Removal and Installation

Toothed belt, removing, installing and adjusting tension

CAUTION! To prevent damage to valves and piston crowns while the toothed belt is removed, do not turn camshaft when crankshaft is at Top Dead Center (TDC)

Removing

- Remove ribbed belt, and remove tensioner for ribbed belt if applicable.
- Remove crankshaft vibration damper/pulley
- Remove coolant pump pulley.
- Remove upper and lower parts of toothed belt guard
- Mark running direction on toothed belt.
- Loosen toothed belt tensioner and remove toothed belt.

Installing

Note: For repairs that require removing the toothed belt from the camshaft sprocket only such as when removing the camshaft or cylinder head; see below.
For repairs that require completely removing the toothed belt; such as when it is being replaced, install and adjust the toothed belt as described as follows.

For Completely Removed Belt

CAUTION! before turning the camshaft, make sure that the pistons are NOT at Top Dead Center (TDC). With the toothed belt removed there is a danger of damaging the valves and piston crowns






- Align marking on camshaft sprocket with marking on cylinder head cover or toothed belt guard.
- Install toothed belt on crankshaft toothed belt sprocket and intermediate shaft toothed belt sprocket (note running direction when installing a used belt).
- Mount crankshaft vibration damper/pulley with at least one bolt (note installation position, holes are offset).






- Align mark on crankshaft vibration damper/pulley with mark on intermediate shaft sprocket (cylinder 1 set to TDC).
- Install toothed belt on tensioner and camshaft toothed belt sprocket.






- Increase tension on toothed belt tension by turning tensioner pulley with spanner 2587 in direction of -arrow-.
^ It must be possible to twist toothed belt by 90° with thumb and forefinger half-way between camshaft and intermediate shaft toothed belt sprockets

- Tighten lock nut on belt tensioner.
- Tightening torque: 45 Nm (33 ft lb)

- Turn crankshaft through two complete revolutions, and check belt tension.
- Remove crankshaft vibration damper/pulley.
- Install lower toothed belt guard.
- Install coolant pump pulley, crankshaft vibration damper/pulley and upper toothed belt guard.

- Install tensioner for poly-ribbed belt, if applicable.
- Tightening torque: 20 Nm (15 ft lb)

- Install ribbed belt.
- Check and, if necessary, adjust ignition timing.

For Belt Removed from the Camshaft Sprocket only

Note: For repairs that require removing the toothed beltfrom the camshaft toothed belt sprocket only, such as when removing the camshaft or cylinder head, install and adjust the toothed belt as described below.

CAUTION! before turning the camshaft, make sure that the pistons are NOT at Top Dead Center (TDC). With the toothed belt removed there is a danger of damaging the valves and piston crowns






- Align mark on camshaft sprocket with mark on cylinder head cover or toothed belt guard.
- Rotate crankshaft and intermediate shaft to place cylinder No.1 at TDC.
- Place toothed belt on camshaft sprocket and adjust toothed belt tension; as above.






- Check that distributor rotor points towards mark for cylinder No.1 on distributor housing. If not, turn distributor until mark and rotor are aligned.
- Turn crankshaft through two complete revolutions and check whether camshaft and crankshaft marks are aligned.
- Check and, if necessary, adjust ignition timing.