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Timing Belt Tensioner

REMOVAL & INSTALLATION

1983–87 626
  1. Loosen the alternator mounting bolts, release the belt tension and remove the alternator belt.
  2. Unfasten the attaching bolts, then remove the upper timing belt cover and gasket. Rotate the engine in the normal direction of rotation until the camshaft pulley mark aligns with the V-notch at the top of the front housing. The notch in the crankshaft pulley will now be aligned with the arrow on the front housing, unless the belt has jumped time.
  3. With brake pliers or another suitable tool, unhook the tensioning spring. Now, unfasten the bolt and remove the tensioner.

    Fig. 1: The timing belt tensioner, tensioner spring and bolt are shown disassembled at the left, and in their installed position at the right

  4. Inspect the tensioner for bearing wear. It should rotate freely and smoothly. If not, replace it.

    To install:

  5. Make sure the belt remains engaged at all three pulleys and that the crankshaft and camshaft pulleys are properly timed. Locate the tensioner on its swivel pin with the slot (through which the mounting bolt passes) centered over the bolt hole. Install the bolt, but do not tighten it.
  6. Connect the tensioner spring. With a wrench on the crankshaft pulley, turn the engine in the normal direction of rotation (clockwise) exactly two full turns until the timing marks are again aligned. Torque the lockbolt to 28–38 ft. lbs. (38–51 Nm).
  7. Install the timing belt cover, using a new gasket if necessary.
  8. Install and properly tension the alternator belt.
1988–89 626/MX-6
  1. Disconnect the negative battery cable.
  2. Tag and disconnect the spark plug wires, then remove the spark plugs.
  3. Remove the engine side cover and the accessory drive belts.
  4. Unfasten the crankshaft pulley, then remove the upper and lower timing belt covers and gaskets. Remove the crankshaft pulley baffle plate and make a note of how it is installed. The curved side should be facing out.
  5. Engage the crankshaft pulley bolt with the appropriate size metric socket and a breaker bar, then turn the crankshaft in the normal direction of rotation until the "arrowed'' 1 mark on the camshaft pulley is aligned with the mark on top of the front housing.
  6. Unbolt and remove the tensioner, then disconnect the tensioner spring from its mount.
  7. Inspect the tensioner for free and smooth rotation; replace if it does not turn smoothly.

    To install:

  8. Connect the spring to the tensioner, then 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.
  9. 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 for a used belt is 0.35–0.39 in. (9–10mm) and for a new belt is 0.31–0.35 in. (8–9mm). If the deflection is not correct, loosen the tensioner lockbolt and adjust the tension as required.
  10. Install the baffle plate so that the curved side faces outward. Install the upper and lower timing belt covers, using new gaskets if necessary.
  11. Install the crankshaft pulley and tighten the pulley screws 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.
  12. Install the engine side cover. Install the spark plugs and torque to specification. Connect the spark plug wires.
  13. Connect the negative battery cable. Check and/or adjust the ignition timing as required.
323 Models
NON-TURBO
  1. Disconnect the negative battery cable. Remove the engine side cover.
  2. Remove the power steering and air conditioning belts, if applicable.
  3. Remove the alternator drive belt and the alternator.
  4. Unfasten the bolts and remove the water pump pulley. Unfasten the bolts and washers, then remove the front portion of the crankshaft pulley together with its spacer.
  5. Tag and disconnect the spark plug wires, then remove all four spark plugs (to make crankshaft rotation easier).
  6. Unfasten and remove both the upper and lower timing belt covers along with their gaskets.
  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 on reusing the belt, be sure to mark the direction of rotation before removal.
  8. Inspect all parts. Check the tensioner for rough rotation. Check the condition of the tensioner spring and replace as necessary.

    To install:

  9. Position the tensioner on the block, then install the bolt and washer, just starting the threads. Connect the spring and 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.
  10. 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 (to produce approximately 22 lbs. or 10 kg pressure) and measure deflection. 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 tension is incorrect, do not try to tension the belt by hand. Instead, fix any binding in the mechanism, if necessary; otherwise, replace the tensioning spring.
  11. Install the timing belt covers, using new gaskets if necessary. Torque the bolts to 69–95 inch lbs. (8–11 Nm).
  12. Install the spark plugs, torquing to 11–17 ft. lbs. (15–23 Nm), then connect the plug wires.
  13. Install the baffle plate along with the crankshaft pulley and washer, torquing the pulley bolts to 11–13 ft. lbs. (15–18 Nm). Install and properly tension the drive belts.
  14. Install the engine side cover. Connect the negative battery cable.
TURBO
  1. Disconnect the negative battery cable. Remove the engine side cover.
  2. Remove the required accessory drive belts. Remove the water pump pulley and crankshaft pulley.

    NOTE: 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/power steering pulley and the crankshaft pulley.

  3. Rotate the engine so that the No. 1 piston is at TDC.
  4. Unfasten and remove the upper, middle and lower timing belt covers along with gaskets from the mountings.
  5. Remove the baffle plate. Remove the timing belt tensioner and spring by disconnecting the spring from its anchor, then loosening the tensioner bolt.
  6. Check the tensioner for rough rotation.

    To install:

  7. Connect the spring to the tensioner, then install the spring and tensioner with the attaching bolt. Move the tensioner to the left until the spring is fully extended and temporarily tighten the tensioner bolt to hold it in place. Torque the tensioner lockbolt to 27–38 ft. lbs. (37–52 Nm).
  8. 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 two pulleys. Loosen and tighten the tensioner, as required, to adjust the tension.
  9. Install the lower and upper timing belt covers, using new gaskets if necessary. Install the spark plugs and connect the plug wires.
  10. Install the baffle plate, with the curved surface facing outward. Install the crankshaft pulley and, where applicable, the air conditioning/power steering pump pulley. Torque the pulley bolts to 9–13 ft. lbs. (12–18 Nm).
  11. Raise the vehicle and install the No. 3 engine mount bracket. Torque the bolts to 44–63 ft. lbs. (60–85 Nm), then remove the lifting equipment.
  12. Install and properly tension the drive belts. Install the engine side cover.
  13. Connect the negative battery cable. Check and/or adjust the ignition timing as required.
929

These vehicles are equipped with an automatic spring-loaded tensioner. Prior to installation, the automatic tensioner must be loaded. For this operation, a press that is capable of producing 2,000 lbs. of force will be required. For illustrations of the loading procedure, refer to the Timing Belt Removal and Installation procedure, earlier in this section.

  1. Rotate the engine so that the No. 1 piston is at TDC. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2. Drain the cooling system. Tag and disconnect the spark plug wires, then remove all six spark plugs (to make crankshaft rotation easier).
  3. Remove the fresh air duct assembly, the cooling fan and radiator cowling. Remove the drive belts.
  4. Remove the air conditioning compressor idler pulley. If necessary, disconnect the compressor and position it to the side.
  5. Remove the crankshaft pulley and baffle plate. Remove the coolant bypass hose and the upper radiator hose.
  6. Unfasten and remove the right timing belt cover and gasket. Unbolt and remove the timing belt automatic tensioner.

    NOTE: If necessary for access, also remove the left timing belt cover and gasket.

    To install:

  7. Place a flat washer on the bottom of the tensioner body to prevent damage to the body. Press the rod into the tensioner body using an arbor press. DO NOT use more than 2,000 lbs of pressure. Once the rod is fully inserted into the body, insert an "L'' shaped pin or small Allen wrench through the body to hold the rod in place. Remove the unit from the press and install it onto the engine block. Torque the mounting bolt to 14–19 ft. lbs. (19–26 Nm).
  8. Remove the pin from the auto tensioner. Turn the crankshaft twice in the normal direction of rotation and check that all the timing marks are aligned properly.
  9. 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.

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

  10. Install the timing belt cover(s), using new gasket(s) if necessary.
  11. Connect the coolant bypass hose and the upper radiator hose to their respective fittings.
  12. Install the crankshaft pulley and baffle plate. Torque the retaining bolts to 7–11 ft. lbs. (10–15 Nm).
  13. Reposition and fasten the air conditioner compressor, if necessary. Install the air conditioning compressor idler pulley.
  14. Install and properly tension the drive belts.
  15. Install the cooling fan, radiator cowling and fresh air duct.
  16. 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.
  17. Fill the cooling system to the proper level.
  18. Connect the negative battery cable. Check and adjust the ignition timing, if necessary.

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