporarily tighten the center bolt.
  10.  
  11. Turn the crankshaft 1/4 turn counterclockwise. Turn the crankshaft clockwise to move the No. 1 cylinder to TDC.
  12.  
  13. Loosen the center bolt and attach special tool (PN 09244-28100) or equivalent to a torque wrench. Apply a torque of 1.88-2.03 ft. lbs. (2.6-2.8 Nm). Tighten the center bolt.
  14.  
  15. Screw the special tool (PN 09244-28000) or 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 the wire was not previously removed.
  16.  
  17. Remove the special tool.
  18.  
  19. 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).
  20.  
  21. 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 (PN 09244-28000) 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.  

  22.  
  23. Install the timing belt covers.
  24.  
  25. Remove the crankshaft pulley, water pump pulley and drive belts.
  26.  
  27. Connect the negative battery cable.
  28.  

3.0L (VIN T) Engine

See Figures 28, 29 and 30



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Fig. Fig. 28: Timing belt components-3.0L (VIN T) engine



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Fig. Fig. 29: Remove the engine support bracket bolts in the number sequence shown. Slowly remove the reamer bolt. The mounting bolts must also be installed in the sequence shown. When installing the reamer bolt, tighten it slowly while spraying it with penetrating lubricant-3.0L (VIN T) engine



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Fig. Fig. 30: Attach the top of the tensioner spring on the engine coolant pump pin. Ensure the hook on the pin is facing down and the hook on the tensioner is facing away from the engine-3.0L (VIN T) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  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.
  6.  
  7. Place a floor jack under the engine to support it.
  8.  
  9. Remove the engine support bracket in the number sequence shown in the illustration. Slowly remove the reamer bolt.
  10.  

The reamer bolt may be heat seized to the support bracket.

  1. Remove the crankshaft pulley.
  2.  
  3. Remove the upper and lower timing belt covers.
  4.  
  5. Turn the crankshaft until the timing marks on the camshaft sprocket and cylinder head are aligned.
  6.  
  7. Loosen the timing belt tensioner bolt and turn the tensioner counterclockwise as far as it will go. Tighten the adjusting bolt.
  8.  
  9. Mark the timing belt with an arrow showing direction of rotation.
  10.  
  11. Remove the timing belt.
  12.  
  13. Remove the crankshaft and camshaft pulleys.
  14.  
  15. Remove the timing belt tensioner.
  16.  

To install:
  1. Install the camshaft sprockets. Tighten bolt to 58-72 ft. lbs. (80-100 Nm).
  2.  
  3. Install the timing belt tensioner.
  4.  
  5. Attach the top of the tensioner spring on the engine coolant pump pin. Ensure the hook on the pin is facing down and the hook on the tensioner is facing away from the engine
  6.  
  7. Rotqate the timing belt tensioner to the extreme counterclockwise position. Temporarily lock the tensioner in place.
  8.  
  9. Align the timing marks of the camshaft and crankshaft sprockets.
  10.  
  11. Install the timing belt on the crankshaft sprocket, then onto the rear camshaft sprocket.
  12.  
  13. Route the belt to the coolant pump pulley, the front camshaft sprocket and the timing belt tensioner.
  14.  
  15. Apply force counterclockwise to the rear camshaft sprocket with tension on the tight side of the belt and check that timing marks are aligned.
  16.  
  17. Loosen the tensioner bolt one or two turns and tighten the timing belt to a tension of 57-84 lbs. (260-380 N).
  18.  
  19. Turn the crankshaft two turns clockwise.
  20.  
  21. Readjust the sprocket timing marks and tighten the tensioner bolts.
  22.  
  23. Install the timing belt covers.
  24.  
  25. Install the crankshaft pulley and tighten to 108-116 ft. lbs. (150-160 Nm).
  26.  
  27. Install the engine support bracket. The mounting bolts must be installed in the sequence shown in the illustration.
  28.  

When installing the reamer bolt, tighten it slowly while spraying it with penetrating lubricant.

  1. Install the air conditioning compressor bracket, compressor, power steering pump and alternator.
  2.  
  3. Install the accessory drive belts.
  4.  
  5. Connect the negative battery cable.
  6.  

 
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