Proceed with the procedures only after the engine has completely cooled down.
Replacing the timing belt on 1.4, 1.6 and 1.8 L DOHC engines
KV - Crankshaft
RV - Camshaft
VN - Water pump
R - Roller
H - Tensioner
Timing Belt Replacement on 2.0L DOHC Engines
KV - Crankshaft
RV - Camshaft
VN - Water pump
R - Roller
H - Tensioner
Removing
Engines 1.4, 1.6 and 1.8 l DOHC
See illustration Replacing the timing belt on 1.4, 1.6 and 1.8 L DOHC engines.
1. Disconnect the negative cable from the battery.
2. Remove the air cleaner.
3. Apply the parking brake, jack up the front of the vehicle and place it on jack stands. Remove the right front wheel.
4. Chalk or paint mark the direction of rotation of the accessory drive belt. After retracting the tensioner with a ring wrench, loosen the belt. Insert a 4mm rod through the aligned holes in the tensioner and support bracket [1]. Remove it from the engine.
5. Remove the upper section of the timing cover [2].
6. Support the engine using the KM-6001 fixture and install the KM-909-B centering tool.
7. Remove the accessory drive belt tensioner.
8. Remove the right powertrain mount assembly with its bracket.
9. After passing the special tool KM-911 [3] into the transmission dome, block the flywheel from turning.
10. Remove the retaining bolt [4] and remove the crankshaft pulley [5].
11. Remove the lower section of the timing cover [6].
12. Remove the flywheel blocking tool.
13. If equipped, remove the camshaft position sensor (CMP).
14. Temporarily screw the crankshaft pulley bolt into place and, turning the crankshaft clockwise, bring the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder (see Bringing the piston of the first cylinder to the position of the top dead center of the end of the compression stroke (TDC). Make sure that the alignment marks [7] are aligned correctly.
15. Check the correct alignment of the timing marks of the gears of the camshafts relative to the upper cut of the cylinder head [8].
16. Lock the gear wheels of the camshafts using the special tool KM-852 [9].
17. Loosen the tensioner bolt [10] and use a bar wrench (Allen) [11] rotate the latter clockwise until the left stop is in the appropriate position [12] - Type 1 or [17] - Type 2.
18. Lightly tighten the tensioner bolt.
19. Remove the timing belt.
2.0L DOHC engines
See illustration Timing Belt Replacement on 2.0L DOHC Engines.
1. Disconnect the negative cable from the battery.
2. Remove the air cleaner.
3. Apply the parking brake, jack up the front of the vehicle and place it on jack stands. Remove the right front wheel.
4. Chalk or paint mark the direction of rotation of the accessory drive belt. After retracting the tensioner with a ring wrench, loosen the belt. Insert a 4mm rod through the aligned holes in the tensioner and support bracket [1]. Remove it from the engine.
5. Remove the top section (And) timing cover [3].
6. Support the engine using the KM-6001 fixture and install the KM-909-B centering tool.
7. Remove the accessory drive belt tensioner.
8. Remove the right powertrain mount assembly with its bracket.
9. Turn the crankshaft clockwise until the alignment marks [4] are aligned.
10. Loosen the mounting bolts [5] and remove the crankshaft pulley [6].
11. Make sure that the distribution marks of the crankshaft [7] are aligned correctly.
12. The alignment marks of the gears of the camshafts must be aligned with the response risks on the back cover of the timing drive [8].
13. Block the gears of the camshafts using the KM-853 special tool.
14. Loosen the tensioner bolt [10] and use a bar wrench (Allen) [11] turn the latter clockwise until the left stop is in the appropriate position [12] - Type 1 or [16] - Type 2.
15. Loosely tighten the tensioner bolt.
16. Remove the timing belt.
Installation
Engines 1.4, 1.6 and 1.8 l DOHC
See illustration Replacing the timing belt on 1.4, 1.6 and 1.8 L DOHC engines.
1. Make sure that the mark on the water pump housing is correctly aligned with the mating mark on the cylinder block [13].
2. Make sure that the alignment marks [7] and [8] are aligned correctly.
3. Starting at the crankshaft sprocket and working counterclockwise, install the timing belt. Make sure the belt is tight in the areas between adjacent wheels.
4. Loosen tensioner bolt [10].
5. Using a bar wrench [11], turn the tensioner counterclockwise until the right stop pointer is in the appropriate position [14] - Type 1 or [18] - Type 2.
6. Loosely tighten the tensioner bolt.
7. Remove the gear blocking tool [9].
8. Rotate the crankshaft two full turns clockwise and check that the alignment marks [7] and [8] are correctly aligned.
9. Using the special tool KM-852, block the gears of the camshafts [9].
10. Loosen tensioner bolt.
11. Turn the tensioner clockwise until the pointer is in the appropriate position [15] - Type 1, new belt, [16] - Type 1, used belt, [19] - Type 2, new belt, [20] - Type 2, used belt.
12. Loosely tighten the tensioner bolt.
13. Remove the tool blocking the gears and slowly turn the crankshaft two full turns clockwise - make sure that the alignment marks [6] and [7] are aligned correctly.
14. Check the correct alignment of the tensioner pointer (see item 11). Repeat the belt tension adjustment procedure if necessary.
15. Tighten the tensioner bolt to the required torque (20 Nm).
16. Pass the KM-911 special tool into the transmission dome and block the flywheel from turning with it [3].
17. Turn out a bolt of fastening of a pulley of a cranked shaft.
18. Reinstall the removed components in the reverse order of removal.
Make sure that the original direction of rotation of the accessory drive belt is observed, if it has not been replaced.
19. Screw in a new bolt of a pulley of a cranked shaft and tighten it with the demanded effort.
20. Remove the gear blocking tool.
2.0L DOHC engines
See illustration Timing Belt Replacement on 2.0L DOHC Engines.
Make sure the tab on the water pump housing is properly aligned with the mating tab on the cylinder block [20].
1. Make sure that the alignment marks [7] and [8] are aligned correctly.
If the camshaft gears were removed, make sure that the guide bushings are correctly positioned.
2. Starting at the crankshaft sprocket and working counterclockwise, install the timing belt. Make sure the belt is tight in the areas between adjacent wheels.
3. Loosen tensioner bolt [10].
4. Using a bar wrench [11], turn the tensioner counterclockwise until the right stop pointer is in the appropriate position [13] - Type 1 or [17] - Type 2.
5. Loosely tighten the tensioner bolt.
6. Remove the gear blocking tool [9].
7. Rotate the crankshaft two full turns clockwise and check that the alignment marks [7] and [8] are correctly aligned.
8. Using the special tool KM-853, block the gears of the camshafts [9] (refer to illustration 41.39).
9. Loosen tensioner bolt.
10. Turn the tensioner clockwise until the pointer is in the appropriate position [14] - Type 1, new belt, [15] - Type 1, used belt, [18] - Type 2, new belt, [19] - Type 2, used belt.
11. Tighten the tensioner bolt to the required torque (20 Nm).
12. Remove the blocking tool [9].
13. Rotate the crankshaft two full turns clockwise and check that the alignment marks [7] and [8] are correctly aligned.
14. Check the correct alignment of the tensioner pointer (see paragraph 65). Repeat the belt tension adjustment procedure if necessary.
15. Reinstall the removed components in the reverse order of removal.
Make sure that the original direction of rotation of the accessory drive belt is observed, if it has not been replaced.
16. Tighten the crankshaft pulley bolts to the required torque (20 Nm).
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