Timing belt replacement - 4-cylinder engine

PROCEDURE

Set the piston in cylinder 1 to the ignition TDC position, see earlier in this chapter.

Remove the V-belts or poly-V belts (see Generator section).

Remove the crankshaft pulley after loosening the Allen-head bolts (not the center bolt!).

Remove the timing belt cover.

Loosen the timing belt (see Timing Belt Tensioning) and remove it.

Install the new timing belt. If the positions of the crankshaft and camshaft sprockets have not been changed, the valve timing may still be correct. For added certainty, check this before final assembly:
Turn the camshaft sprocket so that the mark on the sprocket aligns with the arrow on the rear of the timing belt cover.

If the camshaft must be turned for this, it may only be done if no piston is at TDC, otherwise valves or piston crowns may be damaged.

Install the timing belt on the crankshaft and intermediate shaft sprockets.

Secure the V-belt pulley on the crankshaft with the bolt. Make sure of correct position: depending on engine version, either the locating pin must engage in the pulley, or the mounting holes of the pulley are arranged asymmetrically. In this case, all mounting holes must align with the holes in the crankshaft.

Turn the crankshaft so that the mark on the V-belt pulley points upward.

Align the mark on the intermediate shaft sprocket with the mark on the V-belt pulley.

Install the timing belt, making sure the positions of the various sprockets do not change.

Tension the timing belt.

Remove the distributor cap and check whether the distributor rotor points to the mark on the edge of the distributor housing.

If not, loosen the locking screw.

Turn the distributor so that the rotor and the mark align. It may be necessary to remove the distributor and reinstall it (see Ignition System chapter).

Retighten the locking screws.

Turn the engine two full revolutions and check the valve timing once again.

Before installing the lower timing belt cover, remove the V-belt pulley on the crankshaft once again.

Tighten the pulley to a torque of 20 N·m (for correct installation, see the previous text).

Adjust the ignition timing. If only the timing belt needs to be removed from the camshaft sprocket to replace the cylinder head, the job can be done without special tools. Simply select the required operations from the description.

Set the piston in the No. 1 cylinder to TDC of the ignition timing, see above in this chapter.

Remove the V-ribbed belt (refer to Generator).

Remove the timing belt cover.

Loosen the timing belt (see Timing Belt Tensioning) and remove it.

Install counterholder 2084 on the crankshaft pulley (with damper), loosen the center bolt using extension 2079.

Remove the timing belt pulley.

Mark the direction of timing belt rotation for installation. Keep the direction of rotation when reusing the belt.

Installation: fit the timing belt onto the removed timing belt sprocket.

Install the crankshaft timing belt sprocket together with the timing belt. Make sure the timing belt is not pinched.

Install counterholder 2084 on the crankshaft pulley (with damper), tighten the center bolt using extension 2079 (350 N·m).

Check the TDC position of the camshaft and crankshaft once again.