Due to the service history on the 1989 through 1995 Geo Tracker 1.6 engine, it is recommended that the timing belt be replaced every 60,000 miles. The belt normally will not wear out, however the belt stretches over a period of miles and at this interval the belt tensioner reaches its limit of movement and can no longer apply tension to the belt, causing the belt to fail or come off. This engine has been identified as a freewheeling engine wherein the possibility of engine damage should the belt come off is remote.
Remove the radiator shroud, the cooling fan and fan clutch. Remove the accessory drive belts. Remove the crankshaft pulley bolts and the pulley. Remove the timing belt cover. Turn the crankshaft clockwise until the number 4 cylinder is at top dead center of compression stroke. The timing marks will be aligned on the crank pulley and timing cover. The groove on the crank pulley should be aligned with the O degree mark on the timing belt cover.
Loosen the belt tensioner bolt and the tensioner lever stud that the spring is attached to. Remove the spring and push the tensioner upward and lightly tighten the bolt to hold the tensioner out of the way. Remove the timing belt. Remove the air cleaner and the valve cover.
Loosen all valve lash adjuster screws so that the camshaft can be turned freely. Ensure that the camshaft timing marks are aligned. The dot on the camshaft pulley has a dot under one of the teeth and should be lined up with a V cut into the rear timing belt cover.
Install the new timing belt counter clockwise starting from the crankshaft sprocket making sure that all the tension is on the right side opposite the tensioner. Loosen the tensioner bolt and install the tensioner spring. Turn the crankshaft two turns clockwise until the number 4 cylinder is top dead center of compression stroke with all alignment marks aligned.
Torque the tensioner bolt to 20-foot pounds of torque and the tensioner lever to 8-foot pounds of torque. Install the timing belt cover and the crankshaft pulley. Install the crankshaft pulley bolt and torque the pulley to 8-foot pounds of torque.
Adjust the valve lash to the following: the exhaust to 0.0063 to 0.0075 of an inch and the intake to 0.0051 to 0.0067 of an inch. Both are to be adjusted while the engine is cold. Torque the valve lash adjuster screw locknuts to 13-foot pounds of torque. Install components in reverse order of removal.
