Timing Belt: Service and Repair

REPLACING TOOTHED BELT (32 VALVE ENGINE)

Removal

Note: Disable airbag system prior to beginning procedure. Service and Repair

1. Remove air cleaner intake hoses.
2. Unscrew air guide on radiator at top and bottom, and remove.
3. Loosen and take off drive belts for alternator, power pump, air pump and air conditioner compressor.






4. Disconnect cables for throttle, cruise control and automatic transmission. Remove retainers and clamp on console and place cables outside.
5. Loosen and remove fan console on engine.
6. Pull off left and right ignition leads on distributor cap. Unscrew and place distributor cap aside.






7. Take off both distributor rotors. Disconnect plugs for A/C compressor and toothed belt tightness indicator.
8. Unscrew toothed belt cover upper section on both sides and take off righthand upper section.






9. Unscrew power pump on console and let it hang down on its hoses.






10. Remove clutch slave cylinder. Take off clamp on clutch hose holder and remove push rod. Let cylinder with connected line hang down.

Note: Never operate clutch pedal after removing the slave cylinder.






11. Align mark for 45° BTDC (cyl. 1) on vibration damper with red needle by turning crankshaft clockwise.

Note: Camshafts may be turned without damaging the valves after aligning the 45° mark.






12. Mount Special Tool 9161/1 with original screws to hold the crankshaft.
13. Unscrew bolt (wrench size 27 mm) on crankshaft and take off both pulleys, vibration damper and collar.
14. Loosen and unscrew guide tube for oil dipstick.






15. Unscrew console with alternator on engine.






16. Undo center toothed belt cover, remove left-hand upper section and center toothed belt cover.
17. Slacken toothed belt by turning toothed belt tensioner.






18. Unbolt and remove tensioning roller bracket.
19. Remove toothed-belt from right-hand side over cylinder 1 - 4 camshaft sprocket, water-pump sprocket, cylinder 5 - 8 camshaft sprocket, oil-pump sprocket and crankshaft sprocket.

Installing

1. Installation of toothed belt is the reverse of the above sequence.
2. Turn camshafts to mark and hold firmly in this position.
3. Then turn engine in direction of rotation to ignition TDC (cyl. no.1).

Note: Damage may be caused to the valves if the camschafts move suddenly.

4 Once the toothed belt is in position, adjust the settings. Adjustments

Special note on toothed belt and drive belt
As a rule, make sure the toothed belt and drive belt are not kinked during assembly, packing and storage. Improper handling may cause preliminary damage to the camshaft toothed belt that may be the cause for incipient damage.