Installation (1.6L)
- Install rear timing belt covers, spacer, flange, crankshaft sprocket, washer and retaining bolts. Flange and crankshaft sprocket must be installed in proper direction. See Fig 1.CAUTION: Flange and crankshaft sprocket must be installed in correct direction to prevent damage to timing belt.
- Install camshaft sprockets. Tighten retaining bolts to specification while holding hexagon area of camshaft. Install idler pulley.
- Automatic tensioner rod should be retracted into tensioner housing. Note if plug at bottom of tensioner protrudes past tensioner housing. If plug does protrude, place a washer over plug to prevent plug from contacting vise while pushing rod into tensioner housing.
- Place tensioner assembly in a soft-faced vise, push rod back into the automatic tensioner in small increments until both rod and housing holes are aligned. See Fig 2. Install a.055" (1.39 mm) diameter wire into the holes.
- Remove automatic tensioner from vise and install assembly with wire installed. Install tensioner arm. Install tensioner pulley on tensioner arm with pin holes of tensioner pulley shaft located to the left of the center bolt. See Fig 3. Tighten center bolt.
- Rotate camshaft sprockets so dowel pins are facing upward and timing marks on sprockets are aligned. See Figure. Outer marks on sprockets should be aligned with cylinder head surface.
- When exhaust camshaft sprocket is released, camshaft will rotate one tooth in counterclockwise direction. This rotation will need to be compensated for when installing timing belt.
- Rotate crankshaft and align timing marks on crankshaft and oil pump sprockets. See Figure. If used timing belt is installed, belt must be installed in original direction of rotation.
- Install timing belt around intake camshaft sprocket. Install spring type paper clip on timing belt and camshaft sprocket to hold belt on the sprocket. Clip should be installed just below cylinder head surface on the outer side of camshaft sprocket.
- Install wrench on both camshaft sprocket bolts. Install timing belt around exhaust camshaft sprocket while holding camshaft sprocket bolt so timing mark on camshaft sprocket is aligned with timing mark.
- Install spring type paper clip on timing belt and camshaft sprocket to hold belt on the sprocket. Clip should be installed just below cylinder head surface on the outer side of camshaft sprocket.
- Install timing belt around idler pulley, oil pump sprocket, crankshaft sprocket and tension pulley in this sequence. Remove both spring type paper clips.
- Rotate tensioner pulley inward toward timing belt until belt does not sag and temporarily tighten center bolt on tensioner pulley. Ensure all timing marks are aligned. See Figure.
- To adjust belt tension, rotate crankshaft 1/4 turn counterclockwise and then back clockwise until No. 1 cylinder is at TDC. Ensure timing marks are aligned. Loosen center bolt on tensioner pulley.
- Note pin holes in tensioner pulley. Socket wrench is used to rotate tensioner pulley. Using INCH lb. torque wrench and Socket Wrench (MD998752), apply a torque of 22-24 INCH lbs. (2.5-2.7 N.m) on tensioner pulley. With torque applied to tensioner pulley, tighten tensioner pulley center bolt to 31-40 ft. lbs. (42-54 N.m).
- Install Set Screw (MD998738) in left engine support bracket until the end contacts tensioner arm. See Fig 4. Rotate set screw additional turns until wire can be removed from automatic tensioner. Remove set screw.
- Rotate crankshaft clockwise 2 complete revolutions and allow to remain in this position for approximately 15 minutes. After 15 minutes, measure distance between tensioner arm and automatic tensioner body. See Fig 4. Distance should be.15-.18" (3.8-4.5 mm).
- If this distance cannot be measured due to lack of clearance, an alternate method can be used. Install set screw until it contacts the tensioner arm. See Fig 4.
- From this position, rotate set screw inward while counting number of turns until tensioner arm contacts automatic tensioner housing. See Fig 4. Set screw should screw inward 2 1/2-3 turns if belt tension is correct. Remove set screw. Install rubber plug in rear timing belt cover.
- To install remaining components, reverse removal procedure. Apply sealant to correct areas on semi-circular packing and rocker cover prior to installation. See Figure. Ensure correct bolt is installed in timing belt covers. See Fig 5.