Installation

TIMING BELT

1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing.
2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket (Figure 1).

CAUTION: Ensure that the arrows on both camshaft sprockets are facing up.




Figure 1 Camshaft Sprocket Alignment






3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner (Figure 2).
4. Move the exhaust camshaft sprocket counterclockwise (Figure 2) to align marks and take up belt slack.




Figure 2 Timing Belt Installation






5. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top plate COUNTERCLOCKWISE. The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang (Figure 3). Using the allen wrench to prevent the top plate from moving, torque the tensioner lock bolt to 25 Nm (220 in. lbs.). Setting notch and spring tang should remain aligned after lock nut is torqued.
6. Remove allen wrench and torque wrench.




Figure 3 Timing Belt Tension Adjustment







NOTE: Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement. If TDC is missed, rotate a further two revolutions until TDC is achieved. DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impossible.

7. Rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position (Figure 4).




Figure 4 Crankshaft and Camshaft Timing






8. Check if the spring tang is within the tolerance window (Figure 5). If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 5 through 7.




Figure 5 Timing Belt Tension Verification






9. Install engine mount bracket to engine (Figure 6).
10. Install timing belt front covers and bolts.
11. Install air conditioning/generator belt tensioner and pulley.
12. Install right engine mount.
13. Install crankshaft vibration damper.
14. Install accessory drive belts.
15. Install drive belt splash shield.
16. Install right front wheel.
17. Connect make-up air hose to cylinder head cover.
18. Install air cleaner housing, upper cover, and clean air tube.





Figure 6 Engine Mount Bracket