2. Hand tighten the camshaft gear bolts, and then tighten them with a wrench to a torque of 90-110 Nm.
3. Install intermediate pulley (IN) and tensioner pulley (A). Tighten the idler pulley bolt to 50-60 Nm and the tensioner pulley bolt to 35-55 Nm.
Note. The intermediate pulley is mounted on a cylindrical pin, which is pressed into the water pump housing.
4. Align the camshaft and crankshaft gears with the alignment marks so that the piston of the first cylinder is at the top dead center of the compression stroke.
5. Using a press, slightly compress the tensioner rod. Align the stem with the hole in the tensioner housing and fix this position with a pin. Release tensioner rod. Install the tensioner and tighten the two mounting bolts to a torque of 20-27 Nm.
6. Make sure the gears are dry and free of lubricants. Install the drive belt in the following sequence:
crankshaft gear (A) - intermediate pulley (IN) - left camshaft gear (WITH) - water pump drive pulley (D) - right camshaft gear (E) - tensioner gear (F).
7. Remove the pin (A) from the tensioner.
8. Turn the crankshaft two turns clockwise and measure the length of the tensioner rod. It should be 7-9 mm.
9. Install the engine frame (A). Tighten the mounting bolts (IN) torque 60-70 Nm and bolt (WITH) torque 15-22 Nm.
10. Install the lower drive belt cover (A) and tighten the 4 bolts (IN) torque 10-12 Nm.
11. Install intermediate pulley (A).
12. Install the crankshaft pulley (A). Make sure the grooves on the pulley line up with the lugs on the crankshaft. Tighten the pulley bolt to 180-190 Nm.
13. Install the top drive belt cover (A) and tighten the 7 mounting bolts (IN).
14. Install the power steering pump.
15. Install tensioner (IN) and attachment drive belt (A).
16. Install engine mount bracket (A) and tighten the two nuts and two bolts to 60-80 Nm.
17. Install the right engine cover (A) and tighten the two screws (IN).
18. Install the right front wheel.
19. Install the engine cover.