Installation Procedure

1. Install the toothed belt in the marked direction of rotation, using KM-800-30 to hold the belt in position, and lightly adjust the tensioner roller by hand so that the belt does not unmesh. Adjust counter clockwise. Install a piece of toothed belt and install tool 83 93 985, or equivalent to measure the belt tension. Lightly turn the center bolt on the adjuster rollers. Adjust the lower roller counter clockwise to a tension of 275 - 300 Nm. Tighten mounting bolt to 40 Nm (30 ft. lbs.).

NOTE: The adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

2. Adjust the tensioning pulley with an alien wrench until the two marks are aligned. Tighten to 20 Nm (15 ft. lbs.). Remove the locking tool for camshaft sprockets 1 and 2. Adjust the upper adjusting roller counter-clockwise until the No. 2 sprocket moves 1 - 2 mm clockwise. Tighten to 40 Nm (30 ft. lbs.). Remove the upper locking tool.
3. Turn the engine two revolutions to just before the zero marking and install the locking tool to the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm is against the coolant pump flange and tighten it. Position tool KM-800-20 and check the markings on the camshaft sprocket are aligned with the markings on the tool and that the edge of the belt meets the edge of the sprocket.

NOTE: Also check the tensioning roller to ensure that the marks are in alignment.





4. Install the crankshaft pulley and tighten to 20 Nm (15 ft. lbs.).
5. Install the timing cover.
6. Install the power steering servo pump.
7. Install the belt tensioner and tighten mounting bolts to 40 Nm (30 ft. lbs.).
8. Install the upper part of the generator air intake.
9. Install the coolant pump pulley and connect the upper hose to the expansion tank.
10. Relieve the load from the belt tensioner by turning the belt tensioner pulley locking bolt forwards in the car using a 15 mm wrench. Install the belt on the coolant pump pulley and check the other pulleys. Carefully release the belt tensioner.
11. Install the torque arm engine mounting and install the servo line clamp.
12. Install the torque arm, bolt the lead to the torque arm engine mounting and hook on the power steering servo oil reservoir.