Replacement

LEGEND
1 Bolt
2 Locking plate
3 Camshaft sprocket
4 Toothed belt tensioner
5 Toothed belt
6 Toothed belt cover
7 Bolt
8 Bolt

COMPONENT NOTES AND INFORMATION
1 Camshaft Sprocket
- Tighten to: 30 Nm (22 ft. lbs.), plus an additional 1/2 turn (180°).

2 Locking Plate
- Side with inscribed lettering always faces camshaft.

3 Camshaft Sprockets
- Tighten camshaft sprockets bolt only after toothed belt has been tensioned.
- Holder tool No. 3243, or equivalent, must be installed before installing sprockets.

4 Toothed Belt Tensioner
- Tighten to: 45 Nm (33 ft. lbs.).

5 Toothed Belt
- Refer to Timing Components.

6 Toothed Belt Cover

7 Bolt
- Tighten to: 10 Nm ( 7 ft. lbs.).

8 Bolt
- Tighten to: 25 Nm (18 ft. lbs.)..

PROCEDURES
Removal

CAUTION: Mark the direction of belt travel before removing, using a suitable marker. Reinstalling a used belt in the opposite direction could damage the belt.

- Remove ribbed belt.
- Remove ribbed belt tensioner.
- Unclip camshaft drive belt guard on both sides.
- Turn crankshaft by hand to Top Dead Center (TDC) position.





^ Notch -A- must align with notch -B-.

NOTE: If not aligned, turn crankshaft one more revolution.

- Check camshaft position.
^ Large holes in camshaft sprocket locking plates must face each other.
- Remove Crankshaft Position (CKP) sensor from lefthand side of cylinder block, behind oil cooler (above oil pan).
^ TDC recess in crankshaft must be positioned behind open hole for CKP sensor (inspect visually or by touch).

Crankshaft Holder 3242 Shown In Installed Position:

- Thread crankshaft holding tool 3242 into CKP sensor hole, and tighten slightly.
- Remove vibration damper.
- Remove lower belt guard.

Camshaft Holder 3243 Shown In Installed Position:

- Install camshaft holding tool 3243.
- Loosen left and right camshaft sprocket bolts approximately 3 turns.
DO NOT remove the bolts.
- Remove camshaft holding tool 3243.





- Loosen right and left camshaft sprockets from tapered ends of camshafts using puller (Kukko 20/10 shown).
^ Puller arms must engage on rear of sprocket
^ With engine installed in vehicle, use puller 3032
- Loosen and remove toothed belt.


Installation and Adjustment

- Install toothed belt over both camshaft sprockets.
- Install camshaft holding tool 3243.
- Install toothed belt over remaining sprockets, then over tensioner roller last.

NOTE: The camshaft sprockets must be loose enough on the tapered ends of the camshafts so that the camshafts can still be turned, but not so loose that the sprockets tilt out of alignment.





- The toothed belt tension adjustment is done by turning the tensioning roller with 8 mm hex-key wrench.
- Adjust tensioner so it can just be moved slightly by hand.





- Check belt tension by gripping belt half-way between camshaft sprocket and coolant pump.
Twisting the belt with the thumb and index finger, it must be just possible to twist it approximately 90°.
- Fully tighten tensioner center bolt with 8 mm hex-key wrench.
- Tightening torque: 45 Nm (33 ft. lbs.)
- Fully tighten camshaft sprocket bolts.
- Tightening torque: 30 Nm (22 ft. lbs.) plus 1/2-turn (180°)
- Remove crankshaft holding tool 3243.
- Reinstall CKP sensor.
- Tightening torque: 10 Nm (7 ft. lbs.)

NOTE:
- If crankshaft center bolt has been removed:
^ Always replace.
^ Use only new double hex-head (12-pt) cap screw, grade 9.8.
^ Tightening torque (with bolt oiled): 200 Nm (148 ft. lbs.) plus additional 1/2 turn (180°)