Power Solutions International — Timing Belt Removal and 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
- Use ONLY the PSI Long Life Camshaft and Balance Shaft Belts; use of a non-PSI long life belt is not permitted or recommended.
Procedure
- Mark the belt running direction.
- Use special tool Set screw (MD998738) to release tension on the timing belt.
- Insert a metal wire (1.4 mm) or 1/16" allen wrench into the auto-tensioner set holes.
- Remove the auto-tensioner by loosening the two bolts.
- Loosen the tensioner pulley bolt and remove the timing belt.
- Align timing marks on camshaft, crankshaft and oil pump sprockets.
- Install the timing belt on crankshaft sprocket, oil pump sprocket, idler pulley, camshaft sprocket, tensioner pulley in that order.
- Lift up the tensioner pulley and tighten the center bolt.
- Turn crankshaft a quarter turn counterclockwise, then clockwise until timing marks align.
- Torque tensioner pulley to 3.5 N·m then tighten center bolt to 48 ± 5 N·m.
- Give two clockwise turns to crankshaft, wait 15 minutes.
- Check the auto-tensioner rod protrusion is within 3.8 - 4.5 mm.
Tools required
- Set screw MD998738 Amazon
- Tension pulley socket wrench 800407 Amazon
- Crankshaft sprocket puller 800399 Amazon
- Sprocket stopper 800404 Amazon
- End yoke holder 800405 Amazon
- Pulley holder pin 800406 Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Camshaft sprocket bolt: 88 ± 10 N·m
- Counterbalance shaft sprocket bolt: 45 ± 3 N·m
- Tensioner "B" bolt: 19 ± 3 N·m
- Crankshaft bolt: 162 N·m
- Auto-tensioner: 24 ± 3 N·m
- Tensioner pulley center bolt: 48 ± 5 N·m
- Auto-tensioner rod protrusion standard: 3.8 - 4.5 mm
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.