Contents: Camshaft sprockets ⬇ Crankshaft sprocket ⬇ Tensioner Pulley/Upper Idler Pulley…⬇ Lower guide pulley ⬇
Camshaft sprockets
Please note: New sprocket mounting bolts will be required for installation.
Removal
1. Remove the timing belt as described in Chapter 7. Turn the crankshaft counter-clockwise approximately 60° to move the pistons away from the valves.
2. Lock the camshaft in one of two ways:
- a) Make a locking tool from two pieces of steel strip (one long, one short), and three bolts with nuts. One of the bolts forms the hinge of the forked tool, the two remaining bolts connect its ends to the sprocket (see illustration),
- b) Remove the valve cover (see Chapter 4) and lock the camshaft with a wrench (see illustration).
3. Unscrew the mounting bolt and remove the sprocket from the end of the camshaft (see illustrations). If the sprocket dowel pin is loose at the end of the camshaft, remove it and store it with the sprocket to avoid loss.
4. If necessary, remove the remaining sprockets using the same method.
Installation
5. Before installing the sprocket, check the camshaft oil seal for damage and leaks. If necessary, replace it as described in Chapter 9.
6. Place the locating pin in the working position.
7. Note that the right cylinder head sprockets are marked 1 and 2, and the left cylinder head sprockets are marked 3 and 4. The camshaft sprockets for each head are identical, each with two slots for the dowel pin and two marks. It is important to use the correct slot and mark when installing the sprocket (see illustrations and table).
8. Make sure the camshaft dowel pin is in the correct slot on the sprocket, then install the washer and new mounting bolt (see illustrations).
9. Lock the sprocket using the method used to remove it and tighten the mounting bolt to the tightening torque (see Specifications), then sequentially tighten the bolt to the desired angle (see Specifications), using a socket and extension rod (see illustrations). It is recommended to use an angle template for this to ensure accuracy. If a template is not available, paint alignment marks on the bolt head and flywheel to help ensure that the bolt is turned to the correct angle.
10. Make sure that the correct timing marks on the camshaft sprockets are aligned with the notches on the inner belt cover, then carefully turn the crankshaft in the direction of its rotation so that the mark on its sprocket is flush with the notch on the oil pump housing.
11. Install the timing belt as described in Chapter 7, then (where removed) install the valve cover (see Chapter 4).
Crankshaft sprocket
Please note: A new crankshaft sprocket mounting bolt will be required for installation.
Removal
12. Remove the timing belt as described in Chapter 7.
13. Lock the crankshaft using one of the following methods:
- a) Use the tool described in step 2, screwing its bolts into the opposite pulley mounting holes (see illustration).
- b) On manual transmission models, have an assistant select the highest gear and firmly press the brake pedal.
- c) If the engine or transmission unit has been removed from the vehicle, lock the flywheel/drive plate (see Chapter 15).
14. Loosen the mounting bolt and remove the crankshaft sprocket. Discard the bolt - it must be replaced. If necessary, remove the spacer sleeve from the seal. If the outer surface of the sleeve is damaged, the component must be replaced (see illustrations).
Installation
15. Before installation, inspect the oil seal for damage and leaks and replace if necessary (see Chapter 16).
16. Install the spacer sleeve (where removed) onto the crankshaft, being careful not to damage the sealing edge of the oil seal.
17. Align the sprocket with the crankshaft groove and install it in the working position with the flange facing outward. Install a new mounting bolt.
18. Lock the crankshaft using the method used during removal and tighten the sprocket mounting bolt to the required tightening torque (see Specifications). Sequentially tighten the bolt to the desired angle (see Specifications) using a socket and extension rod. It is recommended to use an angle template to ensure accuracy (see illustrations). If a template is not available, paint alignment marks on the bolt head and flywheel to help ensure that the bolt is turned to the correct angle.
19. Install the timing belt as described in Chapter 7.
Tensioner Pulley/Upper Idler Pulley Assembly
Caution: The tensioner pulley/upper guide pulley must be replaced as an assembly.
Removal
20. Remove the toothed drive belt as described in Chapter 7.
21. Remove the bolts securing the tensioner support plate to the cylinder head and remove the assembly from the engine (see illustrations).
Installation
22. Install the assembly on the cylinder head and tighten the mounting bolts with the specified tightening force Specifications.
23. Install the toothed belt as described in Chapter 7. If a new tensioner assembly is installed, replace the timing belt as well.
Lower guide pulley
Removal
24. Remove the timing belt as described in Chapter 7.
25. Loosen the mounting bolt and remove the lower guide pulley and its spacer gasket from the engine (see illustration).
Installation
26. Place the spacer behind the idler pulley, then install the idler pulley mounting bolt.
27. Install the toothed belt as described in Chapter 7.
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