Installation

Fig. 41 Installing flange & crankshaft sprocket. 1500cc engine:

1. Install flange and crankshaft sprocket as shown in Fig. 41.
2. Torque crankshaft sprocket bolt to 37-43 ft. lbs.
3. Install camshaft sprocket and torque bolt to 47-54 ft. lbs.
4. Install timing belt tensioner as follows:
a. Mount tensioner, spring and spacer, then temporarily tighten pivot bolt.
b. Temporarily tighten the adjusting bolt, then install bottom end of the spring into front case.
c. Secure tensioner to the position nearest the water pump.

Fig. 40 Camshaft & crankshaft sprocket timing marks. 1500cc engine:

5. Ensure timing marks are aligned, Fig. 40.
6. Install timing belt over crankshaft sprocket, then the 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, ensuring 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. 39 Checking timing belt tension. 1400cc & 1500cc engines:

d. Check belt tension by holding belt as shown in Fig. 39, and applying thumb pressure to tension side of belt. Tension is correct when tooth of belt covers approximately 1/4 the width of the tensioner adjuster bolt.
e. Rotate crankshaft clockwise, one full revolution and ensure that timing marks line up.
9. Reverse remaining procedure to complete installation, then adjust valve clearances as outlined.