<!-- from fixya rte -->Tension spring set up on timing belt - 1991 Hyundai Excel 4 Door

The spring tensioner should keep the proper tension on the belt. If the tensioner is not keeping the belt taught, I would suggest having both changed. Much cheaper to have done before the belt skips.

If you have replaced the spring loaded belt tensioner ( leave the pully nut loose ) then on refitting the belt , at a point midway between the two cam pulleys there should be a maximum deflection of .37" to .45 " ( 3/8 to just under 1/2") with a 22 lbs load applied on the belt . the tensioner pulley is then tightened up at the pulley nut to 28 -38ft lbs torque setting

Would you not start over & recheck the timing
belt,cam gears, etc for being set correctly?

You will have to tear it back down where you can get to timing belt and all pulleys.

Timing Belt

Print
REMOVAL and INSTALLATION
See Figures 1, 2 and 3

Fig. Fig. 1: Timing belt, tensioner and camshaft gear

Fig. Fig. 2: Timing belt alignment marks

Fig. Fig. 3: Timing belt tensioner and belt
Timing belts must always be handled carefully and kept completely free of dirt, grease, fluids and lubricants. This includes any accidental contact from spillage, fingerprints, rags, etc. These same precautions apply to the pulleys and contact surfaces on which the belt rides.The belt must never be crimped, twisted or bent. Never use tools to pry or wedge the belt into place. Such actions will damage the structure of the belt and possibly cause breakage.

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Remove the 4 crankshaft pulley bolts and remove the crankshaft pulley.

It is not necessary to loosen the crankshaft timing belt pulley bolt at the center.

1. Remove the timing belt cover.
2. Align the 4 timing marks by turning the crankshaft.
3. Remove the timing belt tensioner, tensioner plate, tensioner spring, spring damper and timing belt.

After the timing belt is removed, never turn the camshaft or crankshaft independently. If turned, interference may occur among the pistons, and valves and parts related to the pistons and valves may be damaged.

1. Inspect the timing belt for wear or cracks and replace as necessary. Check the tensioner for smooth rotation.

To install:

1. Install the tensioner plate to the tensioner.
2. Insert the lug of the tensioner plate into the hole of the tensioner.
3. Install the tensioner, tensioner plate and spring. Do not tighten the tensioner bolt and stud, make the bolt hand tight only.

Be sure that plate movement is installed in the proper direction that causes the same directional movement of the tensioner inner race. If no movement between the plate and inner race occurs remove the tensioner and plate again and reinsert the plate lug into the tensioner hole.

1. Check that the timing mark on the camshaft timing pulley is aligned with the V mark on the cylinder head cover. If not align the 2 marks by turning the camshaft by be careful not to turn it more than the allowable range.
2. Check that the punch mark on the crankshaft timing belt pulley is aligned with the arrow mark on the oil pump case. If not align the 2 marks by turning the camshaft by be careful not to turn it more than the allowable range.
3. With the 4 marks aligned, install the timing belt on the 2 pulleys in such a way that the arrow marks on the belt (if so equipped) coincide with the rotating direction of the crankshaft. In this state the No. 1 piston is at top dead center of its compression stroke.
4. Install the tensioner spring and spring damper. To allow the belt to be free of any slack, turn the crankshaft 2 rotations clockwise after installing the tensioner spring and damper. After removing the belt slack, first tighten the tensioner stud to 8 ft. lbs.. (11 Nm) and then the tensioner bolt to 20 ft. lbs.. (27 Nm).

As a final check, confirm that both sets of timing marks are aligned properly.

1. Ensure that the seal is between the water pump and the oil pump case. Install the timing belt outside cover. Torque the timing belt cover bolts to 8 ft. lbs.. (11 Nm).
2. Install the crankshaft pulley. Fit the keyway on the pulley to the key on the crank timing belt pulley and tighten the 4 bolts to 8 ft. lbs.. (11 Nm).
3. Lower the vehicle and install the negative battery cable.

Hi,


You find the timing marks on the picture below.





Removal
Remove auxiliary 1. drive belts.
2. Support engine.
Remove:
Engine mounting and bracket.
Timing belt upper cover [1].
3.
4. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [2] & [3].
Remove:
Crankshaft pulley bolt [4].
Crankshaft pulley [5]. Use tool No.09213-60017.
5.
6. Ensure timing marks aligned [2] & [3].
7. Slacken tensioner bolt [6]. Move tensioner away from belt and lightly tighten bolt.
Remove:
Timing belt lower cover [7].
Crankshaft sprocket guide washer [9].
Timing belt.
Tensioner pulley.

Installation
Installation
1. Check tensioner pulley for smooth operation.
2. Check free length of tensioner spring is 46,0 mm [8]. Replace spring if necessary.
3. Fit tensioner and spring. Ensure spring is connected correctly.
4. tighten bolt [6].
5. Ensure timing marks aligned [2] & [3].
6. Fit timing belt. Ensure belt is taut between sprockets.
Install:
Crankshaft sprocket guide washer [9].
Timing belt lower cover [7].
Crankshaft pulley [5].
7.
8. Slacken tensioner bolt 1/2 turn [6].
9. Turn crankshaft two turns clockwise to TDC on No.1 cylinder. Ensure timing marks aligned [2] & [3].
Turn crankshaft slowly 1 7/8 turns clockwise until crankshaft pulley timing mark [3] aligned with 45° BTDC mark [10] on
timing belt lower cover [7].
10.
11. Tighten tensioner bolt [6]. Tightening torque: 42 Nm.
12. Install components in reverse order of removal.
13. Tighten crankshaft pulley bolt [4]. Tightening torque: 108 Nm.
Manufacturer: Toyota

1. Remove all necessary components for access to the timing belt cover, then remove the cover.
2. Rotate the crankshaft clockwise and align the timing marks so No. 1 piston will be at Top Dead Center (TDC) of the compression stroke.
3. 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.
4. Mark the timing belt with an arrow showing direction of rotation.
5. Remove the timing belt.
6. If defective, remove the timing belt tensioner.
7. Align the timing marks of the camshaft sprocket and check that the crankshaft timing marks are still in alignment.
8. If removed, 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.
9. Install the free end of the spring into the locating tang on the front case.
10. Position the timing belt over the crankshaft sprocket, then over the camshaft sprocket. Slip the back of the belt over the tensioner wheel.
11. Turn the camshaft sprocket in the opposite of its normal direction of rotation until the straight side of the belt is tight and be sure the timing marks align.
    NOTE If the timing marks are not properly aligned, shift the belt 1 tooth at a time in the appropriate direction until they are aligned.
    
12. Loosen the tensioner mounting bolts so the tensioner works, without the interference of any friction, under spring pressure. Be 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.
13. Tighten the tensioner adjusting bolt, then the tensioner pivot bolt to 15-18 ft. lbs. (20-26 Nm).
    NOTE Bolts must be tightened in the stated order or tension won't be correct.
    
14. Turn the crankshaft 1 turn clockwise until timing marks again align to seat the belt.
15. Loosen both tensioner attaching bolts and let the tensioner position itself under spring tension. Retighten the bolts.
16. 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 approximately 1 / 2 of the way across the head of the tensioner adjusting bolt. Re-tension the belt, if necessary.
17. Install the timing belt covers and all other related components.
    

2.4L Engine
NOTE You may need DRB scan tool to perform the crankshaft and camshaft relearn alignment procedure.

1. Remove or disconnect the following:
   
   • Negative battery cable
     
   • Right front wheel and inner splash shield
     
   • Accessory drive belts
     
   • Crankshaft damper
     
   • A/C compressor/alternator tensioner and pulley assembly
     
   • Lower front timing cover
     
   • Upper front timing cover
     
   • Right engine mount
     
   • Engine mount bracket
     
   
   NOTE This is an interference engine. Do not rotate the crankshaft or the camshafts after the timing belt has been removed. Damage to the valve components may occur. Before removing the timing belt, always align the timing marks.
   
2. Rotate the crankshaft until the Top Dead Center (TDC) mark on the oil pump housing aligns with the TDC mark on the camshaft sprocket (located on the trailing edge of the tooth).
   
3. Loosen the timing belt tensioner lock bolt.
   
4. Insert a 6mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate clockwise until there is enough slack to remove the belt.
   
5. If necessary, remove the camshaft timing belt sprockets.
   
6. If necessary, remove the crankshaft timing belt sprocket using removal tool No. 6793, or equivalent.
   
7. Place the tensioner into a soft-jawed vise to compress the tensioner.
   
8. After compressing the tensioner, insert a pin (a 5/64 in. Allen wrench will also work) into the plunger side hole to retain the plunger until installation.
   

Camshaft and crankshaft alignment marks—2.4L engine




To lock the timing belt tensioner, be sure to fully insert the smaller Allen wrench into the tensioner as shown—2.4L engine





Installation of the timing belt, notice the camshaft alignment— 2.4L (VIN B) engine


To install:

1. If necessary, use tool No. 6792, or equivalent, to install the crankshaft timing belt sprocket onto the crankshaft.
   
2. If necessary, install the camshaft sprockets onto the camshafts. Install and tighten the camshaft sprocket bolts to 75 ft. lbs. (101 Nm).
   
3. Set the crankshaft sprocket to Top Dead Center (TDC) by aligning the notch on the sprocket with the arrow on the oil pump housing.
   
4. Set the camshafts timing marks so the exhaust camshaft is 1/2 notch below intake camshaft sprocket. Make sure the arrows on both camshaft sprockets are facing up
   
5. Install the timing belt starting at the crankshaft, then around the water pump sprocket, idler pulley, camshaft sprockets and around the tensioner pulley.
   
6. Move the exhaust camshaft sprocket counterclockwise to take up the belt slack.
   
7. Insert a 6mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate counterclockwise until there is no slack on the belt. The tensioner setting notch will start to move clockwise. Watch the notch and continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). The setting notch and spring tang should remain aligned after the lock nut is tightened.
   
8. Rotate the crankshaft 2 revolutions and recheck the timing marks.
   
9. Check the spring tang is within the tolerance window. If not within the window, reinsert the Allen wrench and into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate counterclockwise until there is no slack on the belt. The tensioner setting notch will start to move clockwise. Watch the notch and continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). The setting notch and spring tang should remain aligned after the lock nut is tightened.
   
10. Install the engine mount bracket.
    
11. Install the front timing belt covers.
    
12. Install the A/C compressor/alternator tensioner and pulley assembly.
    
13. Install the right engine mount.
    
14. Install the crankshaft damper
    
15. Install the accessory drive belts and adjust to the proper tension.
    
16. Install the right inner splash shield and wheel.
    
17. Reconnect the negative battery cable.
    
18. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool, or equivalent
    

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The Isuzu is a strange animal-when you do the timing belt you set it with #1 TDC "BUT" the distributor is timed with TDC #4 I found this the hard way and finally had to buy a cd with the procedures on it. Send me an e-mail address and I will forward the associated pictures &
info to you.
Jim Young
[email protected]

TIMING BELT & SPROCKETS R & I
NOTE: Some procedures may differ slightly due to engine
construction.
Removal
1) Remove all necessary air ducts. Position No. 4 piston at
TDC of compression stroke. Align timing marks. See Fig. 2. Remove fan
and fan shroud. Remove belts. If necessary, remove radiator and
splashguard.
2) Prevent engine from rotating and remove crankshaft timing
pulley retaining bolt. Remove upper and lower timing belt covers.
Remove spring from tension pulley. Loosen adjusting bolt and move
pulley toward water pump. Remove timing belt.
CAUTION: Ensure pistons are at TDC when rotating camshaft or damage
may result.
Inspection
1) Handle timing belt carefully. Avoid twisting or kinking
belt. Do not allow belt to become contaminated by water, oil, dirt or
other contaminates. Inspect belt for cracks or damage. If necessary,
replace.
2) Measure tension pulley spring length and force. Spring
length should not exceed 2.76" (70.2 mm) and spring force should not
be less than 197-347 lbs. (27-48 kg).
3) Replace tension pulley spring if not within specification.
Installation
1) Pull tensioner fully toward water pump side and
temporarily tighten retaining bolt. Ensure No. 4 cylinder is at TDC on
compression stroke by rotating crankshaft until keyway aligns with
mark on front crankshaft seal housing (12 o’clock). Rotate camshaft
until timing mark on cam gear (arrow) aligns with mark on upper
camshaft cover (notch). See Fig. 2.
NOTE: When timing marks are aligned as stated above, No. 4 piston
is at TDC on compression stroke.
2) Position timing belt over crankshaft sprocket, oil pump
sprocket, camshaft sprocket and tensioner in that order. Ensure belt
is positioned in sequence given and without slack between sprockets.
Loosen tension sprocket adjusting bolt allowing spring tension to
tighten belt. Tighten adjusting bolt temporarily.
3) Temporarily install crankshaft pulley bolt and rotate
crankshaft 2 complete revolutions in opposite direction of engine
rotation, until marks on crankshaft and front oil seal retainer are
aligned again. See Fig. 2. Loosen tensioner lock bolt, allowing
tesioner spring to fully adjust tension. Tighten tensioner lock bolt.
4) Install timing belt covers. To complete installation,
reverse removal procedures. Tighten all bolts to specification. See
TORQUE SPECIFICATIONS table at end of this article.
Fig. 2: 2.3L & 2.6L Timing Alignment Marks
Courtesy of Isuzu Motor Co.

2.7L & 3.5L Engines same Tools & Procedure Rate Me Please 1/2 in. breaker bar & Special Tool 7198 for conventional V-belts and Poly-V belts

1. REMOVAL
   AIR CONDITIONING BELT
   
   NOTE: The A/C drive belt self tensioner is NOT a dynamic tensioner. After adjustment the tensioner bracket bolts are tightened. The torsion spring is no longer responsible for tensioning the A/C belt. The torsion spring is only used for initial belt tensioning.
   1. Remove generator/power steering belt to gain access to A/C belt. Refer to GENERATOR/POWER STEERING BELT for procedure.
   
   
   1. Loosen BUT DO NOT REMOVE tensioner locking bolt and pivot bolt (Fig. 2).
   2. Insert 1/2" drive breaker bar into square opening on belt tensioner. Rotate tensioner counterclockwise until belt can be removed from pulleys (Fig. 2).
   3. Slowly rotate tensioner clockwise to relieve spring load.
   CLEANING
   Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt.
   
   INSPECTION
   Belt replacement under any or all of the following conditions is required:
   
   • Excessive wear
   • Frayed cords
   • Severe glazing

• Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 3).
  
  NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION
  
  AIR CONDITIONING BELT - NEW
  
  WARNING: DO NOT REMOVE A/C BELT TENSIONER LOCKING BOLT WITHOUT FIRST HOLDING THE TENSIONER WITH A 1/2" DRIVE BREAKER BAR, AS PERSONAL INJURY COULD RESULT.

NOTE: Verify that torsion spring position is in the new belt position before installing a NEW belt (Fig. 4). If torsion spring is not in the new belt position, follow steps 1-7 to change the tensioner spring from the USED belt position to the NEW belt position.

1. Insert a 1/2" drive breaker bar into the square opening on the tensioner. Hold counterclockwise pressure on tensioner while removing the locking bolt (Fig. 2).
2. Carefully release spring load of the torsion spring on the tensioner.
3. Remove pivot bolt, tensioner, and spring from front timing cover.
4. Insert spring arm into the NEW belt position on the tensioner (Fig. 4).
5. Install torsion spring, tensioner, and pivot bolt.
6. Install pivot bolt. Tighten only finger tight, at this time.
7. Using a 1/2" drive breaker bar, apply counterclockwise pressure until locking bolt can be installed.
   1. Install the NEW belt by rotating the tensioner counterclockwise until the NEW belt can be installed on pulleys. See (Fig. 5) for belt routing.
   2. Release tensioner and remove breaker bar. Belt is automatically adjusted with the tensioner's torsion spring.
   3. Tighten tensioner locking bolt and pivot bolt to 28 Nm (250 in. lbs.) (Fig. 2).
   4. Install generator/power steering belt.
   AIR CONDITIONING BELT - USED
   
   NOTE: A "used belt" is considered having more than 500 miles of service use. NOTE: Perform steps 1-7 to change the tensioner spring from the NEW belt position, to the USED belt position.
   1. Insert a 1/2" drive breaker bar into the square opening on tensioner. Hold counterclockwise pressure on tensioner, while removing tensioner locking bolt (Fig. 2).
   2. Carefully release the tension of spring on tensioner.
   3. Remove pivot bolt, tensioner, and spring from front cover.
   4. Insert spring into the USED belt position on tensioner bracket (Fig. 4).
   5. Install spring, tensioner bracket, and pivot bolt.
   6. Install pivot bolt. Tighten only finger tight, at this time.
   7. Using a 1/2" drive breaker bar, apply counterclockwise pressure until locking bolt can be installed.
   8. Install the USED belt by rotating tensioner counterclockwise until belt can be installed on pulleys. See (Fig. 5) for belt routing.
   9. Release tensioner and remove breaker bar. Belt is automatically adjusted with the tensioner's torsion spring.
   10. Tighten tensioner locking bolt and pivot bolt to 28 Nm (250 in. lbs.) (Fig. 2).
   11. Install generator/power steering belt.

I Hope This is Of Help To YOU IF So PLEASE HELP ME RATE ME it Helps Thank You Very Much and Happy Motoring !!!!!!!!