Focus Table of Contents Group 3: Powertrain Section 303-01A: ENGINE - 1.4L/1.

6L IN-VEHICLE REPAIR

Timing Belt (213040)

Special Service Tool(s)

Universal Flange Holding Wrench 205-072 (15030A)

Gauge, Bolt Angle 303-174 (21540)

Alignment Plate, Camshaft 303-376 (21162B)

Socket, Spark Plug 303-499 (21202)

Timing Peg, Crankshaft TDC 303-507 (21210)

General Equipment Trolley jack

Materials Cable ties ESE-M1C171-AA ESE-M1244-A Lubricant (spark plug threads Never Seeze) Silicone grease

Removal All Vehicles 1. Disconnect the battery ground lead. For additional information, refer to Section 414-01 .[Battery Disconnect(414-01 Battery, Mounting and Cables,genproc)]

2. 3.

Loosen the bolts on the coolant pump pulley. Raise the vehicle. For additional information, refer to Section 100-02.[Lifting(100-02 Jacking and Lifting,descop)]

4.

Remove the drive belt cover.

5.

Slacken and remove the drive belt.

6.

Remove the crankshaft pulley/vibration damper. 1 2 Attach the special tool using two bolts, M10 x 40 and M10 x 45 and nuts. Remove the bolt. Stop from turning using the special tool.

7.

Remove the coolant pump pulley and the drive belt idler pulley.

8.

Remove the bolts from the timing belt cover. 1 2 Timing belt upper cover Timing belt lower cover Remove the lower cover.

9. 10.

Lower the vehicle. Remove the valve cover. For additional information, refer to Valve Cover(303-01 Engine 1.4L/1.6L,invehic) in this Section.

11.

Remove the spark plugs using the special tool.

12.

Detach the coolant expansion tank. 1 2 Remove the bolt. Unclip the coolant expansion tank and lay it to one side.

13.

Unclip the power steering reservoir and lay it to one side.

14.

Remove the generator and lay it to one side.

1 2 3 15.

Disconnect the plug. Disconnect the positive cable. Detach the generator. Detach the studs.

Place the trolley jack with a wooden block under the oil pan and raise it slightly until the front engine mounting is free from strain.

16. 17.

Remove the engine mounting. Remove the timing belt upper cover.

18.

Remove the front engine mounting bracket (shown with engine removed).

Vehicles with eccentric cam timing belt tensioner 19. Note: If the timing belt will be re-used, mark the running direction. Slacken and remove the timing belt (shown with engine removed). Undo the bolt.

Vehicles with slotted bracket timing belt tensioner 20. Note: When re-using the timing belt, mark the running direction. Slacken and remove the timing belt (shown with engine removed). Installation All Vehicles 1. Set the crankshaft to 20 degrees before TDC. Undo the bolts.

2.

CAUTION: Use the special tool to stop them from turning. Loosen the bolts until the camshaft timing pulleys can be turned on the camshafts. Discard the retaining bolts.

3.

Turn the camshafts to TDC on cylinder number 1 and insert the special tool.

Turn the camshafts by the hexagon using a 21 mm open-ended spanner until the special tool can be inserted.

4.

Note: Running direction marker. Install the timing belt. Starting from the crankshaft timing pulley and working counter-clockwise, put the timing belt in place.

5.

Attach the lower timing belt cover (shown from below).

6.

Note: Use a new bolt. Install the crankshaft pulley/vibration damper. Tighten the bolt in two stages. 1st stage: 40 Nm 2nd stage using Special Tool 303-174: 90 degrees

7.

Note: If it is not possible to insert the special tool, turn back the crankshaft counter-clockwise by approx. 20 degrees. Turn the crankshaft to TDC on cylinder number 1. Remove the blanking plug and screw in the special tool. Carefully turn the crankshaft in a clockwise direction until the crank web touches the special tool.

Vehicles with eccentric cam timing belt tensioner Note: 8. Do not move the eccentric during tightening. Hold with an Allen key. Tension the timing belt (shown with engine removed). Using a 6 mm Allen key, turn the eccentric counter-clockwise until the pointer is exactly in line with the centre of the rectangular hole. Tighten the bolt.

Vehicles with slotted bracket timing belt tensioner Tension the timing belt (shown with engine removed). 9.

Use an 8 mm Allen key to tension until the pointer is exactly in line with the center of the rectangular hole. Tighten the bolts.

All vehicles 10. CAUTION: Do not tighten the camshaft timing pulleys against Special Tool 303-376. Note: Do not turn the crankshaft and the camshaft. Note: Install new camshaft pulley retaining bolts. Tighten the bolts of the camshaft timing pulleys. 11. Remove Special Tool 303-376.

12. 13.

Unscrew the special tool (shown from below). Check the valve timing.

Turn the crankshaft two turns clockwise and turn cylinder number 1 to TDC. Note: If it is not possible to install Special Tool 303-507, turn back the crankshaft counter-clockwise through approx. 20 degrees. Screw in Special Tool 303-507.

Carefully turn the crankshaft in a clockwise direction until the crank web touches Special Tool 303-507.

14.

Check the valve timing by inserting the special tool.

15.

Note: Only if Special Tool 303-376 cannot be inserted. Note: Counterhold using the special tool. Note: The crankshaft must remain at TDC on cylinder number 1. Correct the valve timing.

Loosen the bolt of the affected camshaft. Turn the camshaft by the hexagon until Special Tool 303-376 can be inserted. Tighten the camshaft timing pulley. Check the valve timing again in accordance with the previous steps.

16.

Install the spark plugs using the special tool. Apply lubricantto the spark plug threads.

17. 18.

Install the front engine mounting bracket. Move the timing belt upper cover into position.

19. 20.

Install the engine mounting. Remove the trolley jack.

21.

Install the generator. 1 2 3 Attach the connector. Install the positive lead. Install the studs. Install the generator.

22.

Raise the vehicle. For additional information, refer to Section 100-02.[Lifting(100-02 Jacking and Lifting,descop)]

23.

Unscrew Special Tool 303-507 and screw in the blanking plug.

24.

Install the bolts of the upper timing belt covers.

25.

Install the coolant pump pulley and the drive belt idler pulley.

26.

Fit and tension the drive belt.

27. 28.

Install the drive belt cover. Lower the vehicle.

29.

Clip on the power steering reservoir.

30.

Attach the coolant expansion tank. 1 2 Clip in the expansion tank. Tighten the bolt.

31.

Install the valve cover. For additional information, refer to Valve Cover(303-01 Engine 1.4L/1.6L,invehic) in this Section. Standard finishing operations. Connect the battery negative lead. For additional information, refer to Section 414-01 .[Battery Disconnect(414-01 Battery, Mounting and Cables,genproc)] If necessary secure the cable using cable ties.

32.