Warning. If the toothed belt has been removed, it must always be replaced with a new one.
Removing
Disconnect the wire from the negative battery terminal.
Remove the air filter and the air line connecting it to the mass air flow meter.
Remove the alternator drive belt and power steering pump drive belt (if it is installed).
Remove the front protective cover of the toothed belt by unscrewing the three mounting bolts.
By turning the crankshaft clockwise with a ratchet wrench and a TORX E20 head, set the piston of the 1st cylinder to the TDC position of the end of the compression stroke and check the alignment of the timing marks (see above).
Unscrew the bolts securing the side holder of the inlet and outlet pipes of the oil cooler and take the pipes to the side.
Lock the crankshaft with a TORX E20 wrench.
Unscrew the six bolts securing the crankshaft pulley using the KM 312A tip.
Again check the alignment of the marks for installing the drive of the gas distribution mechanism.
Remove the crankshaft pulley.
Warning. After removing the crankshaft pulley, turning the crankshaft and camshafts is not allowed.
Loosen the toothed belt tensioning roller bolt, loosen the belt tension and remove it.
Installation
Put a new toothed belt on the pulleys.
Install the crankshaft pulley, wrap and tighten the six bolts of its fastening to a torque of 20 kgf·m.
Warning. Toothed belt tension is adjusted at ambient temperature with a cold engine.
Install special tool KM 666 to adjust the belt tension.
Rotate the crankshaft 120°clockwise relative to the TDC position of the piston of the 1st cylinder, which corresponds to the rotation of the camshaft pulleys by seven teeth. Turning should be done slowly. to prevent jumping of the teeth of the toothed belt.
Tighten the idler pulley bolt to the specified torque.
Remove the tool for adjusting the belt tension KM 666.
Turning the crankshaft clockwise, set the piston of the 1st cylinder to the TDC position and check the alignment of the marks for installing the timing mechanism drive.
Install the removed parts in the reverse order of removal, making sure that the rubber bushings of the three bolts securing the toothed belt front protective cover are in the correct position.
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