Installation

TIMING BELT INSTALLATION PROCEDURE:

Timing Gear Alignment Marks:

CAUTION: Do not rotate crankshaft or camshaft. Pistons may strike valves.

1. Place pulleys in position according to marking.
2. Place timing belt on crankshaft and intermediate shaft. Two lines on timing belt should be opposite crankshaft marking.
3. Stretch timing belt and install it on camshaft and belt tensioner.
- Check that timing belt is correctly positioned and that markings on pulleys are opposite markings on engine.
4. Pull on timing belt to depress belt tensioner spring and remove locking drill.

Lower Timing Gear Cover:

5. Install lower timing belt cover and vibration damper.
- Make sure the guide plate is correctly positioned.

CAUTION: Vibration damper fits in one position only. There is a dowel on the crankshaft gear that should fit into a hole in the vibration damper.

Crankshaft Pulley & Vibration Damper:

6. Install crankshaft bolt and washer.

Crankshaft Bolt Torque Procedure:

7. Tighten vibration damper.
- Remove nut and washer from belt tensioner.
- Install tool 5284. Use a nut to retain it.
- Tighten crankshaft bolt:
- Stage 1 60 Nm (44 ft lbs)
- Stage 2 Angle-tighten 60°
- Remove tool 5284.
- Install washer and nut on belt tensioner.




8. Tension timing belt:
- Turn engine to top dead center.
- Slacken belt tensioner nut
- Spring will tension timing belt.
- Tighten belt tensioner nut.

Fan Shroud & Pulley:

Final Installation Procedures:
1. install the following:
- upper timing belt cover.
- coolant pump pulley.
- drive belts loosely.
- fan shroud.
- preheater hose clamp.
- cooling fan.
7. Tension drive belts:
- With correct belt tension, it should be possible to depress belt 5-1O mm (0.2-0.4 in) with thumb pressure.

Battery Ground Lead:

8. Connect battery ground cable.

Adjusting Timing Belt Tension:

9. Warm up engine.
- Check/adjust ignition timing, idle speed and CO content.
- Check cooling system for tightness. Refill as necessary.
10. Turn off engine.
11. Adjust timing belt tension. Remove rubber plug in timing belt cover.
- Rotate engine until at top dead centre.
- Slacken belt tensioner nut.
- Spring will tension timing belt.
- Tighten timing belt tensioner nut.
- Install rubber plug.

NOTE:After driving approx. 1000 km (600 miles: Readjust timing belt.