How do you remove head on 2005 tucson 2.7

/* override srp image link color and background color */ .galleryImage { background-color: #002F56; color: rgb(0, 47, 86); } Fig. 1 Front cover pry pointsFig. 2 No. 1 piston TDC positionFig. 3 No. 1 piston TDC alignmentFig. 4 Camshaft TDC alignmentFig. 5 Timing chain alignmentFig. 6 Lefthand cam phaser alignmentFig. 7 Timing chain alignment marksFig. 8 Upper intake manifold tightening sequenceFig. 9 Valve cover tightening sequence. LefthandFig. 10 Valve cover tightening sequence. Righthand Print Options Print Text Only Print Text and images Print Timing Chain, Replace Caution: The magnetic timing wheels must not come in contact with magnets or any other strong magnetic field. This will destroy the timing wheels ability to correctly relay camshaft position to camshaft position sensor. 1. Disconnect battery ground cable. 2. Remove air cleaner housing assembly. 3. Remove upper intake manifold. 4. Remove valve covers. 5. Remove spark plugs, then raise and support vehicle. 6. Drain cooling system into suitable container. 7. Remove upper and lower oil pans. 8. Remove righthand engine mount bracket. 9. Remove bolts from front cover. 10. Carefully remove front cover by carefully prying at seven indicated points, Fig. 1. 11. Rotate crankshaft counterclockwise to place No. 1 position at TDC on exhaust stroke by aligning dimple on crankshaft with block/bearing junction, Fig. 2. Lefthand side cam phaser arrows should point toward each other and be parallel to valve cover sealing surface. 12. Mark rotation direction of following timing chains for reference during installation: a. Lefthand side cam chain. b. Righthand side cam chain. c. Oil pump chain. d. Primary chain. 13. Reset righthand cam chain tensioner by pushing back tensioner piston and installing tensioner pin tool No. 8514, or equivalent. 14. Reset lefthand cam chain tensioner by lifting pawl, pushing back piston and installing tensioner pin tool No. 8514, or equivalent. 15. Disengage oil pump chain tensioner spring from dowel pin, then remove oil pump chain tensioner. 16. Remove oil pump sprocket T45 retaining bolt, then remove oil pump sprocket and oil pump chain. 17. Install righthand camshaft phaser lock tool No. 10202, or equivalent. Minor rotation may be required to install camshaft phaser lock. 18. Loosen both intake oil control valves, then exhaust oil control valve. 19. Remove righthand camshaft phaser lock tool, then oil control valve from righthand side intake cam phaser. 20. Pull righthand side intake cam phaser off of camshaft, then remove righthand side cam chain. 21. Remove oil control valve, then pull righthand side exhaust cam phaser off camshaft. 22. Install lefthand camshaft phaser lock tool No. 10202, or equivalent. Minor rotation may be required to install camshaft phaser lock. 23. Loosen both intake oil control valve and exhaust oil control valve. 24. Remove lefthand camshaft phaser lock tool, then oil control valve from lefthand side exhaust cam phaser. 25. Pull lefthand side exhaust cam phaser off of camshaft, then remove lefthand side cam chain. 26. Remove oil control valve, then pull lefthand side intake cam phaser off of camshaft. 27. Reset primary chain tensioner by pushing back tensioner piston and installing tensioner pin tool No. 8514, or equivalent. Remove two T30 bolts, then primary chain tensioner. 28. Remove timing chain. 29. Reverse procedure to install, note following: a. Verify No. 1 piston is positioned at TDC by aligning dimple on crankshaft with block/bearing cap junction, Fig. 3. b. Verify camshafts are set at TDC by positioning alignment holes vertically, Fig. 4. c. Ensure timing chain plated link is located at 12 o'clock when dimple on crankshaft is aligned with block/bearing cap junction, Fig. 5. d. Position lefthand side cam phasers so that arrows point toward each other and are parallel to valve cover sealing surface, Fig. 6. e. Torque idler sprocket bolt to 18 ft. lbs. f. Torque oil control valve to 110 ft. lbs. g. Torque oil pump sprocket bolt to 18 ft. lbs. h. Ensure there are 12 chain pins between exhaust cam phaser triangle marking and intake cam phaser circle marking, Fig. 7. i. Torque upper intake manifold bolts to 80 inch lbs., in sequence, as illustrated in Fig. 8. j. Torque lefthand valve cover bolts in sequence, as illustrated in Fig. 9, to 106 inch lbs. k. Torque righthand valve cover bolts in sequence, as illustrated in Fig. 10, to 106 inch lbs. l. Torque timing chain tensioner to 106 inch lbs. m. Torque timing chain guide to 106 inch lbs.
Print - As Shown Print - Fit To Page / 1

• Fig. 1 Front cover pry points
• Fig. 2 No. 1 piston TDC position
• Fig. 3 No. 1 piston TDC alignment
• Fig. 4 Camshaft TDC alignment
• Fig. 5 Timing chain alignment
• Fig. 6 Lefthand cam phaser alignment
• Fig. 7 Timing chain alignment marks
• Fig. 8 Upper intake manifold tightening sequence
• Fig. 9 Valve cover tightening sequence. Lefthand
• Fig. 10 Valve cover tightening sequence. Righthand

Remove the three bolts retaining the upper chain guides and lift it from the cylinder head.

To allow access to the camshaft sprocket bolts, unbolt the upper timing chain cover and carefully pry the cover away from the cylinder head

Set the number one piston at TDC on the compression stroke by aligning the timing marks on the crankshaft damper.

Fig. 6: The number one cylinder is at TDC when the timing marks are aligned as shown (clikc image for zoom)

Check that the mating marks on the sprockets are aligned as shown in the illustration. If not, the crankshaft should be rotated another 360°.

Fig. 7: It may be helpful to paint marks on the chain and sprockets if the marks are not easily visible

Remove the camshaft position sensor. Mark the position of the sensor before removal to help keep the ignition timing correct.




Fig. Line up the mating marks on the lower timing chain with the marks on the sprockets

Hope this helps.

Dual Mass Flywheel, and will also need new clutch Remove the engine coverUsing a [16 mm], rotate the tensioner arm clockwise (about 14° )and remove the belt from the pulley.
Remove the power steering pump pulley, idler pulley, tensioner pulley and crankshaft pulley.
Remove the upper and lower timing belt covers.

Remove the auto tensioner.
NOTE
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.




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

SERVICE MANUAL
Applies to: Santa Fe 2004
GROUP
Engine Mechanical System Timing System



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


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

NOTE
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 the cam 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.
Install the auto tensioner to the front case.
NOTE
At this time auto tensioner's set pin should be compressed and secured with set pin.




Align the timing marks of each sprocket and install the timing belt in the following order. Crankshaft sprocket--> Idler pulley--> camshaft sprocket (LH side)--> Water pump pulley--> camshaft sprocket (RH side)--> Tensioner pulley.
NOTE
In this step, No. 1 cylinder is in the TDC (Compression stroke).
Be very careful if you use your fingers.



Pull out the set pin of the auto tensioner.



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

TIMING BELT & SPROCKETS R & I
NOTE: Some procedures may differ slightly due to engine
construction.
Removal
1) Remove all necessary air ducts. Position No. 4 piston at
TDC of compression stroke. Align timing marks. See Fig. 2. Remove fan
and fan shroud. Remove belts. If necessary, remove radiator and
splashguard.
2) Prevent engine from rotating and remove crankshaft timing
pulley retaining bolt. Remove upper and lower timing belt covers.
Remove spring from tension pulley. Loosen adjusting bolt and move
pulley toward water pump. Remove timing belt.
CAUTION: Ensure pistons are at TDC when rotating camshaft or damage
may result.
Inspection
1) Handle timing belt carefully. Avoid twisting or kinking
belt. Do not allow belt to become contaminated by water, oil, dirt or
other contaminates. Inspect belt for cracks or damage. If necessary,
replace.
2) Measure tension pulley spring length and force. Spring
length should not exceed 2.76" (70.2 mm) and spring force should not
be less than 197-347 lbs. (27-48 kg).
3) Replace tension pulley spring if not within specification.
Installation
1) Pull tensioner fully toward water pump side and
temporarily tighten retaining bolt. Ensure No. 4 cylinder is at TDC on
compression stroke by rotating crankshaft until keyway aligns with
mark on front crankshaft seal housing (12 o'clock). Rotate camshaft
until timing mark on cam gear (arrow) aligns with mark on upper
camshaft cover (notch). See Fig. 2.
NOTE: When timing marks are aligned as stated above, No. 4 piston
is at TDC on compression stroke.
2) Position timing belt over crankshaft sprocket, oil pump
sprocket, camshaft sprocket and tensioner in that order. Ensure belt
is positioned in sequence given and without slack between sprockets.
Loosen tension sprocket adjusting bolt allowing spring tension to
tighten belt. Tighten adjusting bolt temporarily.
3) Temporarily install crankshaft pulley bolt and rotate
crankshaft 2 complete revolutions in opposite direction of engine
rotation, until marks on crankshaft and front oil seal retainer are
aligned again. See Fig. 2. Loosen tensioner lock bolt, allowing
tesioner spring to fully adjust tension. Tighten tensioner lock bolt.
4) Install timing belt covers. To complete installation,
reverse removal procedures. Tighten all bolts to specification. See
TORQUE SPECIFICATIONS table at end of this article.
Fig. 2: 2.3L & 2.6L Timing Alignment Marks
Courtesy of Isuzu Motor Co

chain. R&R instructions from autozone.com pasted below. let me know if you have any more questions.

REMOVAL & INSTALLATION
SOHC Engine See Figures 1, 2, 3 and 4

1. Disconnect the negative battery cable.
2. Remove the timing chain front cover.

During timing chain and sprocket removal, position the crankshaft 90 degrees past Top Dead Center (TDC), to make sure the pistons will not contact the valves upon assembly.

1. Carefully rotate the crankshaft clockwise so the timing mark on the crankshaft sprocket and keyway align with the main bearing cap split line (90 degrees past TDC).
2. Remove bolts, then remove the timing guides and tensioner.
3. Remove the camshaft sprocket bolt, using a 7 / 8 in. (21mm) wrench to hold the camshaft. Then remove the timing chain and camshaft sprocket. Remove the crankshaft sprocket, if necessary.

To install:

1. Inspect the chain for wear and damage. Check the inside diameter of the chain, it should be no more than 16.77 in. (426mm). Inspect the chain guides for wear or cracks and the timing sprockets for teeth or key wear. Replace components as necessary.
2. Verify that the crankshaft is positioned 90 degrees clockwise past TDC from the keyway (keyway at 3 o'clock).
3. Bring the camshaft up to No. 1 TDC by loosely installing the sprocket and rotating the sprocket until the timing pin can be inserted. The camshaft contains wrench flats to assist in turning the shaft. The dowel pin should be at 12 o'clock when the camshaft is at TDC and a timing pin ( 3 / 16 in. drill bit) should then install at about the 8 o'clock position.
4. If removed, install the crankshaft sprocket, then rotate the crankshaft counterclockwise 90 degrees up to No. 1 TDC (keyway at 12 o'clock).
5. Position the chain under the crankshaft sprocket and over the camshaft sprocket. If necessary remove the camshaft sprocket, then slide the camshaft sprocket into position with the chain already engaged. The timing chain should be positioned so that one silver link plate aligns with the reference mark on the camshaft sprocket and the other aligns with the downward tooth (at the 6 o'clock position) on the crankshaft sprocket. The letters FRT on the camshaft sprocket must face forward, away from the cylinder head and excess chain slack should be located on the tensioner side of the block.
6. Temporarily install the timing pin to verify proper alignment of the camshaft and sprocket, then install and tighten the sprocket bolt to 75 ft. lbs. (102 Nm). Again, use a wrench on the camshaft flats to hold the shaft in position while tightening the bolt. Do not allow the camshaft retaining bolt to torque against the timing pin or cylinder head damage will result.
7. Install the chain guides with the words FRONT facing out. Install the fixed guide first and verify the chain is snug against the guide, then install the pivot guide. Tighten the bolts to 19 ft. lbs. (26 Nm) and verify that the pivot guide moves freely.
8. Retract the tensioner plunger and pin the ratchet lever using a 1 / 8 in. No. 31 drill bit inserted in the alignment hole at the bottom front of the component. Install the tensioner and tighten the bolts to 14 ft. lbs. (19 Nm), then remove the drill bit.
9. Make one final check to verify all components are properly timed, then remove all timing pins.
10. Install the timing chain front cover.
11. Connect the negative battery cable, start the engine and check for leaks.
    

Fig. Fig. 1: At 90 degrees past TDC, the crankshaft sprocket timing mark and keyway will align with the main bearing cap split line

Fig. Fig. 2: Exploded view of the timing chain and sprocket assembly-SOHC engine

Fig. Fig. 3: Insert the timing pin to ensure that the camshaft is at No. 1 TDC-SOHC engine

Fig. Fig. 4: When the camshaft is at TDC, rotate the crankshaft counterclockwise 90 degrees to achieve TDC

Timing Chain and Sprockets
REMOVAL & INSTALLATION

1. 
   
   
   
   Fig. 1: At 90 degrees past TDC, the crankshaft sprocket timing
   mark and keyway will align with the main bearing cap split line
   
   
   
   
   
   
   
   Fig. 2: Exploded view of the timing chain and sprocket
   assembly - SOHC engine
   
   
   
   
   
   
   
   Fig. 3: Insert the timing pin to ensure that the camshaft is at
   No. 1 TDC - SOHC engine
   
   
   
   
   
   
   
   Fig. 4: When the camshaft is at TDC, rotate the crankshaft
   counterclockwise 90 degrees to achieve TDC
   
   

DOHC Engine

1. Disconnect the negative battery cable.
   
2. Remove the timing chain front cover.
   NOTE: During timing chain and sprocket removal, position the
   crankshaft 90 degrees past Top Dead Center (TDC) to make sure the pistons will
   not contact the valves upon assembly.
   
   
   
3. Carefully rotate the crankshaft clockwise so the timing mark on the
   crankshaft sprocket and keyway align with the main bearing cap split line.
   
4. Remove the bolts, then remove the timing guides and tensioner.
   
5. Remove the camshaft sprocket bolts, using a 7?8 in. (21mm) wrench
   to hold the camshaft. Then remove the timing chain and camshaft sprocket. Remove
   the crankshaft sprocket, if necessary.
   To install:
   
   
6. Inspect the chain for wear and damage. Check the inside diameter of the
   chain, it should be no more than 23.15 in. (588mm). Inspect the chain guides for
   wear or cracks and the timing sprockets for teeth or key wear. Replace
   components as necessary.
   
7. Verify that the crankshaft is positioned 90 degrees clockwise past TDC. The
   crankshaft keyway should be at 3 o'clock aligned with the main bearing cap split
   line to prevent piston and valve damage.
   
8. Install the camshaft sprockets, retaining bolts and washers. Make sure the
   letters FRT on the sprockets face forward, away from the cylinder block. Use the
   wrench flats provided on the camshafts to hold the shaft and tighten the bolts
   to 75 ft. lbs. (102 Nm).
   
9. Bring the camshafts up to No. 1 TDC by rotating the camshafts and sprocket
   until the dowel pins are at 12 o'clock. Install a 1?6 in. drill bit
   into the hole in the sprocket about 9 o'clock.
   
10. If removed, install the crankshaft sprocket, then rotate the crankshaft
    counterclockwise 90 degree up to No. 1 TDC (keyway and sprocket timing mark at
    12 o'clock, in alignment with the block timing mark).
    
11. Position the timing chain under the crankshaft sprocket and over the
    camshaft sprockets so 2 silver link plates align with the reference marks on the
    camshaft sprockets and another 2 plates align with the downward tooth (at 6
    o'clock position) on the crankshaft sprocket. Excess chain slack should be
    located on the tensioner side of the cylinder block.
    
12. Verify that the crankshaft reference mark aligns with the cylinder block
    mark at 12 o'clock and that the timing pins are installed in the holes at about
    the 9 o'clock position. Remove the timing pins from the camshaft sprockets.
    
13. Install the timing chain fixed guide to the right of the block face toward
    the water pump. Tighten the bolts to 21 ft. lbs. (28 Nm) and verify the chain is
    snug against the guide.
    
14. Install the pivoting chain guide and check for clearance between the block
    and head. Tighten the bolt to 19 ft. lbs. (26 Nm) and verify the guide pivots
    freely.
    
15. Install the 2 forward camshaft bearing caps and the upper timing chain
    guide, then tighten the retaining bolts to 124 inch lbs. (14 Nm).
    
16. Retract the tensioner plunger and pin the ratchet lever using a 1?8 in. (3.18mm) No.
    31 drill bit inserted in the alignment hole at the lower front of the component.
    Install the tensioner and tighten the bolts to 14 ft. lbs. (19 Nm), then remove
    the drill bit.
    
17. Make one final check to verify all components are properly timed, then
    remove all timing pins.
    
18. Install the timing chain front cover.
    
19. Connect the negative battery cable, start the engine and check for leaks.
    
    
    
    
    
    Fig. 5: Rotate the crankshaft clockwise until the timing mark
    on the crankshaft sprocket and keyway align with the main bearing cap split line
    
    
    
    
    
    
    
    
    Fig. 6: Loosen the timing chain tensioner mounting bolt . . .
    
    
    
    
    
    
    
    Fig. 7: . . . and remove the tensioner from the engine block
    
    
    
    
    
    
    
    Fig. 8: Retract the tensioner plunger and pin the ratchet lever
    with a 1?8
    in. (3.18mm) drill bit inserted in the alignment hole
    
    
    
    
    
    
    
    Fig. 9: Remove the mounting fasteners from both timing guides .
    . .
    
    
    
    
    
    
    
    Fig. 10: . . . and remove the timing guides from the engine
    
    
    
    
    
    
    
    Fig. 11: Remove the camshaft sprocket bolts, using a 7?8 in. (21mm) wrench
    to hold the camshaft
    
    
    
    
    
    
    
    Fig. 12: Remove the timing chain and camshaft sprockets
    
    
    
    
    
    
    
    Fig. 13: Insert the timing pins to verify that the camshafts
    are at TDC
    
    
    
    
    
    
    
    Fig. 14: Make sure that the silver link plates and reference
    marks are all in alignment as shown
    
    

see diagrams from autozone.com. Cam sprocket has an "UP" label, but also 2 scribes on the sides to align to upper head surface. The critical part of the job is keeping tension on the side of the belt that is opposite from the tensioner as the tensioner is released onto the belt. The timing marks must be aligned when the job is done.


To install:

1. Install the camshaft timing sprocket so that the UP mark is up and the TDC marks are parallel to the cylinder head gasket surface. Install the key and tighten the bolt to 27 ft. lbs. (37 Nm).
2. Install the crankshaft sprocket so that the TDC mark aligns with the pointer on the oil pump. Install the spacers with their concave surfaces facing in. Install the key. If equipped, install the TDC sensor assembly back into position before installing the timing belt.
3. Install and tension the timing belt. Use a 6 x 1.0 mm x 25 mm bolt threaded through the cam belt tensioner plate to temporarily hold the tensioner.
4. Temporarily install the crankshaft pulley and rotate the crankshaft counterclockwise 5-6 turns to be sure the belt is properly seated.
5. Set the No. 1 piston at TDC for its compression stroke.

WARNING If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.

1. Rotate the crankshaft counterclockwise so that the camshaft pulley moves only 3 teeth beyond its TDC mark.
2. Loosen, then retighten the temporary cam belt tensioner bolt.
3. If the rear balance shaft sprocket/gear case assembly was removed, perform the following:
   1. If the rear balance shaft was moved, rotate the balance shaft until the 6 x 1.0mm x 100 mm bolt can be installed into the maintenance hole to the scribed line.
   2. Align the notch of the balance shaft sprocket edge with the pointer on the gear case. Install the rear balance shaft sprocket/gear case assembly using a new O-ring coated with fresh engine oil. The balance shaft sprocket should be installed in the TDC position. The pointer on the gear should align with the pointer on the oil pump housing plate.
   3. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
   
   
4. If the front balance shaft sprocket was removed, perform the following:
   1. Install a suitable and sturdy screw driver or drift through the maintenance hole in the shaft behind the sprocket to hold the front balance shaft.
   2. Install the front balance shaft sprocket and mounting nut. Torque the nut to 22 ft. lbs. (29 Nm).
   
   
5. Make sure the balance shafts and crankshaft are in the TDC position.
6. Remove the crankshaft pulley, and if removed, install the balance shaft belt drive sprocket.
7. Install the balance shaft belt, making sure the balance shafts and sprockets are still in the TDC position.
8. If removed, install the balance shaft belt tensioner and tension the balance shaft belt.
9. Loosen, then retighten the tensioner adjusting nut to 33 ft. lbs. (45 Nm).
10. Remove the 6 x 1.0mm x 100mm rear balance shaft holding bolt.
11. Temporarily install the crankshaft pulley and rotate the crankshaft 2 revolutions counterclockwise, stopping at TDC.

WARNING If any resistance is felt, stop immediately and determine the cause.

1. Recheck that all of the TDC marks align for both the camshaft and balance shafts.
2. Loosen, then retighten the tensioner adjusting nut to 33 ft. lbs. (45 Nm).
3. Remove the 6 x 1.0 mm x 25 mm bolt used to secure the camshaft timing belt tensioner.
4. Remove the crankshaft pulley and install the lower cover.
5. Install the crankshaft pulley, lubricate the bolt threads and both sides of the crankshaft pulley bolt with fresh engine oil and tighten the crankshaft pulley bolt to 181 ft. lbs. (245 Nm). Do Not use an impact wrench.

See Figures 19 and 20

Fig. Fig. 19: Holding the rear timing balancer shaft-4-cylinder Odyssey

Fig. Fig. 20: Aligning the front timing balancer shaft-4-cylinder Odyssey

1. Install the upper timing cover and the valve cover. Be sure the seals are properly seated.
2. Install the side engine mount. Tighten the through-bolt to 47 ft. lbs. (64 Nm). Tighten the mount nut and bolt to 40 ft. lbs. (55 Nm) each.
3. Remove the floor jack.
4. Install and tension the alternator belt.
5. Install the power steering pump and tension its belt.
6. Install the splash shields.
7. Reconnect the positive and negative battery cables. Enter the radio security code.
8. Check engine operation.

It is typical to have to stretch the belt a tad as you install--needs to be tight across the cam sprockets and from the right cam to the crank gear. Then the tensioner should take up the slack on the other side.

1. 
2. Fig. Camshaft and crankshaft alignment marks-2.4L engine

2. 
   

To install:

Fig. Install the belt tensioner


Fig. Proper timing belt routing

1. Set the crankshaft sprocket at TDC by aligning the sprocket with the arrow on the oil pump housing.
2. Set the camshafts timing marks so that the exhaust camshaft sprocket is a 1 / 2 notch below the intake camshaft sprocket.
3. Install the timing belt by starting at the crankshaft. Go around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner.
4. Move the exhaust camshaft sprocket counterclockwise to align the marks and to remove any slack.
5. Insert a 6mm Allen wrench into the tensioner opening on the top plate of the tensioner pulley. Rotate the top plate counterclockwise. The pulley will move against the belt and the tensioner setting notch will start to move clockwise. Continue to move the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench, to prevent the top plate from moving, tighten the tensioner lock bolt to 220 inch lbs. (25 Nm). Make sure the setting notch and spring tang are still aligned after the lock nut is tighten. If not repeat the procedure.
6. Remove the wrench from the belt tensioner.
   NOTE When repositioning the crankshaft to the TDC position, this must be done during the clockwise rotation movement. If the TDC is missed, rotate a further two full turns until TDC is reached. Do not rotate the crankshaft counterclockwise as this will result in improper tensioner settings.
   
7. Rotate the crankshaft two full revolutions and verify that the TDC marks are properly aligned.
8. Check the spring tang is within the tolerance window, if not repeat the previous two steps.

The Isuzu is a strange animal-when you do the timing belt you set it with #1 TDC "BUT" the distributor is timed with TDC #4 I found this the hard way and finally had to buy a cd with the procedures on it. Send me an e-mail address and I will forward the associated pictures &
info to you.
Jim Young
[email protected]

TIMING BELT & SPROCKETS R & I
NOTE: Some procedures may differ slightly due to engine
construction.
Removal
1) Remove all necessary air ducts. Position No. 4 piston at
TDC of compression stroke. Align timing marks. See Fig. 2. Remove fan
and fan shroud. Remove belts. If necessary, remove radiator and
splashguard.
2) Prevent engine from rotating and remove crankshaft timing
pulley retaining bolt. Remove upper and lower timing belt covers.
Remove spring from tension pulley. Loosen adjusting bolt and move
pulley toward water pump. Remove timing belt.
CAUTION: Ensure pistons are at TDC when rotating camshaft or damage
may result.
Inspection
1) Handle timing belt carefully. Avoid twisting or kinking
belt. Do not allow belt to become contaminated by water, oil, dirt or
other contaminates. Inspect belt for cracks or damage. If necessary,
replace.
2) Measure tension pulley spring length and force. Spring
length should not exceed 2.76" (70.2 mm) and spring force should not
be less than 197-347 lbs. (27-48 kg).
3) Replace tension pulley spring if not within specification.
Installation
1) Pull tensioner fully toward water pump side and
temporarily tighten retaining bolt. Ensure No. 4 cylinder is at TDC on
compression stroke by rotating crankshaft until keyway aligns with
mark on front crankshaft seal housing (12 o’clock). Rotate camshaft
until timing mark on cam gear (arrow) aligns with mark on upper
camshaft cover (notch). See Fig. 2.
NOTE: When timing marks are aligned as stated above, No. 4 piston
is at TDC on compression stroke.
2) Position timing belt over crankshaft sprocket, oil pump
sprocket, camshaft sprocket and tensioner in that order. Ensure belt
is positioned in sequence given and without slack between sprockets.
Loosen tension sprocket adjusting bolt allowing spring tension to
tighten belt. Tighten adjusting bolt temporarily.
3) Temporarily install crankshaft pulley bolt and rotate
crankshaft 2 complete revolutions in opposite direction of engine
rotation, until marks on crankshaft and front oil seal retainer are
aligned again. See Fig. 2. Loosen tensioner lock bolt, allowing
tesioner spring to fully adjust tension. Tighten tensioner lock bolt.
4) Install timing belt covers. To complete installation,
reverse removal procedures. Tighten all bolts to specification. See
TORQUE SPECIFICATIONS table at end of this article.
Fig. 2: 2.3L & 2.6L Timing Alignment Marks
Courtesy of Isuzu Motor Co.

I received this explanation for the 1800 Subaru Leone (same vehicle i think) from another forum. Have yet to make use of it but I hope it helps.

Find top dead centre of Crankshaft. (there are 3 timing marks close together, the middle one is TDC). If you are still unsure then remove number one spark plug and insert a long small screw driver down the hole with the piston near the top of it's stroke. As you rock the engine over back and forth you will feel TDC with the screw driver. By tracing the number one cylinder plucg lead back the distributor cap and then removing the cap you should be able to see if the engine is at number one in the firing sequence.

Rotate the drivers side camshaft

Now rotate the crankshaft one hole turn till the 3 marks are re-aligned.

Now rotate the passenger side camshaft until the hole in the sprocket lines up the the slot in the top of the cam cover. Put belt on.

Rotate the crankshaft 2 whole turns and double check that the sprockets still line up to their respective marks.

Start engine