Saturday, April 16, 2011

How to remove and install timing belt cover and timing belt on mazda 626?

Timing Belt and Sprockets


The timing belt should be replaced every 60,000 miles. Failure to replace the belt may result in damage to the engine.

REMOVAL & INSTALLATION



1990-94 1.6L and 1.8L (except K8) Engines
SOHC Engines

See Figures 1, 2, 3, 4 and 5

  1. Disconnect the negative battery cable. Remove the engine undercover.
  2. Remove the accessory drive belts.
  3. Remove the water pump pulley.
  4. Remove the crankshaft pulley bolts and remove the crankshaft pulley and baffle plate. Using a suitable tool to hold the crankshaft pulley and remove the pulley lockbolt. Remove the crankshaft pulley boss.
  5. Remove the upper and lower timing belt covers.
  6. Tag and disconnect the spark plug wires. Remove the spark plugs.

Spark plugs are removed to make it easier to rotate the engine.

  1. Temporarily reinstall the crankshaft pulley boss and lockbolt.



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Fig. Fig. 1: Crankshaft sprocket timing marks for the 1.6L and 1.8L SOHC engines



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Fig. Fig. 2: Camshaft sprocket timing marks for the 1.6L and 1.8L SOHC engines

  1. Turn the crankshaft, using the bolt, until the camshaft sprocket and crankshaft sprocket timing marks are aligned. Mark the direction of rotation on the timing belt.
  2. Remove the belt tensioner lockbolt, the tensioner wheel and the spring. Remove the timing belt.

Do not rotate the engine after the timing belt has been removed.

  1. Inspect the belt for wear, peeling, cracking, hardening or signs of oil contamination. Inspect the tensioner for free and smooth rotation. Check the tensioner spring free length; it should not exceed 2.520 in. (64mm). Inspect the sprocket teeth for wear or damage. Replace parts, as necessary.
  2. If necessary to remove the sprockets:
    1. Insert a small prybar through one of the camshaft sprocket holes to keep it from turning.
    2. Remove the sprocket bolt and the sprocket from the camshaft.


To install:
  1. Align the dowel on the camshaft with the dowel pin facing straight up. The dowel pin on the camshaft should also be facing upward.
  2. Install the camshaft sprocket bolt. Hold the sprocket with the prybar and tighten the bolt(s) to 36-45 ft. lbs. (49-61 Nm).
  3. Make sure the timing marks on the sprockets are properly aligned.



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Fig. Fig. 3: Install the timing belt tensioner and spring. Fully extend the tensioner spring then tighten the bolt to hold the tensioner pulley



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Fig. Fig. 4: When installing the belt, ensure that there is no looseness on the tension side of the belt

  1. Install the timing belt tensioner and spring. Temporarily tighten the bolt with the spring fully extended.
  2. Install the timing belt so there is no looseness on the tension side. If reusing the old timing belt, make sure it is reinstalled in the same direction of rotation.
  3. Turn the crankshaft 2 turns clockwise and check the timing mark alignment. If the marks are not aligned, repeat Steps 11-14.
  4. Loosen the tensioner lockbolt to set the tension, then torque the bolt to 19 ft. lbs. (25 Nm).
  5. Turn the crankshaft 2 turns clockwise and check the alignment of the timing marks. If they are not aligned, repeat Steps 11-16.



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Fig. Fig. 5: Check timing belt deflection by applying pressure at the point shown, and measuring the deflection

  1. Apply approximately 22 lbs. pressure to the timing belt on the side opposite the tensioner, at a point midway between the sprockets. The belt should deflect 0.43-0.51 in. (11-13mm). If the tension is not as specified, repeat Steps 14-17 or, if necessary, replace the tensioner spring.
  2. Install the spark plugs and connect the spark plug wires.
  3. Install the upper and lower timing belt covers. Tighten the bolts to 95 inch lbs. (11 Nm).
  4. Install the crankshaft pulley boss and tighten the lockbolt to 123 ft. lbs. (21 Nm), while holding the pulley boss with a suitable tool.
  5. Install the crankshaft pulley and baffle plate.
  6. Install the undercover or side cover. Connect the negative battery cable.
  7. Start the engine and check for proper operation. Check the ignition timing.

DOHC ENGINES

See Figures 6, 7, 8, 9 and 10

  1. Disconnect the negative battery cable. Remove the engine undercover.
  2. Remove the accessory drive belts.
  3. Remove the crankshaft pulley bolts and remove the crankshaft pulley.
  4. Remove the outer timing belt guide plate. Remove the inner timing belt guide plate if so equipped.
  5. Tag and disconnect the spark plug wires. Remove the spark plugs.

Spark plugs are removed to make it easier to rotate the engine.

  1. Remove the engine oil dipstick.
  2. Remove the upper, middle and lower timing belt covers.



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Fig. Fig. 6: Crankshaft sprocket timing marks for the 1990-94 1.8L DOHC engine



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Fig. Fig. 7: Camshaft sprocket timing marks for the 1990-94 1.8L DOHC engine

  1. Turn the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. On 1993-94 vehicles, the pin on the pulley boss must face upward.
  2. On 1993-94 vehicles, hold the crankshaft pulley boss with a suitable tool and remove the pulley lockbolt, being careful not to rotate the crankshaft. Remove the crankshaft pulley boss.
  3. Mark the direction of rotation on the timing belt. Loosen the tensioner lockbolt and pry the tensioner outward. Tighten the lockbolt with the tensioner spring fully extended. Remove the timing belt.

Protect the tensioner with a shop towel before prying on it. Do not rotate the crankshaft after the timing belt has been removed.

  1. Remove the tensioner and spring. If necessary, remove the idler pulley.
  2. Inspect the belt for wear, peeling, cracking, hardening or signs of oil contamination. Inspect the tensioner for free and smooth rotation. Check the tensioner spring free length; it should not exceed 2.315 in. (58.8mm). Inspect the sprocket teeth for wear or damage. Replace parts, as necessary.

To install:
  1. If removed, install the idler pulley and tighten the bolt to 38 ft. lbs. (52 Nm).
  2. Install the tensioner and tensioner spring. Pry the tensioner outward and temporarily tighten the tensioner lockbolt with the tensioner spring fully extended.



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Fig. Fig. 8: Pry the tensioner pulley (protect it with a rag) outward to fully extend the spring, then tighten the bolt to hold it in position

  1. Make sure the crankshaft sprocket timing mark is aligned with the mark on the oil pump housing and the camshaft sprocket timing marks are aligned with the marks on the seal plate.
  2. Install the timing belt so there is no looseness at the idler pulley side or between the camshaft sprockets. If reusing the old belt, make sure it is installed in the same direction of rotation.
  3. On 1993-94 vehicles, temporarily install the pulley boss and lockbolt.
  4. Turn the crankshaft 2 turns clockwise and align the crankshaft sprocket timing mark. On 1993-94 vehicles, face the pin on the pulley boss upright. Make sure the camshaft sprocket timing marks are aligned. If they are not, repeat Steps 15-19.
  5. Turn the crankshaft 1 5 / 6 turns clockwise and align the crankshaft sprocket timing mark with the tension set mark for proper belt tension adjustment. On 1992-94 vehicles, remove the lockbolt and pulley boss.



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Fig. Fig. 9: To properly set tension on the belt, turn the crankshaft 15/6 turns and align the tension set mark with the crankshaft sprocket

  1. Make sure the crankshaft sprocket timing mark is aligned with the tension set mark. Loosen the tensioner lockbolt and allow the spring to apply tension to the belt. Tighten the tensioner lockbolt to 38 ft. lbs. (52 Nm).
  2. On 1993-94 vehicles, install the pulley boss and lockbolt.
  3. Turn the crankshaft 2 1 / 6 turns clockwise and make sure the timing marks are correctly aligned.



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Fig. Fig. 10: Check the deflection of the timing belt to ensure proper tension has been set on the belt

  1. Apply approximately 22 lbs. pressure to the timing belt at a point midway between the camshaft sprockets. The belt should deflect 0.35-0.45 in. (9.0-11.5mm). If the deflection is not correct, repeat Steps 21-24.
  2. On 1993-94 vehicles, hold the pulley boss with a suitable tool and tighten the lockbolt to 123 ft. lbs. (21 Nm).
  3. Install the timing belt covers and tighten the bolts to 95 inch lbs. (11 Nm). Install the engine oil dipstick.
  4. Install the spark plugs and connect the spark plug wires.
  5. Install the timing belt inner guide plate, if equipped. Make sure the dished side of the plate faces away from the timing belt. Install the outer guide plate, if equipped.
  6. Install the crankshaft pulley and tighten the bolts to 13 ft. lbs. (17 Nm).
  7. Install the water pump pulley and the accessory drive belts. Adjust the belt tension.
  8. Install the engine side or undercover, as necessary. Connect the negative battery cable.
  9. Start the engine and check for proper operation. Check the ignition timing.

1995 1.6L, 1995-98 1.5L and 1.8L (except K8) DOHC Engines

See Figures 9, 11, 12, 13, 14, 15 and 16

  1. Disconnect the negative battery cable.
  2. Remove the timing belt covers.
  3. Turn the crankshaft until the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump.
  4. On the 1.5L engine, ensure that the Z mark on the camshaft sprocket is pointing straight up and the two notches are even with the valve cover gasket surface.
  5. On the 1.6 and 1.8L engines, align the E and the I marks on the camshaft sprockets are aligned with the marks on the backing plate (they should point down and towards each other at approximately a 45° angle).



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Fig. Fig. 11: Cam and crankshaft sprocket alignment marks for the 1995 1.6L and 1995-98 1.8L (except K8) DOHC engines



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Fig. Fig. 12: Cam and crankshaft sprocket alignment marks for the 1.5L engine

  1. Remove the crankshaft pulley lockbolt and pulley boss.
  2. Lower the vehicle. Insert a camshaft sprocket holding tool between the camshaft sprockets.
  3. Loosen the tensioner pulley lockbolt. Pull the tensioner pulley away from the center of the engine to reduce the tension on the timing belt.



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Fig. Fig. 13: Loosen the tensioner lockbolt and pull it away from the belt to reduce the tension on it

  1. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt.
  2. To remove the tensioner, unhook the tensioner spring, and remove the pulley lockbolt and tensioner.
  3. If necessary to remove the sprockets:
    1. Hold the camshaft by using a wrench on the cast hexagon, and loosen the sprocket mounting bolt.
    2. Remove the sprocket bolt and the sprocket from the camshaft.
    3. If equipped with a manual transaxle, place the shift lever in 4thgear and apply the parking brake. If equipped with an automatic transaxle, remove the flywheel dust cover and install a flywheel locking tool to hold the flywheel.
    4. Remove the crankshaft sprocket bolt, sprocket and key.


To install:
  1. On the 1.5L engine, install the camshaft sprocket, aligning the dowel with the letter Z mark.
  2. On the 1.6L and 1.8L engine, install the camshaft sprocket, aligning the dowel (which should be pointing straight up) with the letter I mark on the intake side, and the letter E mark on the exhaust side.
  3. Install the camshaft sprocket bolt. Hold the camshaft, on the cast hexagon, with the wrench and tighten the bolt to 37-44 ft. lbs. (50-60 Nm).
  4. Install the crankshaft sprocket and key. Align the keyway with the timing mark on the oil pump housing.
  5. Install the crankshaft sprocket bolt. Install the flywheel locking tool, if equipped with automatic transaxle, or place the shift lever in 4th gear and apply the parking brake, if equipped with manual transaxle. Tighten the bolt to 116-122 ft. lbs. (11-20 Nm).



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Fig. Fig. 14: Install the timing belt onto the sprockets following the numbered sequence for 1995 1.6L and 1995-98 1.8L engines



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Fig. Fig. 15: Install the timing belt onto the sprockets following the numbered sequence for the 1.5L engine

  1. Make sure the timing marks on the camshaft and crankshaft sprockets are still aligned.
  2. If removed, position the tensioner with the spring fully extended, and install the lockbolt tightening the mounting bolt to 28-38 ft. lbs. (38-51 Nm).
  3. Install the timing belt. If reusing the original timing belt, make sure it is installed in the same direction of rotation.
  4. Rotate the crankshaft clockwise 1 5 / 6 turns and align the timing marks. Make sure all marks are still correctly aligned.



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Fig. Fig. 16: Measure the timing belt deflection to determine if the proper tension has been set

  1. Loosen the tensioner lockbolt to apply tension to the timing belt. Tighten the tensioner lockbolt to 28-38 ft. lbs. (38-51 Nm). Remove the holding tool from between the camshaft sprockets.
  2. Rotate the crankshaft clockwise 2 1 / 6 turns and make sure all marks are still correctly aligned.
  3. Raise and safely support the vehicle. Install the crankshaft pulley lockbolt and boss. Tighten the bolt to 116-122 ft. lbs. (11-20 Nm).
  4. Install the timing belt covers.
  5. Connect the negative battery cable.

2.0L Engine

See Figures 17 through 29

  1. Disconnect the negative battery cable.
  2. Remove the timing belt covers. Temporarily reinstall the crankshaft pulley bolt.



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Fig. Fig. 17: To remove the timing belt, first remove the timing belt cover then, using a jack and block of wood, support the engine



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Fig. Fig. 18: Next, loosen and remove the engine mount-to-engine block attaching bolts ...



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Fig. Fig. 19: ... as well as the mount-to-body through-bolt ...



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Fig. Fig. 20: ... and remove the engine mount



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Fig. Fig. 21: Mark the direction of rotation on the timing belt in case you need to re-install the original belt



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Fig. Fig. 22: Cam and crankshaft sprocket alignment positions for the 2.0L engine

  1. Remove the front engine mount by supporting the engine then remove the mount attaching bolts and the mount.



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Fig. Fig. 23: Rotate the crankshaft until the timing marks (arrows) on the camshaft sprockets align with each other

  1. Turn the crankshaft until the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump and the camshaft sprocket timing marks, E and I , line up on the camshaft sprockets.
  2. Insert a camshaft sprocket holding tool between the camshaft sprockets.



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Fig. Fig. 24: Loosen the lockbolt on the timing belt tensioner



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Fig. Fig. 25: Turn the timing belt tensioner with an Allen wrench and remove the tensioner spring from the hook pin



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Fig. Fig. 26: Space may be limited when trying to turn the tensioner with the Allen wrench (arrow) ...



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Fig. Fig. 27: ... or when trying to detach the tensioner spring from the hook pin (arrow)

  1. Turn the timing belt tensioner with an Allen wrench and remove the tensioner spring from the hook pin.
  2. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt.



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Fig. Fig. 28: Remove the timing belt from the sprockets and examine it. Refer to Section 1 for examples



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Fig. Fig. 29: If necessary, or in case of high mileage, remove the tensioner pulley by removing the lockbolt

  1. If necessary to remove the sprockets:
    1. Hold the camshaft by using a wrench on the cast hexagon, and loosen the sprocket mounting bolt.
    2. Remove the sprocket bolt and the sprocket from the camshaft.
    3. If equipped with a manual transaxle, place the shift lever in 4thgear and apply the parking brake. If equipped with an automatic transaxle, remove the flywheel dust cover and install a flywheel locking tool to hold the flywheel.
    4. Remove the crankshaft sprocket bolt, sprocket and key.


To install:
  1. Install the camshaft sprocket, aligning the dowel with the number 1mark.
  2. Install the camshaft sprocket bolt. Hold the camshaft, on the cast hexagon, with the wrench and tighten the bolt to 35-48 ft. lbs. (47-65 Nm).
  3. Install the crankshaft sprocket and key. Align the keyway with the timing mark on the oil pump housing.
  4. Install the crankshaft sprocket bolt. Install the flywheel locking tool, if equipped with automatic transaxle, or place the shift lever in 4th gear and apply the parking brake, if equipped with manual transaxle. Tighten the bolt to 108-116 ft. lbs. (1-11 Nm).
  5. Make sure the timing marks on the camshaft and crankshaft sprockets are still aligned.
  6. Install the timing belt. If reusing the original timing belt, make sure it is installed in the same direction of rotation.
  7. Turn the tensioner clockwise with an Allen wrench and install the tensioner spring. Remove the holding tool from between the camshaft sprockets.
  8. Rotate the crankshaft 2 turns in the normal direction of rotation and align the timing marks. Make sure all marks are still correctly aligned.
  9. Remove the crankshaft pulley bolt and install the timing belt covers.
  10. Connect the negative battery cable.

1.8L (K8) and 2.5L (626/MX-6/Probe) Engines

See Figures 30 through 39

  1. Disconnect the negative battery cable.
  2. Support the engine, and remove the nuts and through-bolt from the right side engine mount Remove the mount.
  3. Remove the timing belt covers. Temporarily reinstall the crankshaft pulley bolt.



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Fig. Fig. 30: Camshaft sprocket alignment marks for the 1.8L (K8) and 2.5L engines



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Fig. Fig. 31: Crankshaft sprocket alignment marks for the 1.8L (K8) and 2.5L engines

  1. Turn the crankshaft until the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump and the camshaft sprocket timing marks align with the marks on the cylinder head. The number one piston should be at TDC of the compression stroke.
  2. Remove the 2 bolts from the automatic tensioner, removing the lower one first. Keep the bolt holes aligned by holding the tensioner to reduce the chance of stripping the threads on the bolts.
  3. If the timing belt is to be reused, mark the direction of rotation on the timing belt.
  4. Remove the number one idler pulley. Remove the timing belt.
  5. If necessary, remove the sprockets as follows:
    1. Insert a proper tool through one of the camshaft sprocket holes to keep it from turning.
    2. Remove the sprocket bolt and the sprocket from the camshaft.
    3. If equipped with a manual transaxle, place the shift lever in 4thgear and apply the parking brake. If equipped with an automatic transaxle, remove the flywheel dust cover and install a flywheel locking tool to hold the flywheel.
    4. Remove the crankshaft sprocket bolt, sprocket and key.


To install:
  1. Install the camshaft sprockets (which are marked (R) Right and (L) Left), aligning the dowel on the camshaft with the slot on the sprocket.
  2. Install the camshaft sprocket bolt. Hold the sprocket with a suitable tool and tighten the bolt to 35-48 ft. lbs. (47-65 Nm).
  3. Install the crankshaft sprocket and key. Align the keyway with the timing mark on the oil pump housing.
  4. Install the crankshaft sprocket bolt. Install the flywheel locking tool, if equipped with automatic transaxle, or place the shift lever in 4th gear and apply the parking brake, if equipped with manual transaxle. Tighten the bolt to 116-122 ft. lbs. (11-20 Nm).



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Fig. Fig. 32: Position the automatic tensioner in a press and set a flat washer under the tensioner body to prevent damage to the body plug



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Fig. Fig. 33: Compress the tensioner until the hole in the piston is aligned with the 2nd hole in the case. Insert a pin to keep it compressed



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Fig. Fig. 34: Install the tensioner to the engine and snugly tighten the upper bolt. This will reduce belt tension when installing the upper idler

  1. Position the automatic tensioner in a suitable press. Set a flat washer under the tensioner body to prevent damage to the body plug.
  2. Compress the tensioner until the hole in the piston is aligned with the 2nd hole in the tensioner case. Insert a 0.063 in. (1.6mm) diameter wire or pin through the 2nd hole to keep the piston compressed.
  3. Make sure the camshaft sprocket timing marks are still aligned. Turn the crankshaft counterclockwise until the timing sprocket is offset from TDC by 1 tooth.



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Fig. Fig. 35: Install the timing belt onto the sprockets in the sequence shown



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Fig. Fig. 36: Then install the upper idler pulley while pushing downward on the belt



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Fig. Fig. 37: Pull outward on the lower half of the tensioner and install the lower mounting bolt. Tighten both bolts to specification



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Fig. Fig. 38: Once the tensioner is properly tightened, remove the pin which is holding the piston compressed in the tensioner case



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Fig. Fig. 39: Check for proper belt tension by measuring the belt deflection at the point indicated

  1. With the number one idler pulley removed, install the timing belt. If the original belt is being reused, make sure it is installed in the same direction of rotation. The order of installation is: timing belt (crankshaft) sprocket, number two idler pulley, LH camshaft sprocket, tensioner pulley and RH camshaft sprocket.
  2. Install the number one idler pulley while applying pressure on the timing belt. Tighten the bolt to 28-38 ft. lbs. (38-51 Nm).
  3. Install the automatic belt tensioner and tighten the bolts to 14-18 ft. lbs. (19-25 Nm). Remove the wire or pin from the tensioner.
  4. Rotate the crankshaft 2 turns in the normal direction of rotation and align the timing marks. Make sure all marks are still correctly aligned.
  5. Inspect the timing belt deflection, 0.24-0.31 ft. lbs. (6-8mm), between the crankshaft sprocket and the tensioner pulley. If it is out of specification, replace the auto tensioner.
  6. Remove the crankshaft damper bolt and install the timing belt covers.
  7. Install the right side engine mount. Tighten the nuts to 55-77 ft. lbs. (75-104 Nm) and the through-bolt to 63-86 ft. lbs. (86-116 Nm). Remove the engine support.
  8. Connect the negative battery cable.

2.5L (Millenia) Engine

See Figures 30 through 39

  1. Disconnect the negative battery cable.
  2. Remove the timing belt covers. Temporarily reinstall the crankshaft pulley bolt.
  3. Support the engine, and remove the nuts and through-bolt from the right side (number three) engine mount sub bracket. Remove the sub bracket.
  4. Turn the crankshaft until the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump and the camshaft sprocket timing marks align with the marks on the cylinder head. The number one piston should be at TDC of the compression stroke.
  5. Remove the two bolts from the automatic tensioner, removing the lower one first. Keep the bolt holes aligned by holding the tensioner to reduce the chance of stripping the threads on the bolts.
  6. If the timing belt is to be reused, mark the direction of rotation on the timing belt.
  7. Remove the number one idler pulley. Remove the timing belt.
  8. If necessary to remove the sprockets:
    1. Insert a proper tool through one of the camshaft sprocket holes to keep it from turning.


The right and left camshaft sprockets are different and need to be installed on the same camshaft from which they were removed.

  1. Remove the sprocket bolt and the sprocket from the camshaft.
  2. Remove the flywheel dust cover and install a flywheel locking tool to hold the flywheel.
  3. Remove the crankshaft sprocket bolt, sprocket and key.

To install:
  1. Install the camshaft sprocket so that the R (on right-hand) and L (on left-hand) face out, and align the timing marks with the knock/dowel pin.
  2. Apply clean engine oil to the bolt threads, and install the camshaft sprocket bolt. Hold the sprocket with a suitable tool and tighten the bolt to 91-103 ft. lbs. (123-140 Nm).
  3. Install the crankshaft sprocket and key. Align the keyway with the timing mark on the oil pump housing.
  4. Install the crankshaft sprocket bolt. Install the flywheel locking tool. Tighten the bolt to 116-122 ft. lbs. (11-20 Nm). remove the flywheel locking tool.
  5. Position the automatic tensioner in a suitable press. Set a flat washer under the tensioner body to prevent damage to the body plug.
  6. Compress the tensioner until the hole in the piston is aligned with the 2nd hole in the tensioner case. Insert a 0.060 in. (1.6 mm) diameter wire or pin through the 2nd hole to keep the piston compressed.
  7. Make sure the camshaft sprocket timing marks are still aligned. Turn the crankshaft counterclockwise until the timing sprocket is aligned.
  8. With the number one idler pulley removed, install the timing belt. If the original belt is being reused, make sure it is installed in the same direction of rotation. The order of installation is: timing belt (crankshaft) sprocket, number two idler pulley, LH camshaft sprocket, tensioner pulley and RH camshaft sprocket.
  9. Install the number one idler pulley while applying pressure on the timing belt. Tighten the bolt to 28-38 ft. lbs. (38-51 Nm).
  10. Install the automatic belt tensioner and tighten the bolts to 14-18 ft. lbs. (19-25 Nm). Remove the wire or pin from the tensioner.
  11. Turn the crankshaft clockwise, until the crankshaft sprocket timing mark is again at TDC. This should place all of the belt slack in the automatic tensioner portion of the belt.
  12. Rotate the crankshaft 2 turns in the normal direction of rotation and align the timing marks. Make sure all marks are still correctly aligned.
  13. Inspect the timing belt deflection, 0.24-0.31 in. (6-8 mm), between the crankshaft sprocket and the tensioner pulley. If it is out of specification, replace the auto tensioner.
  14. Install the right side (number three) engine mount sub bracket. Tighten the nuts to 55-77 ft. lbs. (75-104 Nm) and the through-bolt to 63-86 ft. lbs. (86-116 Nm). Remove the engine support.
  15. Remove the crankshaft damper bolt and install the timing belt covers.
  16. Connect the negative battery cable. Start the engine, and check the ignition timing.

2.3L Engine

See Figures 32, 33, 34, 38, 40, 41, 42 and 43

  1. Disconnect the negative battery cable.
  2. Remove the timing belt covers. Temporarily reinstall the crankshaft pulley bolt.
  3. Remove the power steering auto tensioner and pulley.
  4. Turn the crankshaft until the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump and the camshaft sprocket timing marks align with the marks on the cylinder head. The number one piston should be at TDC of the compression stroke.



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Fig. Fig. 40: Camshaft sprocket alignment marks for the 2.3L engine



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Fig. Fig. 41: Crankshaft sprocket timing marks for the 2.3L engine

  1. Remove the two bolts from the automatic tensioner, removing the lower one first. Keep the bolt holes aligned by holding the tensioner to reduce the chance of stripping the threads on the bolts.
  2. If the timing belt is to be reused, mark the direction of rotation on the timing belt.
  3. Remove the timing belt.
  4. If necessary to remove the sprockets:
    1. Insert a proper tool through one of the camshaft sprocket holes to keep it from turning.


The right and left camshaft sprockets are different and need to be installed on the same camshaft from which they were removed.

  1. Remove the sprocket bolt and the sprocket from the camshaft.
  2. Remove the flywheel dust cover and install a flywheel locking tool to hold the flywheel.
  3. Remove the crankshaft sprocket bolt, sprocket and key.

To install:
  1. Install the camshaft sprocket so that the R (on right-hand) and L (on left-hand) face out, and align the timing marks with the knock/dowel pin.
  2. Apply clean engine oil to the bolt threads, and install the camshaft sprocket bolt. Hold the sprocket with a suitable tool and tighten the bolt to 91-103 ft. lbs. (123-140 Nm).
  3. Install the crankshaft sprocket and key. Align the keyway with the timing mark on the oil pump housing.
  4. Install the crankshaft sprocket bolt. Install the flywheel locking tool. Tighten the bolt to 116-122 ft. lbs. (11-20 Nm). remove the flywheel locking tool.
  5. Position the automatic tensioner in a press. Set a flat washer under the tensioner body to prevent damage to the body plug.
  6. Compress the tensioner until the hole in the piston is aligned with the 2nd hole in the tensioner case. Insert a 0.063 inch (1.6 mm) diameter wire or pin through the 2nd hole to keep the piston compressed.
  7. Make sure the camshaft sprocket timing marks are still aligned. Turn the crankshaft clockwise until the timing sprocket is aligned.



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Fig. Fig. 42: Install the timing belt onto the sprockets in the sequence shown

  1. Install the timing belt. If the original belt is being reused, make sure it is installed in the same direction of rotation. The order of installation is: timing belt (crankshaft) sprocket, number two idler pulley, LH camshaft sprocket, both number one idler pulleys, RH camshaft sprocket and the tensioner pulley.
  2. Install the automatic belt tensioner and tighten the bolts to 14-18 ft. lbs. (19-25 Nm). Remove the wire or pin from the tensioner.
  3. Turn the crankshaft clockwise, until the crankshaft sprocket timing mark is again at TDC. This should place all of the belt slack in the automatic tensioner portion of the belt.
  4. Rotate the crankshaft two turns in the normal direction of rotation and align the timing marks. Make sure all marks are still correctly aligned.



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Fig. Fig. 43: Inspect the timing belt tension by measuring the deflection at the point shown

  1. Inspect the timing belt deflection, 0.24-0.31 inches (6-8 mm), between the crankshaft sprocket and the tensioner pulley. If it is out of specification, replace the auto tensioner.
  2. Install the power steering auto tensioner and tighten the bolts to 14-18 ft. lbs. (19-25 Nm). Install the pulley, and tighten the bolt to 29-34 ft. lbs. (40-47 Nm).
  3. Remove the crankshaft damper bolt and install the timing belt covers.
  4. Connect the negative battery cable. Start the engine, and check the ignition timing.



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Timing Belt Cover


REMOVAL & INSTALLATION



1990-94 1.6L and 1.8L (except K8) Engines

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2. Remove the engine under splash shield.



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Fig. Fig. 1: Exploded view of the 1990-94 1.6L and 1.8L SOHC timing belt cover assembly



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Fig. Fig. 2: Exploded view of the 1.8L DOHC timing belt cover assembly

  1. Remove the accessory drive belts. Refer to General Information & Maintenance .
  2. Remove the crankshaft pulley.
  3. Remove the inner and outer timing belt guide plates.
  4. Remove the 2 bolts and remove the upper timing belt cover assembly.
  5. Remove the 1 bolt and remove the lower timing belt cover assembly and gasket.

To install:
  1. Install the lower cover gasket and the lower cover. Tighten the bolt to 69-95 inch lbs. (8-11 Nm).
  2. Install the upper cover gasket and the upper cover. Tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  3. Install the timing belt inner and outer guide plates. Make sure that the inner guide plate is installed in the proper direction.
  4. Install the crankshaft pulley. Tighten the bolts to 109-152 inch lbs. (12-17 Nm).
  5. Install the accessory drive belts. Refer to General Information & Maintenance .
  6. Install the under engine splash shield.
  7. Connect the negative battery cable.

1.5L and 1995 1.6L DOHC Engines

See Figure 3

  1. Disconnect the negative battery cable.
  2. Remove the engine under splash shield.
  3. Drain the cooling system.
  4. Remove the air intake pipe.



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of the timing cover assembly for the 1.5L and 1995 1.6L engines-1995-98 1.8L engine is similar

  1. Disconnect the upper radiator hose and the 2 lower coolant hoses from the thermostat housing.
  2. Remove the power steering, air conditioning and alternator drive belts. Refer to General Information & Maintenance .
  3. Remove the retaining bolts and remove the water pump pulley.
  4. Remove the crankshaft pulley bolts and remove the crankshaft pulley.
  5. Remove the inner and outer timing belt guide plates.
  6. Disconnect the coil electrical connectors and remove coil assembly. Remove the spark plug wires. Be certain to record positioning of plug wires for assembly purposes.
  7. Remove the spark plugs.
  8. Remove the cylinder head cover bolts and remove the cover.
  9. Remove the bolts from the timing belt covers and remove the top, the center and the lower timing belt covers.

To install:
  1. Install the timing belt covers with gaskets and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  2. Apply silicone sealant to the corners of the cylinder head cover and install the cover. Tighten the bolts to 43-78 inch lbs. (5-9 Nm).
  3. Install the spark plugs and tighten them to 11-17 ft. lbs. (15-23 Nm).
  4. Install the coil assembly and connect the electrical connectors and the spark plug wires.
  5. Install the inner and outer timing belt guide plates.
  6. Install the crankshaft pulley and tighten the bolts to 109-152 inch lbs.(12-17 Nm).
  7. Install the water pump pulley and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  8. Install the power steering, air conditioning and alternator drive belts. Refer to General Information & Maintenance .
  9. Install the coolant and radiator hoses and refill the coolant to the proper level.
  10. Install the air intake pipe and connect the negative battery cable.

1995-98 1.8L (except K8) DOHC Engines

See Figure 3

  1. Disconnect the negative battery cable.
  2. Remove the engine under splash shield.
  3. Remove the power steering, air conditioning and alternator drive belts. Refer to General Information & Maintenance .
  4. Remove the retaining bolts and remove the water pump pulley.
  5. Remove the crankshaft pulley bolts and remove the crankshaft pulley.
  6. Remove the inner and outer timing belt guide plates.
  7. Remove the bolt and remove the upper timing belt cover assembly.
  8. Remove the bolts from the middle and lower timing belt cover assembly and remove the covers and the gaskets.

To install:
  1. Install the upper, the center and the lower timing belt covers. Tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  2. Install the timing belt inner and outer guide plates. Make sure that the inner guide plate is installed in the proper direction.
  3. Install the crankshaft pulley. Tighten the bolts to 109-152 inch lbs. (12-17 Nm).
  4. Install the water pump pulley and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  5. Install the P/S, A/C and alternator drive belts. Refer to General Information & Maintenance .
  6. Install the under engine splash shield.
  7. Connect the negative battery cable.

2.0L Engine

See Figures 4, 5, 6, 7 and 8

  1. Disconnect the negative battery cable.
  2. Raise and safely support the vehicle. Remove the right front wheel.



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Fig. Fig. 4: Exploded view of the timing belt cover for the 2.0L engine

  1. Remove the engine under splash shield.
  2. Remove the accessory drive belts. Refer to General Information & Maintenance .



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Fig. Fig. 5: To remove the timing belt cover, first remove the valve cover, then remove the upper belt cover attaching screws ...



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Fig. Fig. 6: ... then pull the cover from the engine. Some careful maneuvering of the cover is required



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Fig. Fig. 7: Next, raise the vehicle, remove the crankshaft damper as well as the lower belt cover attaching screws ...



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Fig. Fig. 8: ... then pull the cover outward and down to remove it from the vehicle

  1. Remove the power steering pump pulley shield.
  2. Remove the power steering pump, leaving the hoses attached and position the pump out of the way.
  3. Remove the retaining bolts and remove the water pump pulley.
  4. Remove the crankshaft pulley bolt and remove the pulley using a steering wheel puller.
  5. Remove the spark plug wires, noting the original location of the wires for installation purposes. Disconnect the power steering hose from the cylinder head cover.
  6. Remove the spark plugs and remove the cylinder head cover bolts. Remove the cylinder head cover with the gasket in place.
  7. Remove the oil level dipstick bolt and remove the oil dipstick and plug the hole.
  8. Remove the timing belt cover bolts and remove the upper and lower covers and the gaskets.

To install:
  1. Install the timing covers with the gaskets in place. Install the timing cover bolts and tighten to 69-95 inch lbs. (8-11 Nm).
  2. Install the bolt that secures the oil level dipstick and tighten the bolt to 69-95 inch lbs. (8-11 Nm).
  3. Apply silicone sealant to the corners of the cylinder head cover and install the cylinder head cover to the engine and tighten the cylinder head bolts to 69-95 inch lbs. (8-11 Nm).
  4. Install the spark plugs to the engine and connect the spark plug wires.
  5. Install the crankshaft pulley, with the guide plate in place behind the pulley. Hold the pulley in place with special tool 49 E011 1A1 or equivalent and tighten the bolt to 116-123 ft. lbs. (157-167 Nm).
  6. Install the water pump pulley and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  7. Install the power steering pump. Tighten the upper bolt to 32-44 ft. lbs. (44-66 Nm) and the lower bolt to 24-33 ft. lbs. (32-46 Nm).
  8. Install the power steering pump pulley shield and tighten the bolt to 60-87 inch lbs. (7-10 Nm).
  9. Install the accessory belts and adjust as necessary. Refer to General Information & Maintenance .
  10. Install the under engine splash shield and install the right front wheel.
  11. Lower the vehicle and connect the negative battery cable.

2.2L Engine

See Figure 9

  1. Disconnect the negative battery cable.
  2. Remove the bolts and remove the engine side cover.



Click image to see an enlarged view

Fig. Fig. 9: Exploded view of the 2.2L engines timing belt cover assembly

  1. Remove the accessory drive belts, refer to General Information & Maintenance .
  2. Remove the crankshaft pulley bolts and remove the crankshaft pulley.
  3. Remove the timing cover bolts and remove the upper and lower covers.

To install:
  1. Install the upper and lower timing belt covers with the gaskets. Tighten the bolts to 61-87 inch lbs. (7-10 Nm).
  2. Install the crankshaft pulley and tighten the bolts to 109-153 inch lbs. (12-17 Nm).
  3. Install the accessory drive belts, refer to General Information & Maintenance .
  4. Install the engine side cover and connect the negative battery cable.

1.8L (K8) and 2.5L Engines

See Figure 10

  1. Disconnect the negative battery cable.
  2. Remove the engine under splash shield.



Click image to see an enlarged view

Fig. Fig. 10: Exploded view of the 1.8L (K8) and 2.5L engines timing belt cover assembly-2.3L engine is similar

  1. Remove the accessory drive belts. Refer to General Information & Maintenance .
  2. Remove the retaining bolts and remove the water pump pulley.
  3. Remove the idler pulley bracket bolt and remove the idler pulley bracket.
  4. Remove the power steering pump bolts and the pump as shown inSuspension & Steering .
  5. Remove the crankshaft pulley bolts and remove the pulley using a steering wheel puller.
  6. Disconnect the crank angle sensor electrical connector and remove the clip from the oil dipstick tube. Remove the oil dipstick and plug the hole.
  7. Remove the bolt from the knock sensor harness bracket.
  8. Remove the 2 bolts that secure the engine harness to the timing cover.
  9. Remove the remaining timing belt cover bolts and remove the covers and the gaskets.

To install:
  1. Install the timing covers with the gaskets in place. Install the timing cover bolts and tighten to 69-95 inch lbs. (8-11 Nm).
  2. Install the 2 bolts that secure the engine harness to the timing cover and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
  3. Install the knock sensor harness bracket to the timing cover and tighten the bolt to 69-95 inch lbs. (8-11 Nm).
  4. Install the oil dipstick tube complete with a new O-ring. Install the crank angle sensor harness clip to the dipstick tube and connect the electrical connector.
  5. Install the crankshaft pulley and loosely tighten the bolt. Hold the pulley in place with special tool 49 E011 1A1 or equivalent and tighten the bolt to 116-123 ft. lbs. (157-167 Nm).
  6. Install the power steering fluid pump assembly and tighten the upper bolts to 23-34 ft. lbs. (31-46 Nm) and the lower bolt to 14-19 ft. lbs. (19-25 Nm).
  7. Install the power steering pump pulley nut and tighten to 46-69 ft. lbs. (63-93 Nm). Connect the power steering fluid line bracket to the engine and tighten the bolts to 69-95 inch lbs. (7.8-11 Nm).
  8. Connect the power steering pressure switch electrical connector and install the power steering oil reservoir and the engine ground.
  9. Install the water pump pulley and the power steering idler pulley. Install the belts and tighten the pulley bolts to 69-95 inch lbs. (8-11 Nm).
  10. Install the A/C belt and adjust as necessary. Refer to General Information & Maintenance .
  11. Install the under engine splash shield and connect the negative battery cable.

2.3L Engine

See Figure 10

  1. Disconnect the negative battery cable.


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the cooling system.
  2. Loosen the lug nuts on the right front wheel.
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle securely on jackstands.
  4. Remove the right front wheel.
  5. Remove the engine under splash shield.
  6. Remove the right-hand dust cover.
  7. Loosen the water pump and power steering pump pulley attaching bolts.
  8. Remove the accessory drive belts.
  9. Remove the crankshaft pulley.
  10. Unbolt and remove the power steering pump pulley.
  11. Remove the water pump pulley attaching bolts and the pulley.
  12. Remove the alternator belt auto tensioner pulley assembly.
  13. Remove the camshaft position sensor.
  14. Unbolt the engine oil dipstick tube and remove it from the engine. Plug the hole to keep debris from falling into the engine.
  15. Unbolt and remove the vacuum pipe.
  16. Remove the upper radiator hose.
  17. Support the engine from underneath and remove the No. 3 (front) engine mount.
  18. Remove the timing belt cover attaching bolts and remove the covers.

To install:
  1. Inspect the dust seals on the belt covers and replace them as necessary.
  2. Position the timing belt covers and install the attaching bolts. Tighten the bolts to 70-95 inch lbs. (8-11 Nm).
  3. The remainder of the installation is the reverse of the removal procedure. Tighten all fasteners to specification.
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