Power Solutions International — Timing Belt Installation
Maintenance
From a Power Solutions International service manual — check it applies to your exact model before use.
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Before you start
- If the shaft is turned with the bolt, the belt will be over tensioned.
Procedure
- Align camshaft sprocket timing mark with mark on rocker cover.
- Align crankshaft sprocket timing mark with mark on front case.
- Align oil pump sprocket timing mark with its mating mark.
- Insert Phillips screwdriver (shank 8 mm) into cylinder block plug hole; should insert 60 mm or more.
- Install timing belt on crankshaft sprocket, oil pump sprocket, idler pulley, camshaft sprocket and tensioner pulley in order.
- Lift tensioner pulley and tighten center bolt.
- Remove screwdriver and install plug.
- Turn crankshaft a quarter turn counterclockwise then clockwise until marks align.
- Loosen tensioner pulley center bolt with Tension pulley socket wrench (800407), torque to 2.5-2.6 N·m, then tighten center bolt to 48 ± 5 N·m.
- Rotate Set screw (800425) until push rod hole aligns with body hole.
- Remove wire and special tool. Give two clockwise turns to crankshaft, wait 15 minutes, check wire reinsertion and rod protrusion.
Tools required
- Tension pulley socket wrench 800407 Amazon
- Set screw 800425 Amazon
- Torque wrench 0 to 5.0 N·m Amazon
- Phillips head screwdriver (shank diameter 8 mm) Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Tightening torque: 48 ± 5 N·m
- Standard value rod protrusion: 3.8 - 4.5 mm
- Torque to 2.5-2.6 N·m
Source: Power Solutions International service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.