For 1990-2009 cars

#### Special Tools

• | EN 6625 Crankshaft Locking Device

• | EN 6340 Camshaft Locking Tool

• | EN 6333 Timing Belt Tensioner Locking Pin

For equivalent regional tools, refer to Special Tools.

### Removal Procedure

1. Open the hood.
2. Remove the air cleaner housing. Refer to Air Cleaner Inlet Duct Replacement.
3. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Replacement.
4. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
5. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
6. Remove the timing belt lower front cover. Refer to Timing Belt Lower Front Cover Replacement.
7. Set engine to "TDC"

Set crankshaft balancer in direction of engine rotation to "cylinder 1 TDC of combustion stroke" (1).

8. Remove the bolt (1).
9. Install EN 6625 locking device (2) to block the crankshaft.
10. Lower the vehicle by its full height.
11. Install EN 6340 locking tool into the camshaft position actuator adjusters.

| Note: The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of EM-6340-Left during this process but must be somewhat above as shown.

• | Install EN 6340-Left locking tool (1) in the camshaft position actuator adjusters as shown.

| Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EM-6340-Right

• | Install EN 6340-Right locking tool (2) in the camshaft position actuator adjusters as shown.

12. Remove EN 6340 locking tool .
13. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
14. Loosen the timing belt tensioner bolt.
15. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an Allen key (1).
16. Install the EN 6333 locking pin (3).
17. Lower the vehicle by its full height.

Note: Note the direction of the belt.

18. Remove the timing belt.

### Installation Procedure

Note: If the toothed belt has been used, observe direction of rotation.

1. Install the timing belt (1) in the enclosed assembly tool (2).
2. Guide the timing belt through the engine mount bracket with the assembly tool.
3. Remove the assembly tool.

Note: Threading the timing belt through the engine mount bracket is only permissible in conjunction with the assembly tool supplied with NEW timing belts as otherwise it is possible to damage the toothed belt at this stage by kinking it.

4. Install the timing belt.
5. Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.
6. Place the timing belt on the exhaust and intake camshaft position actuator adjusters.
7. Raise the vehicle by its full height.
8. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an Allen key (1).
9. Remove the EN 6333 locking pin (3).

Note: The timing belt tensioner moves automatically to the correct position.

10. Release tension on timing belt tensioner.

Caution: Refer to Fastener Caution in the Preface section.

11. Tighten the timing belt tensioner bolt to 20 N·m (15 lb ft).
12. Remove bolt (1).
13. Remove EN 6625 locking device (2) to block the crankshaft.
14. Install the bolt (1) and tighten to 75 N·m (56 lb ft).
15. Lower the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
16. Timing check.

| Note: Note the marking at the camshaft sprockets.

• | Turn the crankshaft 720 degrees in the direction of engine rotation by the bolt on the crankshaft balancer.

| Note: The spot-type marking (4) on the intake camshaft position actuator adjuster does not correspond to the groove of EN-6340-Left during this process but must be somewhat above as shown.

• | Install EN 6340-Left locking tool (1) into the camshaft position actuator adjusters as shown.

| Note: The spot type marking (3) on the exhaust camshaft position actuator adjuster must correspond to the groove on EN-6340-Right.

• | Install EN 6340-Right locking tool (2) into the camshaft position actuator adjusters as shown.

• | Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.

17. Remove the EN 6340 locking tool .

Note: Note the marking at the crankshaft balancer and the cover.

18. Control the crankshaft balancer position.

Markings on torsional crankshaft balancer (1) and lower cover (1) must align.

19. Install the timing belt lower front cover. Refer to Timing Belt Lower Front Cover Replacement.
20. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
21. Lower the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
22. Install the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Replacement.
23. Install the air cleaner housing. Refer to Air Cleaner Inlet Duct Replacement.