4-cylinder engine
Remove V- or V-ribbed belts (chapter «Generator»).
Remove the pulley on the crankshaft after loosening the hexagon socket bolts (not the center bolt!).
Remove toothed belt guard.
Loosen toothed belt (cm. «Toothed belt tension») and take it off.
Put on a new toothed belt. If the position of the crankshaft and camshaft pulleys has not been changed, it is possible that the valve timing has not yet been knocked down. But for greater certainty, you need to check this before the final assembly.
Rotate the camshaft sprocket so that the mark on the sprocket is under the arrow on the back of the toothed belt guard.
If this requires turning the camshaft, then this can only be done if none of the pistons is in the TDC position, otherwise the valves or piston crowns may be damaged.
Slide the toothed belt onto the crankshaft and countershaft gears.
Secure the crankshaft V-belt pulley with only one bolt. When doing this, ensure the correct position: depending on the engine version, either the locking pin must engage in the pulley or the pulley mounting holes must be arranged asymmetrically. In this case, all mounting holes will be in the same plane as the crankshaft holes.
Rotate the crankshaft so that the marking on the V-belt pulley points up.
Align the mark on the countershaft gear with the mark on the V-belt pulley.
Fit the toothed belt, taking care not to change the position of the various gears.
Pull on toothed belt.
Remove the ignition distributor cap and check if the distributor slider points to the mark on the edge of the distributor housing
Otherwise, loosen the lock screw.
Turn the ignition distributor so that the slider and the mark match, it may be necessary to remove the ignition distributor and reinstall it (chapter «Ignition system»).
Tighten the lock screws again.
Turn the crankshaft completely twice and check the timing again.
Before installing the lower part of the toothed belt guard, remove the crankshaft V-belt pulley again.
Tighten pulley to 20 Nm (correct installation, see previous text).
Adjust ignition.
In a 5-cylinder engine, the TDC camshaft mark for the first cylinder is located on the reverse side of the toothed pulley. The back of the toothed belt guard is slotted (arrow), through which you can check whether the mark is exactly near the top edge of the cylinder head cover.
5 cylinder engine
If you need to remove the toothed belt only from the camshaft gear to replace the cylinder head, you can do without special tools. You just need to select the necessary operations from the description.
Set the piston in the first cylinder to the TDC of the ignition moment, see above in this chapter.
Remove the front upper cross member of the engine compartment (chapter «Body elements»).
Loosen the radiator mounting on the right side in the direction of the vehicle, tilt it forward and support it. This will give freedom of action during subsequent dismantling.
Unscrew the fan with a viscous coupling, for this you need a special so-called fork wrench (chapter «Cooling system»).
Remove V-belt (chapter «Generator»).
Remove toothed belt guard.
Loosen toothed belt (cm. «Toothed belt tension») and take it off.
Install counter support 2084 on the crankshaft pulley (with damper), loosen the central bolt with extension 2079.
Remove pulley with toothed belt.
Mark the running direction of the toothed belt for installation. Maintain direction with used belts.
Installation: Slide the toothed belt onto the removed toothed pulley.
Install the crankshaft sprocket together with the toothed belt onto the crankshaft. Make sure that the toothed belt is not pinched.
Install counter support 2084 on the crankshaft pulley (with Damper), tighten the central bolt with extension 2079 (350 Nm).
Recheck the TDC position of the camshaft and crankshaft.
On the reverse side of the crankshaft sprocket, align the mark with the upper left edge of the cylinder head cover (watch it through a small slit). When rotating the camshaft, no piston must be at TDC, otherwise the valves or piston crowns may be damaged.
Crankshaft: Align the TDC mark on the flywheel with the mark in the observation hole of the clutch housing. Or use the installation markings on the pulley.
Fit the toothed belt onto the camshaft, idler pulley and water pump, but do not change the position of the camshaft and crankshaft.
Tighten toothed belt
Turn the crankshaft 2 turns and check the timing again.
Check the position of the ignition distributor as described for the 4-cylinder engine.
Install ignition.
For a 5-cylinder engine, the TDC marks are also located on the crankshaft pulleys. Positions (1) And (2) show marks with toothed belt guard installed, position (3) And (4) show the TDC position with the toothed belt guard removed.
6 cylinder engine
Here you will find a description of the work, but nothing can be done at home without special tools.
Remove V-belt with tensioner (chapter «Generator»).
Remove toothed belt guard on both sides (see above in this chapter).
Turn the crankshaft to the TDC position of the ignition moment of the first cylinder. The marks on the crankshaft pulley and the toothed belt guard must be aligned, the large holes of the fixing plates on the camshaft gears must be directed towards each other towards the middle of the engine.
Unscrew the ignition timing sensor from the cylinder block and screw in the special tool instead «crankshaft retainer 3242». The tool must fit into the rear hole of the crankshaft. Lightly tighten.
Remove the crankshaft V-ribbed pulley, unscrew the toothed belt guard from below.
Mark the running direction of the toothed belt for reassembly. Keep the direction of passage with already used belts.
Install special tool «camshaft retainer 3243» on the fixing plates of the camshafts.
Loosen the camshaft gear bolts approximately three turns.
Remove special tool 3243.
Remove both camshaft gears from the cones. To do this, use a claw puller. Install the grips on the reverse side of the toothed belt gear; bolt stays the same (loosened three turns).
After preliminary work, regulation can begin.
If you need to replace the toothed belt, this is done immediately.
For further work, you need to put on a toothed belt.
Install special tool again «camshaft retainer 3243» on the locking plates of the camshafts.
Check the special tools again for correct installation.
The camshaft gears must be so superimposed on the cone that, although they can rotate with the shaft, they do not sway from side to side (hand tightened bolt).
Tighten the toothed belt now (see description earlier in this chapter).
Tighten camshaft gears to 70 Nm.
Remove special tools.
Reinstall the removed parts.
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