In-vehicle Repair Special Tool(s) | Remover/Installer, Hose Clamp 303-397 | | Alignment Peg, Crankshaft 303-732 | | Locking Tool, Crankshaft 303-734 | | Alignment Peg, Camshaft 303-735 | General Equipment CAUTION:Only install the timing belt after the engine has cooled to workshop temperature. | -
Disconnect the battery ground cable. For additional information, refer to: Battery Disconnect. | | -
Remove the cowl panel grille. For additional information, refer to: Cowl Panel Grille. | | -
Remove the accessory drive belt. For additional information, refer to: Accessory Drive Belt - 1.6L Diesel. | | -
Drain the cooling system. For additional information, refer to: Cooling System Draining, Filling and Bleeding. | | -
CAUTION:Protect the generator with lint free material to prevent contamination. Using the special tool, disconnect the coolant expansion tank hose. - Detach the coolant expansion tank and position to one side.
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CAUTION:Do not support the engine directly on the oil pan. Using a trolley jack and suitable wooden blocks, support the engine. | | -
Remove the engine front mount. | 8. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Timing belt upper cover retaining bolts 2 - Timing belt upper cover 3 - Engine front mount bracket retaining bolts 4 - Engine front mount bracket 7 - Timing belt lower cover retaining bolts 8 - Timing belt lower cover All vehicles | -
To install, reverse the removal procedure. | Vehicles with front and rear power windows Removal Details Item 5 : Crankshaft pulley retaining bolt | -
NOTE:Do not discard the old crankshaft pulley bolt. Using a suitable power tool remove the crankshaft pulley bolt. | Item 11 : Camshaft pulley | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Align the camshaft. - Turn the crankshaft until the alignment hole in the camshaft pulley is at the 10 o'clock position.
| Item 12 : Crankshaft timing pulley | -
Remove the timing belt guide. | | -
CAUTION:Do not touch the outer sensor ring. Remove the crankshaft timing pulley. | Installation Details Item 12 : Crankshaft timing pulley | -
Check the correct position of the crankshaft timing pulley Woodruff key. | | -
CAUTION:Do not touch the outer sensor ring. NOTE:Install the old crankshaft pulley bolt. NOTE:Do not tighten the crankshaft pulley bolt at this stage. Install the crankshaft timing pulley. | | -
CAUTION:Do not touch the outer sensor ring. Using the special tool, align the crankshaft. | Item 11 : Camshaft pulley | -
Using the special tool, align the camshaft pulley. | Item 9 : Timing belt | -
Using the special tool, align the high-pressure fuel pump pulley (engine shown removed for clarity). | | -
Remove the special tool (engine shown removed for clarity). | | -
NOTE:Make sure the camshaft alignment holes are in line. Check the camshaft alignment. | | -
CAUTION:Install the timing belt with the direction arrows in the direction of crankshaft rotation. NOTE:Install a new timing belt. Install the timing belt. | | -
NOTE:Using an Allen key, maintain tension until the timing belt tensioner bolt is tightened. Tension the timing belt (engine shown removed for clarity). - Turn the timing belt tensioner adjustment arm counterclockwise tension the timing belt slightly.
- The pointer must be positioned between the sides of the window.
- Tighten the timing belt tensioner retaining bolt.
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CAUTION:Do not touch the outer sensor ring. Remove the special tool. | | -
Install the timing belt guide. | | -
NOTE:Only rotate the crankshaft in the normal direction of rotation. Rotate the crankshaft ten revolutions. | | -
CAUTION:Do not touch the outer sensor ring. Using the special tool, align the crankshaft. | | -
Install the special tool. - If the special tool cannot be installed, repeat the previous steps.
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CAUTION:Do not touch the outer sensor ring. Remove the special tool. | | -
CAUTION:Do not touch the outer sensor ring. Remove the crankshaft pulley retaining bolt. | Item 6 : Crankshaft pulley | -
CAUTION:Make sure the special tool engages correctly. NOTE:Only rotate the crankshaft in the normal direction of rotation. Using the special tool, lock the flywheel. - Rotate the crankshaft until the special tool aligns with one of the slots in the flywheel.
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NOTE:Install a new crankshaft pulley retaining bolt. Install the crankshaft pulley. - Tighten the crankshaft pulley bolt in two stages.
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