Installation

Fig. 9 Flange & Crankshaft Sprocket Installation:

Fig. 8 Camshaft & Crankshaft Sprocket Timing Marks:

TIMING BELT INSTALLATION
1. Install flange and crankshaft sprocket as shown in Fig. 9.
2. Tighten crankshaft sprocket bolt.
3. Install camshaft sprocket.
4. Install timing belt tensioner as follows:

a. Mount tensioner, spring and spacer, then temporarily tighten pivot bolt.
b. Temporarily tighten adjusting bolt, then install bottom end of spring into front case.
c. Secure tensioner to position nearest water pump.

5. Ensure timing marks are aligned, Fig. 8.
6. Install timing belt over crankshaft sprocket, then camshaft sprocket, keeping tension side of belt tight as belt is installed. If used belt is installed, ensure belt is installed in original direction.
7. Apply counterclockwise force to camshaft sprocket to tighten tension side of belt, ensure that timing marks remain aligned.
8. Install crankshaft pulley to prevent belt from slipping off sprocket, then adjust belt tension as follows:

a. Loosen tensioner bolts to allow tensioner to bear against belt, then tighten adjusting bolt and pivot bolt. Tighten adjusting bolt first to prevent tensioner from rotating away from belt.
b. Rotate crankshaft clockwise one full revolution, then realign crankshaft sprocket timing mark with pointer. Crankshaft must be rotated smoothly, in clockwise direction. Do not apply any force other than spring force of tensioner to timing belt.
c. Loosen tensioner pivot and adjusting bolts, then tighten adjuster bolt and pivot bolt. Tighten adjusting bolt first to prevent tensioner from rotating away from belt.

Fig. 10 Triming Belt Tension Inspection:

d. Check belt tension by holding belt as shown in Fig. 10, and applying thumb pressure to tension side of belt. Tension is correct when tooth of belt covers approximately 1/4 width of tensioner adjuster bolt.
e. Rotate crankshaft clockwise one full revolution and ensure timing marks line up.

9. Reverse remaining procedure to complete installation, then adjust valve clearances as outlined under Valve Adjustment.