Removal
1. Remove the timing belt as described in Chapter 5 or 6.
2. To remove the camshaft sprocket, hold the pulley with a tool and loosen the bolt. Alternatively, an old timing belt can be used to hold the pulley, wrapped around the sprocket and gripped with pliers (see illustrations).
7.2 Method of locking the camshaft sprocket when the bolt is loosened.
3. A special tool may be required to remove the crankshaft sprocket. Unscrew the bolt and remove the sprocket from the end of the crankshaft. If necessary, remove the woodruff key from the groove in the crankshaft. (On the F7P engine (with 16 valves) there is no key.)
4. The intermediate shaft/roller sprocket can be removed in the same way (see illustration).
7.4 Remove the intermediate shaft bolt.
Check the woodruff key again.
5. To remove the crankshaft sprocket, you will need a puller. The puller can be made from two bolts, a metal plate and a crankshaft pulley bolt. When you loosen the pulley bolt, the sprocket will come off the end of the crankshaft.
If necessary, remove the woodruff key from the groove in the crankshaft (see illustration).
7.5. Remove the crankshaft sprocket.
6. Loosen the nut or bolt and remove the upper idler pulley or tensioner mechanism. If necessary, unscrew the upper and lower rear drive covers at this stage (see illustration).
7.6. Remove the lower rear cover of the drive.
7. Loosen the nut or bolts and remove the lower idler pulley or timing belt tensioner (see illustration).
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7.7 Remove the lower idler pulley assembly.
Inspection
8. Inspect the sprocket teeth for nicks and other damage. Also inspect the water pump pulley teeth. The teeth are wear resistant and should last for the life of the engine.
9. Manually unscrew the tensioner pulley and check that it rotates freely. Do not try to clean it with solvent, it may get into the bearing and wash out the grease. If there is wear, replace the tensioner and/or idler pulley.
Installation
10. Install the timing belt idler pulley and tighten the nut or bolt to the torque specified in the Specifications.
11. Install the tensioner mechanism, but do not tighten the nut at this stage.
12. Install the upper and lower rear timing belt covers and tighten the bolts.
13. Make sure the woodruff key is in the crankshaft keyway, then install the sprocket.
14. Make sure the woodruff key is in the keyway of the intermediate shaft, then install the sprocket. Apply a small amount of locking compound to the bolt threads. Insert the bolt with the washer and tighten it to the tightening torque specified in the Specifications, holding the sprocket using one of the methods described in point 2 (see illustration).
7.14. When tightening the bolt, hold the intermediate shaft sprocket with a special tool.
15. Install and secure the camshaft sprocket in the same manner while holding the camshaft.
16. Install the toothed drive belt, see Chapter 5 or 6.