Withdrawal
Remove the engine hood. Remove poly V-belt. Remove top toothed belt cover by opening buckles -arrows-.
Position crankshaft in direction of engine rotation "TDC". The notch on the poly V-belt pulley for the crankshaft must line up with the edge of the -0- mark.
The fixing holes in the camshaft sprockets must line up with the calibration holes in the camshaft housing -arrows-.
Instruction. If the fixing holes are on opposite sides, then the crankshaft must be rotated one more turn.
Insert locking pins -D- of camshaft lock -T10016- as far as they will go into the calibration holes in the camshaft bearing housing as follows: Through the locking hole of the inlet camshaft gear -C-. Through the fixing hole of the exhaust camshaft gear. The locking pin handles must be at the same height -line A-. Push retainer -B- into inlet camshaft sprocket as far as it will go. Remove engine mounts.
Carefully! Risk of engine damage. In order to prevent the belt drive pulley on the crankshaft from slipping off the drive pulley, it is forbidden to turn the crankshaft when the V-ribbed belt pulley is loose. Before turning the crankshaft, secure the toothed belt gear for the crankshaft with a bolt and 2 washers.
Remove poly V-belt pulley for crankshaft. Remove bottom cover for toothed belt by unscrewing bolts -arrows- and opening clips -1-.
Remove bolts -arrows- and remove engine mount -1-.
Check position "TDC" Camshaft: The flattened tooth on the toothed belt sprocket -1- for the crankshaft must align with the mark -arrow- on the oil pump housing.
Remove bolt -1- for main drive belt tensioner. Remove camshaft clamp -T10016-.
Turn tensioning pulley anti-clockwise -arrow- with socket wrench and remove toothed belt.
Installation
Install in reverse order, paying attention to the following: if removed, install toothed belt tensioner for main drive and turn anti-clockwise to the indicated position -arrow- with an hexagon socket wrench.
Finger-tighten the bolt for the toothed belt tensioner for the main drive. The bolt -2- for the oil pump housing must be seated in the recess in the support plate -1-.
Instruction. Observe the designation of the running direction of the previously used belt.
Fit main drive toothed belt -B- in sequence, coolant pump, tensioner pulley, crankshaft and intake camshaft.
A. Toothed belt for mating drive.
Re-insert locking pins -D- of camshaft lock -T10016- as far as they will go into the caliper holes in the camshaft bearing housing.
Tension the toothed belt, to do this turn the tensioning pulley clockwise arrow A- until the pointer -3- is above the mark -arrow B- in the base plate -1-. Tighten bolt for toothed belt tensioner for main drive. Remove camshaft clamp -T10016-. Turn the crankshaft in the direction of engine rotation 2 turns and set it back to "TDC".
Check position "TDC" Camshaft: The flattened tooth on the toothed belt sprocket -1- for the crankshaft must align with the mark -arrow- on the oil pump housing.
The fixing holes in the camshaft sprockets must line up with the calibration holes in the camshaft housing -arrows-.
Check whether the locating pins -D-camshaft lock -T10016- are inserted again as far as they will go into the calibration holes in the camshaft bearing housing as follows: through the locating hole in the inlet camshaft gear -C-. Through the fixing hole of the exhaust camshaft gear. If the holes are not aligned, then repeat the setting. Installation is in the reverse order, while it is necessary to install the poly-V-belt pulley for the crankshaft, install the engine mount.
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