Toothed belt replacement

Removing

1. Open the hood.

2. Cover the fenders of the car with a protective coating.

3. Remove the battery cover and disconnect the negative battery terminal.

4. Remove the engine cover.

5. Remove the front fenders.

6. Remove motor mounting bracket.

Attention. Avoid contact of the toothed belt with coolant and engine oil, as this may damage it and make it impossible to use it again.

7. Set the piston of the first cylinder to the top dead center position:

• Remove the cover bolt for the camshaft housing.
• Install EN-46789 retainer (1) into the camshaft housing.
• Turn the engine crankshaft clockwise until the lock FN-46789 (1) audibly got hooked.

8. Remove the oil pump bolt (1).



9. Install the pin (1) locking fixture EN-46788.




10. Fixing the crankshaft with EN-46788 (1).



11. Install holding key EN-47634 (2) with extension EN-956-1 (3) on the camshaft pulley (1).



12. Loosen the camshaft sprocket bolt.

13. Loosen tensioner bolt (2), to relieve tension on the toothed belt (1).



14. Remove the EN-46788 retainer.


15. Remove toothed belt (1), preliminarily noting the direction of its rotation.

Attention. Be careful not to damage the toothed belt. A damaged toothed belt cannot be reused.

Installation

1. Fix the crankshaft using the EN-46788 clamp:

• Install a new toothed belt onto the crankshaft sprocket.
• Install the EN-46788 retainer (1).

Note. Make sure that the belt does not fall off the toothed pulley during the installation of the retainer.

2. Install the toothed belt in the following sequence:

Note. The marks on the toothed belt must match the marks on the toothed pulleys (see arrows in the picture).

The toothed belt tensioner must be loosened.

• Start installing the timing belt from the crankshaft pulley (4).
• Install the belt on the tensioner pulley (5).
• Install the belt on the water pump pulley (6).
• Install the belt on the high pressure fuel pump sprocket (1).
• Install the belt on the camshaft sprocket (2).
• Finally install the toothed belt onto the idler pulley (3).

3. Return the tensioner (1) to working position:

• Loosen tensioner bolt.
• Return the movable pointer to the marked position (hole), as shown by the arrows in the figure.
• Tighten tensioner bolt to 25 Nm.

4. Tighten the camshaft sprocket bolt:

• Install holding key EN-47634 (2) with extension EN-956-1 (3) on the camshaft pulley (1).
• Tighten camshaft sprocket bolt to 120 Nm.

5. Remove the retaining key EN-47634 (2) with extension EN-956-1 (3).

6. Remove the EN-46788 and EN-46789 fasteners.

Attention. Turn the engine crankshaft ONLY clockwise!

7. Turn the engine crankshaft 720° (two turns).

8. Check the correct installation of the timing belt by inserting the EN-46789 and EN-46788 clamps.

9. Remove the EN-46788 and EN-46789 fasteners.


10. Install the oil pump bolt and tighten to 9 Nm.



11. Install motor mounting bracket.

12. Install the front wheel arches.

13. Install the engine cover.

14. Connect the negative battery terminal and install the battery cover.

15. Remove the protective covers from the wings of the car.

16. Close the hood.