| CAUTION | This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. |
Scheme 1
- Remove ignition key. Remove engine stabilizer brace. On turbo models, remove plastic pipes between turbocharger and charge air cooler, and between turbocharger and air cleaner. Set them aside.
- Remove clamp from intake manifold for turbocharger for cylinders Nos. 1, 2 and 3. Turn upper section of pipe toward firewall. On all models, lift power steering fluid reservoir, and place on top of engine. NOTE: Ensure power steering fluid does not leak out of ventilation hole.
- Using a 15-mm wrench, rotate accessory drive belt tensioner clockwise to relieve tension on belt. (Scheme 1) Lift off accessory drive belt. Remove upper timing belt cover.
- Remove air duct, cover, surround and control module box. Remove hose between thermostat housing and expansion tank. Remove front timing belt cover.
- Seal hose between expansion tank and radiator. Disconnect hose at expansion tank. Lift expansion tank and place on top of engine.
- Raise and support vehicle. Remove right front wheel. Remove plastic nuts from cover in fender liner. Install upper timing belt cover.
- Rotate crankshaft clockwise until timing marks are aligned. (Scheme 2) Rotate crankshaft further 1/4 turn clockwise, then rotate counterclockwise until marks are aligned. CAUTION: Timing marks are not always provided! It is recommended to mark camshaft pulleys before removal!
- Remove upper timing belt cover. Remove 4 vibration damper screws. Remove vibration damper. Remove accessory drive belt. On models with hydraulic timing belt tensioner, go to next step. On models without hydraulic timing belt tensioner, go to step 11.
- Install Counterhold (999 5433), and remove crankshaft center nut. (Scheme 3) Remove counterhold and accessory drive belt pulley.
- Remove timing belt tensioner/hydraulic unit upper screw, then loosen lower screw. Turn tensioner/hydraulic unit so that cylinder comes free. Remove lower screw. Remove tensioner/hydraulic unit. Remove timing belt.
- Remove belt cover behind crankshaft pulley for accessory drive belt. Spray universal oil around rubber sleeve on underside of oil pump. Remove rubber sleeve.
- Slightly loosen timing belt tensioner center screw. Hold screw from turning. Using a 6-mm hex wrench in eccentric, turn tensioner counterclockwise until eccentric is at 10 o'clock position. (Scheme 4) Remove timing belt.
