Removal

1. Disconnect battery ground cable and remove left engine under cover.
2. Disconnect accelerator cable and breather hose and remove air intake pipe from between turbocharger and throttle body.
3. Remove distributor cap and spark plug wires as an assembly.
4. Remove accessory drive belts.
5. Support engine as needed, then remove left engine mount bracket.
6. Remove power steering pump and water pump pulleys.
7. Disconnect PCV hose, then remove rocker cover, gasket and packing, and the timing belt upper cover.
8. After removing rocker cover, back off all valve adjusting screws until tip of each screw protrudes less than 0.08 inch (2 mm) from rocker arm. This is essential to provide enough freeplay at camshaft to allow correct valve timing during timing belt installation.
9. Remove damper pulley, crankshaft pulley and lower timing belt cover.

Fig. 35 Timing belt, tensioner and sprockets. 1600cc engine:

Fig. 36 Crankshaft timing mark detail. 1600cc engines.:

10. Rotate crankshaft clockwise until crankshaft and camshaft timing marks are aligned as shown in Figs. 35 and 36.
11. Loosen belt tensioner bolts, move tensioner toward water pump to relieve tension on belt, then tighten tensioner bolts.
12. Remove timing belt. If belt is to be reused, place chalk mark on back of belt indicating direction of rotation. To ensure proper operation, reused belt must be installed in original position.
13. Remove crankshaft sprocket, camshaft sprocket and timing belt tensioner as needed.
14. Inspect belt and replace if any of the following conditions are noted:
a. Hardened back surface rubber with back surface glossy, non-elastic and so hard that no mark is produced when fingernail is forced into surface.
b. Cracked back surface rubber.
c. Cracked or separated canvas.
d. Cracks at tooth bottom or side of belt.