1. |
Remove the engine cover.

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2. |
Using a [16 mm], rotate the tensioner arm
clockwise (about 14° )and remove the belt from the
pulley. |
3. |
Remove the power steering pump pulley, idler
pulley, tensioner pulley and crankshaft pulley.

|
4. |
Remove the upper and lower timing belt
covers.

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5. |
Remove the auto tensioner.
Rotate the crankshaft clockwise and
align the timing mark to set the No.1 cylinder's piston to TDC
(compression stroke).
At this time, the timing marks of the
camshaft sprocket and cylinder head cover should coincide with
each other.

| |
6. |
Unbolt the tensioner to remove the timing
belt.
If you plan to use the timing belt
again, mark the rotation direction on the belt so you
reinstall it correctly.

| |
1. |
Install the idler pulley to water pump
boss.
Insert and install the idler pulley to
the roll pin that is pressed in the water pump
boss.

| |
2. |
Install the tensioner arm and plain washer to
the cylinder block. |
3. |
Install the tensioner pulley to the tensioner
arm. |
4. |
Install the camshaft sprockets and align the
timing marks.

•
|
When installing the camshaft
sprockets, fasten them tightly while holding the
hexagonal part of the
camshaft. |
•
|
Before installing the timing belt,
if the timing marks of the cam sprocket and the cylinder
head cover do not coincide, do not rotate thecam
sprocket more than 3 teeth in either
direction. |
•
|
Rotating the sprocket more than 3
teeth may allow the valve and piston to touch each
other. |
•
|
If the cam sprocket is rotated
more than 3 teeth unavoidably, rotate the crankshaft
counter-clock wise a bit before rotating the cam
sprocket. | | |
5. |
Install the auto tensioner to the front
case.
At this time auto tensioner's set pin
should be compressed and secured with set pin.

| |
6. |
Align the timing marks of each sprocket and
install the timing belt in the following order.
1.Crankshaft sprocket → 2.Idler pulley →
3.camshaft sprocket (LH side) → 4.Water pump pulley → 5.camshaft
sprocket (RH side) → 6.Tensionerpulley.
•
|
In this step, No. 1 cylinder is in
the TDC (Compression
stroke). |
•
|
Be very careful if you use your
fingers.

| | |
7. |
Pull out the set pin of the auto
tensioner.

|
8. |
Install the upper and lower timing belt
covers. |
9. |
Install the power steering pump pulley, idler
pulley, tensioner pulley and crankshaft
pulley. |
10. |
Using the wrench [16mm], rotate the tensioner
arm clockwise (about 14°) and install the belt to the
pulley. |
11. |
Install the engine
cover. |
How to adjust the tension of the timing
belt
1. |
Rotate the crankshaft 2 turns clockwise and
measure the projected length of the auto tensioner at TDC ( #1
Compression stroke) after 5
minutes. |
2. |
The projected length should be 7 ~ 9mm (0.27 ~
0.31in.). |
3. |
Verify that the timing marks of each sprocket
are in their specified position.
If the timing marks are not in their
specified position, repeat from 6 above.

| |
1. |
Inspect the belt closely. If the following
problems are evident, replace the belt with a new one.
(1) |
Hardened back surface of
rubber
Back surface is glossn, non-elastic and
so hardthat when the nail of your finger is pressed into it,
no mark is produced.

|
(2) |
Cracked back surface of
rubber.

|
(3) |
Side of belt is badly worn.
A belt in good condition should
have clear-cut sides as if it were cut with a sharp
knife.

| |
(4) |
Teeth are badly worn out.
Last stage : Canvas on the load side of
the tooth flank worn down and rubber exposed (tooth width
reduced). |
(5) |
Missing tooth

| |
2. |
If backlash or an irregular noise is observed
when rotating the pulley, replace the timing belt tensioner and
idler pulley.

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