Table of contents: Removal ↓ Installation ↓
Removal
Remove the engine hood. Remove the poly V-belt. Remove the upper toothed belt cover, to do this, open the clamps "arrows".
Set the crankshaft in the direction of engine rotation to "TDC". The mark on the poly V-belt pulley for the crankshaft should coincide with the edge of the "0" mark.
The fixing holes in the camshaft sprockets must coincide with the calibration holes in the camshaft housing "arrows".
Instructions: If the fixing holes are on opposite sides, the crankshaft must be turned one more revolution.
Insert the locking pins "D" of the camshaft lock "T10016" into the gauge holes in the camshaft bearing housing as far as they will go as follows: Through the locking hole of the intake camshaft gear "C". Through the locking hole of the exhaust camshaft gear. The handles of the locking pins must be at the same height "line A". Push the holder "B" into the intake camshaft gear as far as it will go. Remove the engine mounts.
Caution! Risk of engine damage. To prevent the crankshaft timing belt pulley from slipping off the drive pulley, do not turn the crankshaft with the poly V-belt pulley loose. Before turning the crankshaft, secure the crankshaft timing belt pinion with a bolt and 2 washers.
Remove the poly V-belt pulley for the crankshaft. Remove the lower cover for the toothed belt, to do this, unscrew the bolts "arrows" and open the clamps "1".
Unscrew the bolts "arrows" and remove the engine support bracket "1".
Check the TDC position of the camshaft: the flattened tooth on the toothed belt gear "1" for the crankshaft should coincide with the "arrow" mark on the oil pump housing.
Unscrew bolt "1" for the main drive belt tension roller. Remove the camshaft lock "T10016".
Turn the tension roller counterclockwise with a socket wrench "arrow" and remove the toothed belt.
Installation
Installation is in the reverse order, taking into account the following: if removed, install the tension roller of the toothed belt for the main drive and turn it with an Allen key counterclockwise to the indicated position "arrow".
Tighten the bolt for the main drive toothed belt tension roller by hand. Bolt "2" for the oil pump housing should be in the recess of the support plate "1".
Instructions: Observe the direction of travel markings of the previously used belt.
Install the toothed belt for the main drive "B" in the sequence, coolant pump, tension roller, crankshaft and intake camshaft.
A. Toothed belt for coupled drive.
Re-insert the locking pins "D" of the camshaft locking tool "T10016" into the gauge holes in the camshaft bearing housing until they stop.
Tighten the toothed belt by turning the tension roller clockwise arrow A- until the pointer "3" is above the mark "arrow B" in the main plate "1". Tighten the bolt for the tension roller of the toothed belt for the main drive. Remove the camshaft lock "T10016". Turn the crankshaft in the direction of engine rotation by 2 turns and set it again to "TDC".
Check the TDC position of the camshaft: the flattened tooth on the toothed belt gear "1" for the crankshaft should coincide with the "arrow" mark on the oil pump housing.
The fixing holes in the camshaft sprockets must coincide with the calibration holes in the camshaft housing "arrows".
Check whether the locking pins "D" of the 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 locking hole of the intake camshaft gear "C". Through the locking hole of the exhaust camshaft gear. If the holes are not aligned, repeat the adjustment. Installation in the reverse order, in this case it is necessary to install the poly V-belt pulley for the crankshaft, install the engine mount.
This article was previously published on the resource AUDIMANUAL