In-vehicle Repair Special Tool(s) | Locking tool, flywheel 303-393 | | Adapter for 303-393 303-393-02 | | Locking Tool, Crankshaft 303-748 | | Locking Tool, Timing Belt Tensioner 303-1054 | | Locking Tool, Camshaft Adjustment Unit 303-1097 | General Equipment WARNING:Do not smoke or use any kind of naked flame when working on or near any fuel-related components. Highly flammable vapors are always present and may ignite. Failure to observe this instruction can lead to injury. | -
Remove the right-hand front wheel. For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation). | | -
Remove the air cleaner. For additional information, refer to: Air Cleaner - 1.6L Duratec-16V Ti-VCT (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation). | | -
Remove the generator. For additional information, refer to: Generator - 1.6L Duratec-16V (Sigma) (414-02 Generator and Regulator, Removal and Installation). | | -
Remove the starter motor. For additional information, refer to: Starter Motor - 1.6L Duratec-16V Ti-VCT (Sigma) (303-06 Starting System, Removal and Installation). | | -
Detach the coolant expansion tank from the wheel housing and lay it to one side. | 6. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Coolant pump pulley bolts 2 - Timing belt cover bolts 7. Install the components in the order indicated in the following illustration(s) and table(s). 5 - Timing belt cover bolts 6 - Coolant pump pulley bolts Removal Details Item 3 : Crankshaft belt pulley | -
NOTE:Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft until the marking on the VCT unit is at the 11 o'clock position. | | -
Raise the vehicle. For additional information, refer to: (100-02 Jacking and Lifting) Jacking (Description and Operation), Lifting (Description and Operation). | | -
Remove the blanking plugs and install the special tool. - Carefully turn the crankshaft clockwise against the special tool.
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CAUTION:Make certain that the crankshaft is on the crankshaft locking tool. Using the special tool, lock the crankshaft. | | -
Remove the crankshaft pulley. | Item 4 : Timing belt cover, lower | -
Remove the lower timing belt cover. | Item 5 : Engine front mounting bracket retaining bolts | -
Position the trolley jack with the wooden block under the engine and raise the engine until the front engine mount is free from load. | | -
NOTE:Discard the front engine mount nuts. NOTE:Mark the installed position of the front engine mount. Remove the front engine mount. | Item 6 : Timing belt | -
NOTE:Scribed lines on the exhaust side and dot marks on the inlet side. Install the special tool. | | -
Pull the timing belt towards the alternator to bring the tensioning pulley in basic position, and secure with the special tool. | Installation Details Item 1 : Timing Belt | -
NOTE:Beginning at the VCT elements, fit the timing belt clockwise over the crankshaft timing belt pulley. Install the timing belt. | | -
CAUTION:Only remove the special tool once the timing belt is correctly laid in place. Failure to observe this instruction may lead to injury and/or component damage. Tension the timing belt. | Item 2 : Timing belt cover, lower | -
Measure the depth of the bore in the crankshaft. - Depth of bore = 42 mm: install M12 x 29 mm central bolt.
- Depth of bore = 52 mm: install M12 x 44.5 mm central bolt.
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Install the timing belt lower cover. | Item 3 : Crankshaft belt pulley | -
CAUTION:Counterhold the crankshaft pulley using the special tool. NOTE:Install a new crankshaft pulley bolt. Install the crankshaft pulley. - Counterhold the crankshaft pulley using the special tool and tighten the crankshaft pulley bolt in two stages.
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NOTE:Only turn the crankshaft in the normal direction of rotation. Turn the crankshaft about two revolutions until the marking on the VCT unit is at the 11 o'clock position. | | -
CAUTION:Make certain that the crankshaft is on the crankshaft locking tool. Attach the special tool. - Carefully turn the crankshaft clockwise against the special tool.
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Install the special tool. - If the special tool cannot be installed, repeat the adjustment according to the preceding steps.
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Install the blanking plugs. | Item 4 : Engine front mounting bracket retaining bolts | -
NOTE:Install new front engine mount nuts. Install the front engine mount. | |