Want to know where to set up timing marks and how to reinstall hydrulic t/belt tensioner

The timing settings for the Isuzu 320 V6 engine will depend on the specific year and model of the engine, as well as the type of timing system it uses. However, here are the general steps for setting the timing on a typical Isuzu V6 engine:

1. Remove the timing cover: Start by removing the timing cover to access the timing components.
2. Locate the timing marks: Locate the timing marks on the crankshaft and camshaft sprockets. The marks may be visible on the sprockets themselves or on the timing cover.
3. Rotate the engine: Use a socket and breaker bar to rotate the engine until the timing marks on the crankshaft and camshaft sprockets are lined up as specified in the service manual.
4. Check the tensioner: Check the timing belt tensioner to ensure it is properly adjusted and functioning correctly. If the tensioner is worn or damaged, it should be replaced.
5. Adjust the timing belt: If necessary, adjust the timing belt tension by loosening the tensioner bolt and moving the tensioner until the belt is at the correct tension. Then, tighten the tensioner bolt to secure the tensioner in place.
6. Reinstall the timing cover: Once the timing belt is properly adjusted, reinstall the timing cover and any other components that were removed.

It is important to follow the manufacturer's recommended procedures for setting the timing on your specific Isuzu V6 engine to ensure proper operation and prevent engine damage. If you are unsure about the correct timing settings or procedures, it is recommended to consult a service manual or take your vehicle to a qualified mechanic for assistance.

I strongly recommend you consult a repair manual for the timing belt install procedure. Depending if you have a hydraulic or mechanical tensioner for the belt, the procedure is different. If you register for free at www.autozone.com, listing make, model and year, you could find the procedure under "repair guides".
Here is a shortened guide: Align notch of crank sprocket with the arrow on the oil pump housing, then back off 3 notches or teeth, (counterclockwise to back off).
Align notch of cam sprocket with mark on the inner belt cover-it is at top of engine-notch on cam will be almost straight up.
Move crankshaft to 1/2 notch before arrow on oil pump housing. Install belt starting at crankshaft, then around water pump, then around camshaft sprocket last.
Move crank to TDC (notch right with arrow) to take up belt slack.
Reinstall tensioner, and tighten fasteners as follows: Mechanical tensioner-250 inch pounds.
Hydraulic tensioner assembly pulley bolt-50 foot pounds. Hydraulic tensioner assembly and pivot bracket bolt-23 foot pounds.
Remove tensioner plunger pins-for either mechanical or hydraulic tensioners. Tension is correct when plunger pin can be removed and replaced easily.
Rotate crankshaft at least two revolutions, and recheck timing marks.
Reinstall timing belt cover, engine mount bracket, engine mount, and crankshaft damper. Tighten crank damper pulley bolt to 105 foot pounds.
Reinstall drive belts and accessories.

I know the info on the tensioner is confusing: why you need to consult a repair manual or register at autozone. You have to compress the plunger on the hydraulic tensioner after removing it and insert a pin (a very small Allen wrench works-5/64 inch Allen wrench). If a mechanical tensioner, you will need an 8 mm Allen wrench to rotate the tensioner counter clockwise (this is before or after removed from engine), the use a 1/8 inch or 3 mm Allen wrench to insert into plunger hole, to hold the tensioner retracted until installed. See what I mean? Post back if unclear...or just find the repair procedure. Sorry, no diagrams available for me. I'm too old and crochety-lol.

Removal & Installation

2.5L (VIN H) Engine

1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with a insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.
2. Remove the right inner splash-shield.
3. Remove the accessory drive belts.
4. Remove the crankshaft damper.
5. Remove the right engine mount.
6. Place a suitable floor jack under the vehicle to support the engine.
7. Remove the right engine mount bracket.
8. Remove the timing belt upper left cover, upper right cover and lower cover.
9. Loosen the timing belt tensioner bolts.
   NOTE Before removing timing belt, be sure to align the sprocket timing marks to the timing marks on the rear timing belt cover.
   
10. If the present timing belt is going to be reused, mark the running direction of the timing belt for installation. Remove the timing belt and the tensioner.
11. Remove the camshaft timing belt sprockets from the camshaft, if necessary.
12. Remove the crankshaft timing belt sprocket and key.
13. Place the tensioner into a soft-jawed vise to compress the tensioner.
14. After compressing the tensioner place a pin into the plunger side hole to retain the plunger until installation.
    
    

    Fig. Timing belt engine sprocket timing-2.5L (VIN H) Engine
    

To install:

1. If removed, reinstall the camshaft sprockets onto the camshaft. Install the camshaft sprocket bolt and tighten to 65 ft. lbs. (88 Nm).
2. If removed, reinstall the crankshaft timing belt sprocket and key onto the crankshaft.
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, then back off the sprocket three notches before TDC.
4. Set the camshafts to align the timing marks on the sprockets with the marks on the rear timing belt cover.
5. Install the belt on the rear camshaft sprocket first.
6. Install a binder clip on the belt to the sprocket so it won't slip out of position.
7. Keeping the belt taut, install it under the water pump pulley and around the front camshaft sprocket.
8. Install a binder on the front sprocket and belt.
9. Rotate the crankshaft to TDC.
10. Continue routing the belt by the idler pulley and around the crankshaft sprocket to the tensioner pulley.
11. Move the crankshaft sprocket clockwise to TDC to take up the belt slack. Check that all timing marks are in alignment.
12. Reinstall the tensioner to the block but do not tighten it at this time.
13. Using special tool No. MD998767 and a torque wrench on the tensioner pulley, apply 39 inch lbs. (4.4 Nm) of torque to the tensioner. Tighten the tensioner pulley bolt to 35 ft. lbs. (48 Nm).
14. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner bracket and tighten the fasteners to 17 ft. lbs. (23 Nm).
15. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily.
16. Rotate the crankshaft two revolutions clockwise and recheck the timing marks. Check to be sure the tensioner plunger pin can be easily installed and removed. If the pin does not remove and install easily, perform the procedure again.
17. Reinstall the timing belt cover.
18. Reinstall the engine mount bracket.
19. Reinstall the right engine mount.
20. Remove the engine support.
21. Install the crankshaft damper and tighten to 134 ft. lbs. (182 Nm).
22. Reinstall the accessory drive belts and adjust them.
23. Reinstall the right inner splash-shield.
24. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool or equivalent.

2.5L (VIN N) Engine

1. Disconnect the negative battery cable.
2. Remove the accessory drive belts.
3. Using Crankshaft Holding Tools MB990767 and MB998754, remove the crankshaft bolt and remove the pulley.
4. Remove the heated oxygen sensor connection.
5. Remove the power steering pump with the hose attached and position it aside.
6. Remove the power steering pump bracket.
7. Place a floor jack under the engine oil pan, with a block of wood in between, and raise the engine so that the weight of the engine is no longer being applied to the engine support bracket.
8. Remove the upper engine mount. Spraying lubricant, slowly remove the reamer (alignment) bolt and remaining bolts and remove the engine support bracket.
   NOTE The reamer bolt is sometimes heat-seized on the engine support bracket.
   
9. Remove the front timing belt covers.
10. If the timing belt is to be reused, draw an arrow indicating the direction of rotation on the back of the belt for reinstallation.
11. Align the timing marks by turning the crankshaft with MD998769 Crankshaft Turning tool. Loosen the center bolt on the timing belt tensioner pulley and remove the belt.
    WARNING Do not rotate the crankshaft or camshaft after removing the timing belt or valvetrain components may be damaged. Always align the timing marks before removing the timing belt.
    
12. Check the belt tensioner for leaks and check the pushrod for cracks.
13. If the timing belt tensioner is to be replaced, remove the retaining bolts and remove the timing belt tensioner. When the timing belt tensioner is removed from the engine, it is necessary to compress the plunger into the tensioner body.
14. Place the tensioner in a vise and slowly compress the plunger. Take care not to damage the pushrod.
    NOTE Position the tensioner in the vise the same way it will be installed on the engine. This is to ensure proper pin orientation for when the tensioner is installed on the engine.
    
15. When the plunger is compressed into the tensioner body, install a pin through the body and plunger to hold the plunger in place until the tensioner is installed.
    
    

    Fig. Camshaft and crankshaft alignment marks-Chrysler 2.5L (VIN N) engines
    

To install:

1. Install the timing belt tensioner and tighten the retaining bolts to 17 ft. lbs. (24 Nm), but do not remove the pin at this time.
2. Check that all timing marks are still aligned.
3. Use bulldog clips (large paper binder clips) or other suitable tool to secure the timing belt and to prevent it from slacking. Install the timing belt. Starting at the crankshaft, go around the idler pulley, then the front camshaft sprocket, the water pump pulley, the rear camshaft sprocket and the tensioner pulley.
4. Be sure the belt is tight between the crankshaft and front camshaft sprocket, between the camshaft sprockets and the water pump. Gently raise the tensioner pulley, so that the belt does not sag, and temporarily tighten the center bolt.
5. Move the crankshaft 1 / 4 turn counterclockwise, then turn it clockwise to the position where the timing marks are aligned.
6. Loosen the center bolt of the tensioner pulley. Using MD998767 tensioner tool, and a torque wrench apply 3.3 ft. lbs. (4.4 Nm) tensional torque to the timing belt and tighten the center bolt to 35 ft. lbs. (48 Nm). When tightening the bolt, be sure that the tensioner pulley shaft does not rotate with the bolt.
7. Remove the tensioner plunger pin. Pretension is correct when the pin can be removed and installed easily. If the pin cannot be easily removed and installed it is still satisfactory as long as it is within its standard value.
8. Check that the tensioner pushrod is within the standard value. When the tensioner is engaged the pushrod should measure 0.149-0.177 in. (3.8-4.5mm).
9. Rotate the crankshaft two revolutions and check the timing marks. If the timing marks are not properly aligned remove the belt and repeat Steps 17 through 23.
10. Install the timing belt covers.
11. Install the engine mounting bracket.
12. Lower the engine enough to install the engine mount onto bracket and remove the floor jack.
13. Install the power steering pump bracket and pump.
14. Install the crankshaft pulley and tighten the retaining bolt to 13 ft. lbs. (18 Nm).
15. Install the accessory drive belts.
16. Properly fill the cooling system.
17. Connect the negative battery cable.
18. Check for leaks and proper engine and cooling system operation.

"The crankshaft timing pointer must be perfectly aligned with the white mark on the flywheel or flex-plate; the camshaft pulley must be aligned so that the word UP is at the top of the pulley and the marks on the edge of the pulley are aligned with the surfaces of the head.
Install the timing belt over the pulleys and tensioners.
Loosen the bolt used to lock the timing belt tensioner. Loosen, then tighten the timing belt adjusting nut.
Turn the crankshaft counterclockwise until the cam pulley has moved 3 teeth; this creates tension on the timing belt. Loosen, then tighten the adjusting nut and tighten it to 33 ft. lbs. (45 Nm). Tighten the bolt used to lock the timing belt tensioner.
Realign the timing belt marks, then install the balancer belt drive sprocket on the crankshaft.
Align the front balancer pulley; the face of the front timing balancer pulley has a mark, which must be aligned with the notch on the oil pump body. This pulley is the one at 10 o'clock to the crank pulley when viewed from the pulley end.
Align the rear timing balancer pulley (2 o'clock from the crank pulley) using a 6 x 100mm bolt or rod. Mark the bolt or rod at a point 2.9 in. (74mm) from the end. Remove the bolt from the maintenance hole on the side of the block; insert the bolt or rod into the hole. Align the 2.9 in. (74mm) mark with the face of the hole. This pin will hold the shaft in place during installation.
Install the balancer belt. Once the belts are in place, be sure that all the engine alignment marks are still correct. If not, remove the belts, realign the engine and reinstall the belts. Once the belts are properly installed, slowly loosen the adjusting nut, allowing the tensioner to move against the belt. Remove the pin from the maintenance hole and reinstall the bolt and washer.
Turn the crankshaft 1 full turn, then tighten the adjuster nut to 33 ft. lbs. (45 Nm). Remove the bolt used to lock the timing belt tensioner."

" " Chilton Library

REMOVAL
1. Disconnect negative battery cable.
2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air conditioning (A/C) compressor drive belt.
3. Remove P/S and/or A/C drive belt.
4. Loosen generator mounting bolts and adjusting bolt.
5. Remove generator bolts.
6. Remove water pump pulley.
7. Remove crankshaft pulley.
8. Remove upper and lower timing belt covers.
9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine.
10. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.
Do not move camshaft or crankshaft once timing marks have been correctly positioned.
11. Loosen tensioner pulley lock bolt.
12. Protect timing belt with a rag.
13. Remove tensioner pulley.
14. Remove timing belt. Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation.

INSTALLATION
1. Install tensioner pulley. Replace tensioner spring whenever timing belt is replaced.
2. Pull tensioner pulley to its furthest point and tighten lock bolt.
3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
4. Check that "I" mark on intake camshaft pulley is aligned with mark on seal plate and "E" mark on exhaust camshaft pulley is aligned with mark on seal plate.
If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal.
5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley, and tensioner pulley in that order.
6. Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and exhaust camshaft pulleys.
7. Loosen tensioner pulley lock bolt and allow tensioner spring to apply tension to timing belt.
Do not add additional tension.
8. Tighten tensioner pulley lock bolt to specified torque.
Tightening torque:28~38 lb-ft (38~51 N·m, 3.9~5.2 kg-m)
9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing mark on engine block.
10. Check that "I" mark on intake camshaft pulley and "E" mark on exhaust camshaft pulley are aligned with marks on seal plate.
11. If they are not aligned, remove timing belt and start process from tensioner installation.
12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection is not correct, repeat from tensioner installation.
Deflection pressure:22 Ib. (98 N, 10 kg)Deflection:0.39~0.50 in. (11~13 mm)
13. Install lower and upper timing belt covers in that order.
Tightening torque:5.8~8.0 Ib-ft (7.9~10.7 N·m, 0.8~1.1 kg-m)
14. Install timing belt guide plate and crankshaft pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
15. Install water pump pulley.
Tightening torque:9.0~12.6 lb-ft (12.3~17.2 N·m, 1.3~1.8 kg-m)
16. Install generator belt and adjust the tension.
17. Install P/S and/or A/C drive belt and adjust the tension.
18. Connect negative battery cable.

INSPECTION
Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt.
1. Replace timing belt if it is contaminated with oil or grease.
2. Check timing belt for uneven wear, fraying, peeling, cracking and hardening. Replace timing belt as necessary.
3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm).
4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation.
5. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage.
Replace any component that shows damage, excessive wear, or that appears prone to a possible failure.

I’m happy to help further over the phone at https://www.6ya.com/expert/jeremy_69f3cc28d95bf514

1. Remove or disconnect the following:
   
   
2. Negative battery cable Accessory drive belt and tensioner Timing belt cover Right front wheel Right inner splash shield Crankshaft pulley
   
3. Align the timing marks.

1. Removing Timing Belt

1. Loosen the timing belt tensioner bolt (1).
2. Use an 8mm Allen wrench, and turn the tensioner (2) counterclockwise 1 / 4 turn.
3. Insert a 1 / 8 inch drill bit in the hole (3) to lock the belt tensioner in place.
4. Remove the timing belt (4).
   
   To Install :
   
   
5. Install the timing belt in a counterclockwise direction starting at the crankshaft.
   
6. Remove the drill bit to unlock the timing belt tensioner.
   
7. Rotate the crankshaft two complete turns and check that the timing marks align.
   
8. Tighten the tensioner bolt to 15-22 ft. lbs. (20-30 Nm).
   
9. Reinstall or connect the following:
   
   Crankshaft pulley. Tighten the bolt to 81-96 ft. lbs. (110-130 Nm). Right inner splash shield Right front wheel Timing belt cover Accessory drive belt and tensioner Negative battery cable
10. Start the engine and check for proper operation
    

1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s).
2. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to TDC of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner timing belt cover or the edge of the cylinder head.
3. With the distributor cap removed, the rotor should be pointing toward the No. 1 mark on the rim of the distributor housing. On 8 valve engines, the notch on the crankshaft pulley should align with the dot on the intermediate shaft sprocket.
4. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt.
5. Slide the timing belt from the sprockets.

To install:

1. Check the alignment of the timing marks. On 16 valve engines, the mark on the tooth should align with the mark on the rear belt cover.
2. Install the new timing belt and tension the belt so it can be twisted 90 ° at the middle of it's longest section, between the camshaft and intermediate sprockets.
3. Recheck the alignment of the timing marks and, if correct, turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck belt tension and timing marks. Readjust as required. Torque the tensioner nut to 33 ft. lbs. (45 Nm).
4. Install the belt cover and accessory drive belts.
5. If the belt is too tight, there will be a growling noise that rises and falls with engine speed.

WARNING Timing belt maintenance is extremely important! The A4 and Passat model utilize an interference-type, non-free-wheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. The recommended replacement interval for the timing belt is at least every 6 years or 60,000-90,000 miles (96,000-144,000 km), depending on vehicle usage and engine type.
NOTE If removed and reinstalled, the timing belt must be installed in the same rotational direction as removed.

VW Passat & Audi A4 1990-2000 Repair Guide
Timing Belt - REMOVAL & INSTALLATION

WARNING Do NOT turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.


2.0L (9A, ABA) Engines

1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s).
2. Temporarily reinstall the crankshaft pulley bolt and turn the crankshaft to TDC of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner timing belt cover or the edge of the cylinder head.
3. With the distributor cap removed, the rotor should be pointing toward the No. 1 mark on the rim of the distributor housing. On 8 valve engines, the notch on the crankshaft pulley should align with the dot on the intermediate shaft sprocket.
4. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt.
5. Slide the timing belt from the sprockets

Fig. Adjusting the belt tension on a 2.0L 8 valve



Fig. Remove the timing belt cover




Fig. Align the timing marks





Fig. Locate the tensioner




Fig. Loosen the tensioner bolt




Fig. Mark the belts direction of rotation


To install:

1. Check the alignment of the timing marks. On 16-valve engines, the mark on the tooth should align with the mark on the rear belt cover.
2. Install the new timing belt and tension the belt so it can be twisted 90° at the middle of it's longest section, between the camshaft and intermediate sprockets.
3. Recheck the alignment of the timing marks and, if correct, turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck belt tension and timing marks. Readjust as required. Torque the tensioner nut to 33 ft. lbs. (45 Nm).
4. Install the belt cover and accessory drive belts.
5. If the belt is too tight, there will be a growling noise that rises and falls with engine speed.

continue...

jack up on stands, remove LF wheel and water shield. disconnect battery, buy a crankshaft pulley holding tool from OTC, swing p.s. reservoir out of the way, remove both accesory belts, front motor mount, valve cover, dipstick and tube, crank pulley, timing belt cover, set engine at TDC #1 (align marks), remove nut on tensioner shaft to loosen both belts, remove the belts and tensioners (replace all), replace water pump NOW, install timing pulley, reinstall spring (use dipstick tube bolt to hold back the timing pulley with the slot in the bracket on the pulley until the belt is installed), install balance shaft belt, pulley and spring, once tensioned rotate engine once and retension by loosening the nut and retightening. Make sure the marks are still lined up, and reinstall everything. New valve cover gasket set with silicone in the corners. fill with coolant and bleed system once finished. it is a good idea to also change all the oil seals while you are in there.

STEP 1 Remove Air Filter. STEP 2 Loosen the bolts securing the crankshaft pulley. Remove the load from the belt tensioner by turning the belt tensioner pulley locking bolt forward in the car using a 15 mm wrench. Remove the belt from the coolant pump pulley and slowly release the belt tensioner. STEP 3 Remove the belt tensioner and remove the steering pump pulley STEP 4 Remove the water pump pulley use the engine bracket to pry against. STEP 5 Remove the timing cover and Remove the right-hand front wheel and the cover in the wheel housing. STEP 6 Remove the crankshaft pulley (undo the six bolts but do not remove the centre bolt). STEP 7 Place the engine top dead center and Zero the engine. The markings on the camshaft sprockets and timing cover should be in alignment as also should the marking on the crankshaft. Use locking tools 83 95 006 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft (These tools can be purchased from Saab (18774177222) or from Baum Tools). STEP 8 Before removing the toothed belt mark its direction of rotation . To facilitate refitting the belt can be marked at both the camshaft marking and the crankshaft marking. STEP 9
STEP 10 Fit the toothed belt according to the marked direction of rotation. Use setting tool 83 95 006 to keep the belt in place and adjust the tensioning roller loosely by hand to prevent the belt from jumping off. Adjust counterclockwise. Fit a section of the toothed belt and fit tool 83 93 985 to measure the belt tension. Loosely tighten the centre bolts of the adjusting rollers. Adjust the lower adjusting roller counter clockwise to a belt tension of 275-300 Nm. Turning torque 30 lb.ft ft ******The adjustment of the belt tension is for preparation ONLY and must not be used as a check when the belt adjusted for the final time! STEP 11 Turn the engine over two revolutions until just before the zero mark and place the locking tool on the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm rests against the coolant pump's flange and then tighten the arm. Fit setting tool 8395006 and check that the markings on the camshaft sprockets are aligned with the markings in the tool. ********Check that the A marking is approximately 2mm above B marking. If the distance is less readjustment is necessary. STEP 12 Fit the crankshaft pulley and Tighten to a torque of 15 foot lbs. STEP 13 Reinstall the inner wheel cover and front right wheel.
STEP 14 Reinstall Timing Cover.
STEP 15 Reinstall the water pump pulley use the engine bracket for leverage. STEP 16 Reinstall the power steering pulley and tighten to 6 foot lbs. STEP 17 Reinstall the belt tensioner and tighten to 30 foot lbs. STEP 18 Remove the belt tensioner load/pressure by turning the belt tensioner pulley locking bolt forwards in the car using a 15 mm wrench. Install the belt on the coolant pump pulley. Carefully release the belt tensioner. STEP 19 Reinstall the Air Cleaner and hoses that accompany Release the belt tension and remove the toothed belt.