Timing Belt & Sprockets: Installation

Install spacer, flange and crankshaft sprocket. See Fig 1. Insert camshaft sprocket and tighten retaining bolt. Align camshaft and crankshaft sprockets timing marks with No. 1 piston at TDC on compression stroke.

Fig 1: Mounting Timing Belt Flange and Sprocket Installing flange incorrectly could result in a damaged belt.
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Mount belt tensioner, spring, spacer and temporarily tighten bolt. Position spring against tensioner first, then against case and tighten bolt. See Fig 2. Positon and secure tensioner toward water pump.

Fig 2: Installing Timing Belt Tensioner on 1.4L Engine Use care when winding spring to prevent damage to the front cover.
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Install timing belt on crankshaft and camshaft sprockets. Ensure tension side is tight and timing marks are aligned when pressure is applied to turn camshaft in reverse direction.
Align dowel and install crankshaft pulley. Loosen tensioner bolt. Ensure proper mesh of belt and sprocket. With only spring tension applied to belt, tighten tensioner spring bolt first and slotted adjustment hole bolt last.
Slowly turn crankshaft one revolution clockwise and realign crankshaft sprocket timing mark at TDC. Do not push or shake belt while turning nor turn crankshaft in counterclockwise direction.
Loosen tensioner spring bolt first then slotted adjustment hole bolt. Tighten tensioner bolts to 15-18 ft. lbs. (20-24 N.m) by tightening slotted adjustment hole bolt first and tensioner spring bolt last.
Check belt tension by pushing tension side of timing belt in horizonatally using about 11 lbs. (5 kg) force. Timing belt tooth end should be approximately 1/4 of tensioner mounting bolt head width (across flats) away from bolt head center. See Fig 3.

Fig 3: Checking Timing Belt Tension on 1.4L Engine Use moderate force when checking belt tension.

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Install spacer, flange and crankshaft sprocket. See Figure. Align crankshaft sprocket timing mark with front case timing mark. Lightly oil camshaft spacer and insert onto camshaft.
Install camshaft sprocket, tighten bolt to specifications and align timing marks. Install tensioner spring and tensioner and temporarily tighten bolt. Rotate tensioner flange and install flange bolts.
Install tensioner spring with end bent at right angle on tensioner projection and straight end of spring on water pump body. See Fig 1. Secure tensioner in position nearest water pump.

Fig 1: Installing Timing Belt Tensioner on 1.6L Engine Install straight end of spring on water pump body; bent end on tensioner projection.
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Secure tensioner in position nearest water pump. Install timing belt in order of crankshaft sprocket, oil pump sprocket and camshaft sprocket, while keeping belt slackening.
Ensure all individual timing marks are aligned and that tension side of belt is tight. Align dowel and temporarily install crankshaft pulley. Lightly push tensioner by hand to ensure belt and sprocket are in complete mesh.
Tighten tensioner nut then tighten bolt. Turn crankshaft one revolution clockwise, smoothly without pushing, jerking or turning counterclockwise. Loosen tensioner bolt and nut to allow spring pressure to tighten belt.
Tighten tensioner nut, then tighten bolt to 16-21 ft. lbs. (22-29 N.m). Check tensioner adjustment by holding center of tension side of belt and seal line of inner cover between thumb and forefinger. See Fig 2.

Fig 2: Checking Timing Belt Tension on 1.6L Engine Do not twist or push belt to test its tension.
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Clearance should be.47" (12 mm). Readjust if necessary. Remove crankshaft pulley and install timing belt upper and lower front covers. Install crankshaft pulley and tighten.