Removing
Disconnect the earth cable from the battery.
Remove the air filter see paragraph 4.44.
Remove cover from clutch housing see point 9.
Remove the V-belt see point 22.3.
Remove the top and bottom timing belt covers, see point 6.7.
Remove vibration damper (four screws).
Remove cover from camshaft housing.
Remove the vacuum pump see 7.14.
Rotate the crankshaft in the direction of engine rotation until the top dead center mark on the flywheel matches the top dead center mark on the high pressure fuel pump. To do this, engage fourth gear and push the car, or set the gearbox to idle and rotate the crankshaft accordingly (apply a replaceable socket wrench head to the crankshaft belt pulley).
The crankshaft is at TDC for the first cylinder if the valves of the fourth cylinder overlap. In this position, you can use the KM-537 tool instead of a vacuum pump.
Using the KM-537 tool, block the camshaft, see 7.15.
Unscrew the fixing screws of the camshaft gear. At the same time, using a wrench, hold the camshaft from turning, see point 1.6.
Loosen fixing screws (arrow) water pump.
Using the KM-509 wrench, turn the water pump counterclockwise, as a result, the tension of the V-belt is weakened. You can also use a 41 mm wrench. However, the alternator must first be removed.
Disconnect the engine mount to the right of the side member.
Pull the engine off the side member. Remove the toothed belt from the drive gears and stretch it between the side member and the engine mount.
Installation
Check if the TDC marks match.
Pull a new toothed belt between the side member and the engine mount.
Fasten the engine mount to the side member.
Pull on the toothed belt see point 6.6.
Tighten coolant pump screws to 25 Nm.
Tighten vibration damper screws to 50 Nm (4 things).
Check, if necessary, whether the TDC marks match.
Tighten the camshaft gear fixing screws to 90 Nm while holding the camshaft against turning with a wrench.
Check valve timing, see 7.15.
Check the injection timing of the high pressure fuel pump, see clause 7.11.
Install vacuum pump.
Install the camshaft housing cover and tighten the screws.
Install the upper and lower toothed belt covers.
Install and tighten the V-belt, see point 22.3.
Install the clutch dome cover.
Install the air filter.
Connect ground cable to battery.
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