Withdrawal
1. Remove the timing belt as described in paragraph 4. If necessary, remove the rear timing belt cover from the cylinder block (pic. 5.1).
Tensioner/roller
2. To remove the tensioner assembly on ADP, ADR engines (until 07/97), AFY (until 07 97), AEB, AJL, APT, AP\N remove the lower mounting bolt and the assembly mounting bolt on the roller hub (fig 5.2). The roller hub can now be removed from the stud by unscrewing the fastening nut. The stud can be removed from the cylinder head. On ADR, AFY engines, unscrew the bolt and remove the parasitic roller from the tensioner housing.
3. To remove the tensioner pulley assembly on ADR engines (from 08/97) and AFY (from 08/97 make sure that the springs are securely fixed by the drill shank (see paragraph 4) and unscrew the bolt from the eccentric hub. Remove the tensioner mounting bolts including one on the hub and remove the spring assembly with the roller from the front engine strut (fig 5.3). Remove the bearing bush.
4. To remove the semi-automatic tensioner on AHL engines, unscrew the fastening nut and remove the tensioner with plate from the guide pin. Note that the tensioner base is fixed in the cylinder head bore.
Camshaft sprocket
5. Turn away a bolt of fastening of an asterisk of a camshaft, holding an asterisk about turning by the tool shown not drawing. Remove bolt with washer (if provided), an asterisk and (if provided) key (pic. 5.5, a-c).
Auxiliary shaft sprocket (except AHL engine)
6. Remove the sprocket mounting bolt while holding it from turning with a tool (see picture). Remove bolt, sprocket and (if provided) key (pic. 5.6, a, b).
Attention: the sprocket is installed with the TDC mark and the protrusion outward.
Crankshaft sprocket
7. Turn away a bolt of fastening of an asterisk of a crankshaft, remove an asterisk (pic. 5.7, a, b). The bolt is tightened very tightly, the crankshaft must be fixed from turning. On manual transmission models, shift into a higher gear and have an assistant depress the brake pedal properly. If an automatic transmission is installed, remove the front cover of the gearbox and lock the ring gear with a flat-bladed screwdriver.
Examination
8. Clean sprockets and check for wear or damage. Turn the tensioner roller and make sure it turns smoothly.
9. Check for wear and damage to the tensioner, if necessary, replace the assembly.
Installation
Crankshaft sprocket
10. Install the sprocket on the crankshaft toe. While holding the crankshaft stationary in the manner used for removal, tighten the sprocket mounting bolt to the specified torque.
Note: The crankshaft cannot be rotated - the valves can be bent.
11. Install the timing belt as described in paragraph 4.
Auxiliary shaft sprocket (except AHL engines)
12. Install the key in the shaft groove and put on the sprocket. Install the release bolt and tighten to the specified torque while holding the sprocket from turning using the method used for removal.
13. Install the timing belt - see paragraph 4.
Camshaft sprocket
14. Install the key in the camshaft groove, put on the asterisk, tighten the bolt in place with the washer (if there). Tighten the bolt to the specified torque while holding the sprocket from turning using the method used for removal. On ADR and AFY engines, the sprockets are mounted with a protrusion outwards.
15. Install the timing belt - see paragraph 4.
Tensioner/roller
16. Install roller/tensioner and spring assembly in reverse order of removal.
17. Install timing belt - see paragraph 4.
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