Installation

REASSEMBLY

NOTE: Allow the tensioner to remain in the assembled state and install it temporarily as follows:

1. Temporarily tighten the tensioner as shown in illustration, so that one extended end of the tensionerv spring is assembled to the bend of the tensioner bracket. (the spring tensioner is inoperative and not loaded).

2. Then set the extended end of tensioner spring at front case with drive etc.





3. Install the timing belt so as not to allow slack to the tension side. Make sure that all timing marks are at their correct positions and the tensioner is in a loaded state by applying force to the camshaft sprocket in a counterclockwise direction.





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








3. Align the timing marks of the camshaft sprocket and crankshaft 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, temporarily 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 coolant 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. If the 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 bolt 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 Nm (11 lb)], the timing belt cog end is aprox. 1/2 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 Ib.ft)

15. Install the crankshaft pulley. In this case, make sure that the crankshaft sprocket pin fits the small hole in the pulley.
16. Install the fan belt and adjust the belt tension.
17. Install the coolant pump pulley
18. Install V-belt and adjust the belt tension.