Camshaft Drive Belt, Removal and Installation

Toothed belt, removing and installing

Removing

CAUTION: Mark the direction of belt travel before removing, using a crayon or marker. Reinstalling a used belt in the opposite direction could damage the belt

- Remove ribbed belt, refer to Drive Belt - Service and Repair - Procedures Service and Repair
- Unclip toothed belt guard on both sides.






- Crank engine by hand to Top Dead Center (TDC) position.
- Check camshaft position. Large holes in camshaft sprocket locking plates must face toward each other. If not, turn crankshaft one more revolution.
- Remove Crankshaft Position (CKP) sensor from left-hand side of cylinder block.

The TDC hole in the crankshaft must be positioned behind the hole of the removed CKP sensor (visible and/or tangible).

Crankshaft Holder 3242 Shown In Installed Position:

- Screw crankshaft holder 3242 into hole left by CKP sensor, and tighten slightly.
- Remove ribbed belt tensioner.
- Remove left and right toothed belt guard.
- Remove vibration damper, refer to Cylinder Block Assembly - Harmonic Balancer - Crankshaft Pulley - Service and Repair - Procedures. Service and Repair
- Remove lower toothed belt guard.

Installing






- Loosen right and left camshaft sprockets from tapered ends of camshafts using puller (Kukko 20-10 or equivalent).

Note: The arms of the puller must engage on the rear of the sprocket.

- Install toothed belt over both camshaft sprockets first, then over remaining sprockets, then over tensioning roller last.

Camshaft Holder 3243 Shown In Installed Position:

- Install camshaft holder 3243.

Note: The camshaft sprockets must be loose enough on the tapered ends of the shafts so that the camshafts can still be turned, but sprockets do not tilt out of alignment.

Adjusting toothed belt tension

- Adjust toothed belt tension by turning tensioning roller with 8 mm hex socket wrench.
- Tighten tensioning roller center bolt with another 8 mm hex socket wrench.
- Check toothed belt tension between right camshaft sprocket and coolant pump.






- Check belt tension.

Holding toothed belt half way between camshaft sprocket and coolant pump with thumb and index finger, it must just be possible to twist toothed belt by 90°.

Tightening torque for tensioning roller: 45 Nm (33 ft lb)

Center crankshaft bolt:
Always replace
Use only new double hex head (12-pt.) cap screw grade 9.8
Tightening torque (bolt oiled): 200 Nm (148 ft lb) plus additional 1/2 turn (180°)