Installation

INSTALLATION





1. Install the flange and crankshaft sprocket as shown. Pay close attention to their mounting directions.
2. Install the camshaft sprocket and tighten the bolt to the specified torque.

Tightening torque:

Camshaft sprocket bolt: 80 - 100 Nm (800 - 1000 kg.cm, 59 - 72.8 lb.ft)
Crankshaft spocket bolt: 150 - 160 Nm (1500 - 1600 kg.cm 110 - 118 lb.ft)








3. Align the timing marks of the camshaft sprocket and crank shaft sprocket with the No.1 piston placed at top dead center on its compression stroke.





4. To install the timing belt tensioner, first mount the tensioner. spring, and spacer. Temporarily tighten the bolts. Next tempo rarily tighten the tensioner long hole side washer and bolts. Install the bottom end of the spring against the front case as shown in the illustration.





5. Secure the tensioner, positioned towards the water pump.
6. Install the timing belt on the crankshaft sprocket.
7. Install the timing belt on the camshaft sprocket. When the timing belt is installed on the camshaft sprocket make sure that the tension side is tight. Then, check to ensure that when the tension side is tightened by turning the camshaft sprocket in a reverse direction, all timing marks are in line.
8. Loosen the tensioner mounting bolts 1 and 2 in that order as shown. This will apply spring tension to the timing belt only. Check the belt to ensure that it is not out of position.
9. Tighten the tensioner tightening bolts 1 and 2 in that order. lfthe bolt 1 is tightened first, the tensioner will move with the belt in the direction that the belt is tightened.
10. Give the crankshaft one turn in operating direction (clock-wise) and realign crankshaft sprocket timing mark with the top dead center position.

CAUTION: Do not turn the crankshaft in a counterclockwise direction. The crankshaft should turn smoothly.

11. Loosen the tensioner attaching bolts 1 and 2 in that order.
12. Tighten the tensioner attaching bolts 2 and 1 in that order to the specified torque.

Tightening torque
Tensioner attaching bolt 20 - 27 Nm (200 - 270 kg.cm, 14 - 20 lb.ft)





13. Then recheck the belt tension. Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49 N (11 lb~, the timing belt cog end is approx. 1A of the tensioner mounting bolt head radius (across flats) away from the bolt head center.





14. Install the timing belt cover.

Tightening torque
Timing belt cover bolt 10 - 12 Nm (100 - 120 kg.cm 7.2 - 8.7 lb.ft)

15. Install the crankshaft pulley. In this case, make sure that the crankshaff sprocket pin fits the small hole in the pulley.

Tightening torque
Crankshaft pulley bolt 10 - 12 Nm (100 - 120 kg.cm, 7.2 - 8.7 lb.ft)

16. Install the fan belt and adjust the belt tension.
17. Install the water pump pulley
18. Install V-belt and adjust the belt tension.