Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Timing Belt and Covers

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REMOVAL & INSTALLATION



1983-87 626-Except Diesel

See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12

For access, safely support the car, then remove the right front wheel and splash shield.

  1. Loosen the alternator mounting bolts and relieve belt tension, then remove the alternator belt.
  2.  
  3. Unfasten the attaching bolts, then remove the upper timing belt cover and gasket.
  4.  



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Fig. Fig. 1: Remove the bolts which fasten the upper timing belt cover ...



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Fig. Fig. 2: ... and remove the cover



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Fig. Fig. 3: Unfasten the four mounting bolts which retain the crankshaft pulley ...



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Fig. Fig. 4: ... and remove the pulley



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Fig. Fig. 5: If necessary, pull outward slightly on the fender skirt to provide clearance for crankshaft pulley removal



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Fig. Fig. 6: Unfasten and remove the lower timing belt cover



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Fig. Fig. 7: Align the camshaft pulley mark (A) with the V-notch at the top of the front housing

  1. Unfasten the four mounting bolts and remove the front pulley from the hub on the crankshaft. Then, remove the attaching bolts and the lower timing belt cover and gasket.
  2.  
  3. Now, rotate the engine in its normal direction (clockwise when viewed from the passenger's side) until the camshaft pulley mark (A) aligns with the V-notch at the top of the front housing. At this point, the notch in the crankshaft pulley will align with the arrow on the front housing. Note that if the belt has jumped time, these marks will not align simultaneously. If that is true, your first step after belt removal should be align the crankshaft marks.
  4.  
  5. Loosen the tensioner lockbolt until it can be turned by hand. Then, remove the tensioner spring (brake pliers may be helpful).
  6.  
  7. Mark the direction of rotation on the belt if it may be reused and remove it. Inspect the belt and replace if it is oil soaked, or shows excessive wear, peeling, cracking, or hardening. Inspect the tensioner for free and smooth rotation; replace if it does not turn smoothly.
  8.  

To install:
  1. Position the tensioner all the way toward the intake valve side.
  2.  
  3. Install a new belt or reinstall the old one with the arrow indicating the proper direction of rotation (that is, the arrow should point clockwise around the top pulley when viewed from the passenger side of the car). Make sure the belt teeth engage the water pump pulley and the camshaft/crankshaft pulleys, with the belt running straight from top to bottom on the right side. Then, route the belt around the tensioner pulley.
  4.  



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Fig. Fig. 8: Align the notch in the crankshaft pulley with the arrow on the front housing



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Fig. Fig. 9: Use a wrench to loosen the tensioner lockbolt



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Fig. Fig. 10: If the timing belt is reusable, mark its direction of rotation before removal



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Fig. Fig. 11: Slip the timing belt off the crankshaft pulley and remove from above



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Fig. Fig. 12: Install the timing belt around the camshaft, crankshaft, and water pump pulleys, then inside the tensioner pulley. If present, be sure the directional arrow on the belt points in the proper direction

  1. Install the spring to the tensioner. With a wrench on the crankshaft pulley, turn the engine in its normal direction of rotation until the crankshaft has rotated two turns and verify that the camshaft pulley returns to its former position. Torque the tensioner lockbolt to 28-38 ft. lbs. (38-51 Nm). If the belt is a used one, check deflection. Under 22 lbs. (10 kg) pressure, the belt should deflect 0.47-0.55 in. (12-14mm). You can repeat this step to reseat and retension the belt, then recheck deflection. If a used belt won't pass the test, replace it.
  2.  
  3. Install the lower timing belt cover, using a new gasket if necessary. Torque the bolts to 5-7 ft. lbs. (7-9 Nm). Do the same with the upper cover.
  4.  
  5. Install the front pulley and alternator belt. Be sure to properly tension the belt.
  6.  
  7. Install the splash shield and right front wheel, then lower the car.
  8.  

626 Diesel
FRONT TIMING BELT

See Figures 13 and 14

This procedure includes camshaft pulley (sprocket) removal and timing belt crankshaft pulley (sprocket) removal, even though belt removal/installation is possible without those steps. If you choose not to remove the camshaft pulley and timing belt crankshaft pulley, omit Steps 9-13.

To perform this procedure, you will need a 6mm hexagonal (Allen type) socket wrench. If you choose to remove the camshaft pulley, you will also need a puller with bolts that screw into the threaded holes in the pulley.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belts and right side splash shield. Remove the cylinder head cover.
  4.  



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Fig. Fig. 13: Align the mark on the camshaft pulley with the mark on the front seal plate



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Fig. Fig. 14: After removing the timing belt, rotate the crankshaft 45° clockwise to guard against piston or valve damage

  1. Using a 6mm hex (Allen type) wrench, unfasten the bolts and remove the crankshaft pulley.
  2.  
  3. Remove the right and left timing belt covers along with their gaskets.
  4.  
  5. Turn the crankshaft via the bolt at its center until the timing marks on the camshaft pulley and front seal plate align.
  6.  
  7. Loosen the lockbolt on the belt tensioner, push the tensioner to the left (so as to tighten the spring and loosen the belt), then hold it there as you retighten the lockbolt. Now, unbolt and remove the torque stop from in front of the timing belt.
  8.  
  9. If you plan on reusing the belt, mark the direction of rotation, then remove the belt.
  10.  
  11. Turn the crankshaft 45 degrees to the right of the timing mark on the front of the oil pump housing, as shown. (This will prevent damaging the pistons and valves.)
  12.  
  13. Hold the camshaft with an open-end wrench installed on the flats located just behind the center bearing. Loosen the pulley lockbolt, but do not remove it. Then, install a puller by screwing its two outer bolts into the threaded holes in the pulley. When these two bolts are threaded in all the way, tighten the bolt at the center of the puller, so that its inner end rests against the lockbolt. Continue tightening the center bolt until it frees the pulley from the camshaft. Be sure to retain the key and examine it; if the key is worn or scored, dress it with a fine jeweler's file or a piece of emery cloth. If worn to excess, replace the key.
  14.  
  15. If the timing belt crankshaft pulley must be removed, use a tire iron or suitable flywheel locking device to hold the flywheel in place as you remove the lockbolt. The pulley slides right off the crankshaft. Be sure to retain both the washer and key. Inspect the key as described above.
  16.  
  17. Inspect all parts. Check the belt for peeling and cracks or for excessively worn/broken teeth. Check the tensioner for rough rotation. Replace worn or damaged parts, as necessary.
  18.  

To install:
  1. Install the timing belt crankshaft pulley with its key, the spacer, and the bolt. Restrain the flywheel and torque the bolt to 116-123 ft. lbs. (157-167 Nm).
  2.  
  3. Install the camshaft pulley and lockbolt. Hold the camshaft by the flats with an open-end wrench as you torque the bolt to 41-48 ft. lbs. (56-65 Nm).
  4.  
  5. Realign the camshaft pulley and front seal plate timing marks (located at about 2 o'clock). Turn the crankshaft backward (counterclockwise) until the timing mark on the oil pump housing and the notch on the rear of the timing belt crankshaft pulley again align.
  6.  
  7. Install the timing belt (in the same direction of rotation, if it is being reused). The teeth should engage, the right side should be straight (without play), and the timing marks should align for both the camshaft and crankshaft pulleys. Make sure to route the belt over the tensioner and around the water pump pulley.
  8.  
  9. Loosen the tensioner lockbolt so that the spring is fully free to tension the belt. Then, turn the engine via the crankshaft bolt two full revolutions in the direction of normal rotation. Torque the tensioner lockbolt to 23-34 ft. lbs. (31-46 Nm).
  10.  
  11. Recheck alignment of the timing marks (if they are not lined up, you will have to relieve the tension and reinstall the belt with the timing marks properly aligned). Check the timing belt deflection by pressing the belt inward with thumb pressure on the span between the camshaft and water pump pulleys. With a force of about 22 lbs. (10 kg), it should deflect about 0.41-0.47 in. (10.5-12mm). If the tension is not correct and all procedures have been properly followed, replace the tensioner spring and repeat Step 16. Do not try to tension the belt by manually adding tension to the tensioner mechanism!
  12.  
  13. Reinstall the torque stop. Reinstall the timing belt covers, using new gaskets if they are cracked or brittle. Torque the cover bolts to 5-7 ft. lbs. (7-9 Nm).
  14.  
  15. Install the crankshaft pulley, being careful to align its dowel pin. Using a hexagonal socket, torque the bolts to 17-24 ft. lbs. (23-33 Nm).
  16.  
  17. Install the cylinder head cover and right side splash shield.
  18.  
  19. Install and properly tension the drive belts. Connect the negative battery cable.
  20.  

REAR TIMING BELT

See Figure 15

This procedure includes camshaft pulley (sprocket) removal and fuel injection pump pulley (sprocket) removal, even though belt removal/installation is possible without those steps. If you choose not to remove the camshaft pulley and fuel injection pump pulley, omit Steps 7-11.

If you choose to remove the camshaft pulley and the fuel injection pump pulley, you will also need a puller and two bolts M8 x 32mm x 45mm.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rear timing belt cover.
  4.  



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Fig. Fig. 15: To remove tension from the rear timing belt, use a small prytool to lift the tensioner away from the belt, then tighten the locknut

  1. Remove the cylinder head cover and gasket.
  2.  
  3. Turn the crankshaft until the rear camshaft pulley and rear seal plate timing marks align.
  4.  
  5. Loosen the locknut for the belt tensioner. Using a small prytool as shown in the illustration, turn the tensioner to remove all tension from the belt. Tighten the tensioner locknut while holding the tensioner in the fully released position.
  6.  
  7. If you plan on reusing the belt, be sure to mark it for reinstallation in the same position. Then, remove the belt.
  8.  
  9. Hold the camshaft with an open-end wrench installed on the flats located just behind the center bearing. Loosen the pulley lockbolt, but do not remove it. Then, install a puller by screwing its two outer bolts into the threaded holes in the pulley. When these two bolts are threaded in all the way, tighten the bolt at the center of the puller, so that its inner end rests against the lockbolt. Continue tightening the center bolt until it frees the pulley from the camshaft. Be sure to retain the key and examine it; if the key is worn or scored, dress it with a fine jeweler's file or a piece of emery cloth. If worn to excess, replace the key.
  10.  
  11. Install the two M8 x 32mm x 45mm bolts through the two holes in the injection pump drive pulley and into the rear seal plate. (These will keep the pulley from turning.) Unfasten the pulley locknut, then use a puller to remove the pulley from the injection pump driveshaft.
  12.  
  13. Inspect all parts. Check the belt for peeling and cracks or for excessively worn/broken teeth. Check the tensioner for rough rotation. Replace worn or damaged parts, as necessary.
  14.  

To install:
  1. Install the fuel injection pump pulley onto the pump shaft with the key. If necessary, rotate the pulley slightly to align the timing marks. Install the bolts which prevent it from rotating. Leave these bolts in position as you complete the procedure. Then install the washer and locknut and torque it to 43-51 ft. lbs. (58-69 Nm).
  2.  
  3. Install the camshaft pulley and lockbolt. Hold the camshaft by the flats with an open-end wrench as you torque the bolt to 41-48 ft. lbs. (56-65 Nm). Then, make sure the mark on the camshaft pulley is still aligned with the mark on the rear seal plate.
  4.  
  5. Install the timing belt (in the proper direction of rotation, if it is being reused). Engage it with the teeth of the injection pump pulley first, and then with the teeth of the camshaft pulley. The lower span should be tight with both sets of timing marks aligned. The upper span runs below the tensioner pulley.
  6.  
  7. Remove the two affixing bolts from the fuel injection pump pulley.
  8.  
  9. Loosen the tensioner locknut so the tensioner spring is free to position the tensioner. Then, turn the crankshaft two full turns in the normal direction of rotation. Make sure both sets of timing marks are still in alignment. If not, the belt has been installed a tooth or two off-time and will have to be properly reinstalled.
  10.  
  11. Torque the tensioner locknut to 15-20 ft. lbs. (20-27 Nm).
  12.  
  13. Check the deflection of the belt by pressing upward on the lower span with your thumb. With a force of about 22 lbs. (10 kg), the belt should deflect about 0.37 in. (9.5mm). If the tension is not correct and all procedures have been properly followed, replace the tensioner spring and repeat Step 14. Do not try to tension the belt by manually adding tension to the tensioner mechanism!
  14.  
  15. Install the rear timing belt cover and the cylinder head cover with a new gasket.
  16.  
  17. Reconnect the negative battery cable.
  18.  

1988-89 626/MX-6

See Figures 16, 17, 18 and 19

  1. Disconnect the negative battery cable.
  2.  
  3. Tag and disconnect the spark plug wires, then remove the spark plugs (for easier crankshaft rotation).
  4.  
  5. Remove the engine side cover and the accessory drive belts.
  6.  
  7. Unbolt the crankshaft pulley, then remove the upper and lower timing belt covers along with their gaskets. Remove the crankshaft pulley baffle plate and note how it is installed. The curved side should be facing out.
  8.  
  9. Engage the timing belt pulley's lockbolt with an appropriate size metric socket and breaker bar, then turn the crankshaft in its normal direction of rotation until the "arrowed" 1 mark on the camshaft is aligned with the mark on top of the front housing (see illustration). Unbolt and remove the tensioner, then disconnect the tensioner spring from its mount.
  10.  



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Fig. Fig. 16: Timing belt components-1988-89 626 and MX-6



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Fig. Fig. 17: Camshaft pulley and front housing timing mark alignment-1988-89 626 and MX-6



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Fig. Fig. 18: Timing belt pulley and front housing timing mark alignment-1988-89 626 and MX-6



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Fig. Fig. 19: Checking timing belt deflection on 1988-89 626 and MX-6

  1. Remove the timing belt. If the old timing belt is to be reused, mark the direction of rotation, prior to removal. Keep the timing belt away from dirt, grease and oil.
  2.  
  3. Inspect the belt and replace if it is oil soaked, or shows excessive wear, peeling, cracking, or hardening. Inspect the tensioner for free and smooth rotation; replace if it does not turn smoothly. Replace all damaged components as necessary.
  4.  

To install:
  1. Align the timing mark on the timing belt pulley with the matchmark on the lower front housing. Recheck the camshaft pulley and front housing alignment marks. Turn the camshaft as necessary to realign the marks.
  2.  
  3. Install the spring and tensioner with the attaching bolt. Connect the spring to its anchor. Using a small prybar wrapped in a rag, gently pry on the tensioner until the spring is fully extended, then temporarily tighten the tensioner bolt to hold it in place.
  4.  
  5. Install the timing belt. (A used belt should be installed in the original direction of rotation as indicated by the rotational arrow marked on the belt prior to removal.) Make sure that there is no looseness on the water pump pulley and idler pulley side of the belt.
  6.  
  7. Loosen the tensioner lockbolt and turn the crankshaft twice in the direction of engine rotation to align the timing marks on the camshaft and crankshaft pulleys.
  8.  
  9. Make sure that all timing marks are aligned correctly. If not, remove the timing belt tensioner and timing belt, then repeat Steps 8-11 until all the timing marks are correctly aligned.
  10.  
  11. Torque the tensioner lockbolt to 27-38 ft. lbs. (37-51 Nm). Apply 22 lbs. (10 kg) of pressure to the belt and check the timing belt deflection. Deflection should be 0.35-0.39 in. (9-10mm) for a used belt, or 0.30-0.33 in. (8-9mm) for a new belt . If the deflection is not correct, loosen the tensioner lockbolt and adjust the tension. Repeat Steps 11-13 to adjust the tension. If it still cannot be brought to specification, replace the tensioner spring.
  12.  
  13. Install the baffle plate so that the curved side faces outward. Install the upper and lower timing belt covers, using new gaskets if necessary.
  14.  
  15. Install the crankshaft pulley and tighten the bolts in a criss-cross pattern to 9-13 ft. lbs. (12-18 Nm). Install all the accessory drive belts and adjust the drive belt tension.
  16.  
  17. Install the engine side cover. Lightly coat the threads of the spark plugs with anti-seize compound. Install the spark plugs and torque to specification. Connect the spark plug wires.
  18.  
  19. Connect the negative battery cable. Check and/or adjust the ignition timing as required.
  20.  

1986-89 323 Non-Turbo

See Figure 20

On some vehicles, it may be necessary to remove the No. 3 engine mount nuts and lower the engine to remove the crankshaft pulley.

  1. Disconnect the negative battery cable. Remove the engine side cover.
  2.  
  3. Remove the power steering and/or air conditioning belt, if applicable.
  4.  
  5. Remove the alternator drive belt and the alternator.
  6.  
  7. Unfasten and remove the water pump pulley. Unfasten the bolts and washers, then remove the crankshaft pulley along with its spacer.
  8.  



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Fig. Fig. 20: Align the marks as shown before removing/installing the timing belt-1986-89 323 non-turbo

A separate A/C and/or power steering drive pulley may be mounted in front of the crankshaft pulley.

  1. Unbolt, then remove the upper and lower timing belt covers along with their gaskets.
  2.  
  3. Tag and disconnect the spark plug wires, then remove all four spark plugs (to make crankshaft rotation easier).
  4.  
  5. Using a socket on the crankshaft bolt, turn the engine in its normal direction of rotation until the trailing (second) mark on the camshaft pulley aligns with the matching mark on the end of the cylinder head cover (see the illustration).
  6.  
  7. Remove the bolt mounting the timing belt tensioner to the front of the block. Remove the washer, the tensioner spring and the tensioner. If you plan of reusing the belt, be sure to mark the direction of rotation, then remove the timing belt.
  8.  
  9. Inspect the belt and replace if it is oil soaked, or if it shows excessive wear, peeling, cracking, or hardening. Inspect the tensioner for free and smooth rotation; replace if it does not turn smoothly. Replace all damaged components as necessary.
  10.  

To install:
  1. Position the tensioner on the block, then install the bolt and washer, just starting the threads. Connect the spring, then slide the tensioner as far as it will go to the left (away from tensioning the belt), so that spring tension is maximized. Tighten the bolt enough to hold the tensioner in this position.
  2.  
  3. Check to make sure that the marks on the camshaft pulley and cylinder head cover are still aligned. Also, check that the marks on the front of the block and the timing belt pulley are still aligned; realign the marks, if necessary.
  4.  
  5. Install the timing belt. (If the belt is being reused, make sure that the directional arrow is facing in the normal direction of rotation.) The belt should be installed so that the pulleys and teeth mesh, the right side is slightly tight, and the timing marks remain aligned.
  6.  
  7. Loosen the tensioner lockbolt. Turn the crankshaft two full revolutions in the normal direction of engine rotation (clockwise), so that the timing marks again align. If the marks align, proceed to Step 14. If they do not align, reshift the tensioner away from tensioning the belt and lock it there with the bolt. Remesh the teeth on the belt so the timing marks align and the right side of the belt is straight, then repeat this step.
  8.  
  9. Torque the tensioner lockbolt to 14-19 ft. lbs. (19-26 Nm). Place a ruler near the right side of the belt at the center of the span. Depress the belt with a thumb and measure the deflection while applying 22 lbs. (10 kg) pressure. The belt should deflect 0.35-0.39 in. (9-10mm) on 1986 models, 0.35-0.51 in. (9-13mm) on 1987 models, or 0.47-0.51 in. (12-13mm) on 1988-89 models. If the tension is correct, proceed to Step 15. If the tension is incorrect, do not try to adjust the belt by hand. Instead, fix any binding in the mechanism, if present; otherwise, replace the tensioning spring and repeat Steps 12-14.
  10.  
  11. Install the timing belt covers, using new gaskets if necessary. Torque the retaining bolts to 69-95 inch lbs. (8-11 Nm).
  12.  
  13. Install the spark plugs, torquing to 11-17 ft. lbs. (15-23 Nm), and reconnect the plug wires.
  14.  
  15. Install the baffle plate along with the crankshaft pulley and spacer. (Be sure to also install the A/C and/or power steering drive pulley, if applicable.) Torque the pulley bolts to 9-13 ft. lbs. (12-18 Nm).
  16.  

Be sure to raise the engine and fasten the No. 3 engine mount bracket, if previously moved.

  1. Install and tension the drive belts, then install the engine side cover.
  2.  
  3. Connect the negative battery cable.
  4.  

1988-89 323 Turbo

See Figure 21

  1. Disconnect the negative battery cable. Remove the engine side cover.
  2.  
  3. Remove the required accessory drive belts, then remove the water pump pulley and crankshaft pulley. (An A/C and/or power steering drive pulley may also be attached to the crankshaft pulley.)
  4.  

Support the engine with a suitable hoist and remove the No. 3 engine mount installation bolts, then lower the engine in order to remove the air conditioning and/or power steering drive pulley and the crankshaft pulley.

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Fig. Fig. 21: Timing mark alignment-1988-89 323 turbo

  1. Tag and disconnect the spark plug wires, then remove all four spark plugs (to make crankshaft rotation easier).
  2.  
  3. Rotate the crankshaft so that the No. 1 piston is at TDC.
  4.  
  5. Remove the timing cover assembly retaining bolts. Remove the upper, middle and lower timing covers and gaskets from their mountings.
  6.  
  7. Remove the baffle plate. Remove the timing belt tensioner and spring, then remove the timing belt. (If the old belt is being reused, first mark its direction of rotation.)
  8.  
  9. Inspect all parts. Check the belt for peeling and cracks or for excessively worn/broken teeth. Check the tensioner for rough rotation.
  10.  

To install:
  1. Be sure that the timing mark on the timing belt pulley is aligned with the mark on the engine. Also, be sure that the camshaft pulleys are properly aligned as shown in the timing mark illustration. (Note that the I mark on the intake side camshaft pulley should be at the top. The E mark on the exhaust side camshaft pulley should also be at the top.)
  2.  
  3. Install the spring and tensioner with the attaching bolt. Move the tensioner to the left until the spring is fully extended, then temporarily tighten the tensioner bolt to hold it in place.
  4.  
  5. Install the timing belt by keeping as much tension on the right side of the belt as possible. Used belts must be installed in their original direction of rotation.
  6.  
  7. Turn the crankshaft twice in the normal direction of rotation and make sure that all the timing marks are aligned (see illustration). Loosen the tensioner lockbolt and apply tension to the belt.
  8.  
  9. Torque the tensioner lockbolt to 27-38 ft. lbs. (37-51 Nm), then turn the crankshaft twice in the normal direction of rotation to ensure that all the timing marks are still correctly aligned.
  10.  
  11. Measure the belt tension by applying 22 lbs. (10 kg) of pressure between the camshaft pulleys. The deflection should be 0.33-0.45 in. (8.5-11.5mm) between the pulleys for both new and used timing belts.
  12.  
  13. If the timing belt tension is not within specifications, repeat Steps 11-13 or replace the tensioner spring.
  14.  
  15. Install the lower, middle and upper timing belt covers, using new gaskets if necessary.
  16.  
  17. Lightly coat the threads of the spark plugs with a suitable anti-seize compound and torque the plugs to 11-17 ft. lbs. (15-23 Nm). Reconnect the plug wires.
  18.  
  19. Position the baffle plate, making sure that the curved surface faces outward, then install the crankshaft pulley. (Be sure to also install the A/C and/or power steering drive pulley, if applicable.) Torque the pulley bolts to 9-13 ft. lbs. (12-17 Nm).
  20.  
  21. Install the water pump pulley and torque its mounting bolts to 6-8 ft. lbs. (8-11 Nm).
  22.  
  23. Raise the vehicle and install the No. 3 engine mount bracket. Torque the bolts to 44-63 ft. lbs. (60-85 Nm). Remove the lifting equipment, then install and properly tension the drive belts.
  24.  
  25. Install the engine side cover and connect the negative battery cable. Check and/or adjust the ignition timing, as required.
  26.  

929

See Figures 22, 23, 24 and 25

  1. Rotate the engine so that the No. 1 piston is at TDC. Properly relieve the fuel system pressure, as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable and drain the cooling system.
  4.  
  5. Tag and disconnect the spark plug wires, then remove all six spark plugs (to make crankshaft rotation easier).
  6.  



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Fig. Fig. 22: Timing mark alignment-929



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Fig. Fig. 23: Loading the timing belt auto tensioner-929



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Fig. Fig. 24: Once the tensioner is loaded, use an "L" shaped pin or a small Allen wrench to hold it in place



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Fig. Fig. 25: Install the timing belt onto the pulleys in the order shown

  1. Remove the fresh air duct, the cooling fan and radiator cowling. Remove the drive belts.
  2.  
  3. Remove the air conditioning compressor idler pulley. If necessary, unfasten the compressor and position it to the side.
  4.  
  5. Remove the crankshaft pulley and baffle plate. Remove the coolant bypass hose and the upper radiator hose.
  6.  
  7. Remove the timing belt cover assembly retaining bolts. Remove the left and right timing belt covers and gaskets. Turn the crankshaft to align the mating marks of the pulleys.
  8.  
  9. Remove the upper idler pulley. Remove the timing belt. If reusing the belt, be sure to mark the direction of rotation. Remove the timing belt auto tensioner.
  10.  

To install:
  1. Reload the timing belt tensioner as follows:
    1. Place a flat washer on the bottom of the tensioner body to prevent damage to the body and position the unit on an arbor press.
    2.  
    3. Press the rod into the tensioner body. Do not use more than 2,000 lbs of pressure.
    4.  
    5. Once the rod is fully inserted into the body, insert a suitable "L" shaped pin or a small Allen wrench through the body and the rod to hold the rod in place.
    6.  
    7. Remove the unit from the press.
    8.  

  2.  
  3. Install the tensioner onto the block and torque the mounting bolt to 14-19 ft. lbs. (19-26 Nm).
  4.  

Leave the pin in place, it will be removed later.

  1. Make sure that all the timing marks are aligned properly. With the upper idler pulley removed, wrap the timing belt around each pulley in the order shown in the illustration. Install the upper idler pulley and torque the mounting bolt to 27-38 ft. lbs. (37-51 Nm). Rotate the crankshaft twice in the normal direction of rotation to align all the timing marks.
  2.  
  3. Make sure all the marks are aligned correctly. If not, repeat Step 11.
  4.  
  5. Remove the pin or wrench from the tensioner. Again turn the crankshaft twice in the normal direction of rotation, and make sure that all the timing marks are aligned properly.
  6.  
  7. Check the timing belt deflection by applying 22 lbs. (10 kg) of force midway between the right-side camshaft pulley and the lower idler pulley. If the deflection is not 0.20-0.28 in. (5-7mm), repeat the adjustment procedure.
  8.  

Excessive belt deflection is caused by auto tensioner failure or an excessively stretched timing belt.

  1. Install the left and right timing belt covers, using new gaskets if necessary.
  2.  
  3. Connect the coolant bypass hose and the upper radiator hose to their respective fittings.
  4.  
  5. Install the crankshaft pulley and baffle plate. Torque the retaining bolts to 7-11 ft. lbs. (10-15 Nm).
  6.  
  7. Reposition and fasten the air conditioner compressor, if necessary. Install the air conditioning compressor idler pulley.
  8.  
  9. Install and properly tension the drive belts.
  10.  
  11. Install the cooling fan, radiator cowling and fresh air duct.
  12.  
  13. Lightly coat the threads of the spark plugs with a suitable anti-seize compound and torque the plugs to 11-17 ft. lbs. (15-23 Nm). Reconnect the plug wires.
  14.  
  15. Fill the cooling system to the proper level.
  16.  
  17. Connect the negative battery cable. Check and adjust the ignition timing, if necessary.
  18.  

 
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