Removal
1. Remove the outer drive belt covers as described in Chapter 11, points 1-5.
2. To lock the tensioner in the position for removal and installation, move the tensioner indicator lever clockwise until the holes in the support plate and the lever are aligned. Then insert a pin of the appropriate diameter to secure them (see illustration). Now you can unscrew the tensioning mechanism or remove the belt.
3. Check that the tensioner roller rotates smoothly and easily, without noise, play, or jerking (sticking). Also check that there are no signs of physical wear or damage. If the tensioner has any defects, or if you are simply in doubt about the effectiveness of the spring, the entire assembly must be replaced.
Installation
4. When installing, make sure that the protrusion of the tensioner support plate enters the hole in the oil pump casing, then tighten the tensioner bolt and remove the locking pin: the tensioner should move freely.
5. Adjust the belt tension as described below.
Adjustment
6. Whenever the timing belt is damaged, whether due to belt replacement or any other engine overhaul, the tension adjustment procedure should only be performed on a cold engine.
7. Assume that the belt has been removed and installed, i.e. that the crankshaft pulley, timing belt, outer covers have been removed, and the tensioner mechanism (see above) has been disconnected and cylinder #1 is in the ignition position (only up to TDC on the compression stroke). Temporarily install the crankshaft pulley, secure it with the bolt and remove the spark plugs so that the crankshaft can rotate freely.
8. Note also that it is much easier to rotate the coolant pump with the required precision using a special key (Kent-Moore tool #KM-421-A). Alternatively, you can use the Sykes-Pickavani tool #031300) (see illustration).
9. Having installed the belt correctly (see Chapter 11), check that the mark on the crankshaft sprocket and the line on the camshaft sprocket are aligned with their corresponding notches on the rear timing belt cover (see illustrations).
10. Tighten the belt by loosening the three mounting bolts and turning the coolant pump clockwise until the holes in the tension indicator arm and the support plate are aligned (the tension mechanism indicator lever will then be able to move fully clockwise until it reaches the stop). Lightly tighten the pump mounting bolts just enough to prevent the pump from moving.
11. Using a wrench, tighten the bolt on the crankshaft pulley and smoothly turn the crankshaft (without jerking, otherwise the belt teeth may jump) 2 full turns (720°) clockwise until the timing marks on the camshaft and crankshaft sprockets are aligned as described in step 13. The position of the water pump should not change.
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12. Loosen the timing belt by turning the coolant pump counterclockwise until the tension indicator pointer is in the center of the notch in the support plate; in this position the tension of the toothed drive belt is considered correct (see illustration). Tighten the coolant pump bolts to the specified tightening torque Specifications (see section 3). then turn the crankshaft two turns clockwise and recheck the installation.
13. If the pointer is not aligned with the notch, repeat the procedure from step 7. Finally, install all removed components.
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