How to Replace timing belt on Toyota Aygo 1.4 HDi 2006

Toyota Aygo 1.4 HDi 2006 cambelt change instructions and replacement inteval. Full guide!

Special tools

• Crankshaft pulley holding tool – No.09330-00021.

Special precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Repair times – hrs

Camshaft drive belt/chain – R & I	5,90
Camshaft drive belt/chain, AC – R & I	6,10

Valve timing procedures

Removal

NOTE: Timing belt cannot be replaced with engine installed in vehicle.

1. Raise and support front of vehicle.
2. Remove:
   • Front bumper.
   • Engine undershield.
   • Cooling fan.
3. Drain coolant.
4. Disconnect hoses, wiring and ancillaries.
5. Remove engine and transmission assembly.
   NOTE: Engine and transmission are removed from below vehicle.
6. Place engine and transmission on suitable stand or cradle.
7. Remove:
   • Timing belt upper cover [1] .
   • Auxiliary drive belt.
   • RH engine mounting bracket.
   • Crankshaft pulley bolt [2] .
   • Crankshaft pulley [3] .
   • Timing belt lower cover [4] .
8. Fit crankshaft pulley bolt [2] .
9. Turn crankshaft slowly clockwise until crankshaft sprocket timing hole aligned [5] .
10. Ensure camshaft sprocket timing hole aligned [6] .
11. Remove:
    • Crankshaft pulley bolt [2] .
    • Timing belt guide [7] .
12. Remove:
    • Tensioner pulley bolt [8] .
    • Tensioner pulley.
    • Timing belt.

Installation

1. Check tensioner pulley and guide pulley for smooth operation.
2. Ensure crankshaft sprocket timing holes correctly aligned [5] .
3. Ensure camshaft sprocket timing holes correctly aligned [6] .
4. Fit tensioner pulley and bolt [8] . Tighten bolt finger tight.
5. Fit timing belt. Ensure belt is taut between sprockets and pulleys.
6. Turn tensioner pulley anti-clockwise until pointer aligned in window [9] . Use Allen key.
7. Tighten tensioner pulley bolt [8] . Tightening torque: 30 Nm.
8. Fit crankshaft pulley bolt [2] .
9. Turn crankshaft slowly two turns clockwise.
10. Ensure crankshaft sprocket timing holes correctly aligned [5] .
11. Ensure camshaft sprocket timing holes correctly aligned [6] .
12. If not: Repeat tensioning procedure.
13. Remove crankshaft pulley bolt [2] .
14. Fit:
    • Timing belt guide [7] .
    • RH engine mounting bracket.
    • Timing belt lower cover [4] .
    • Crankshaft pulley [3] .
    • Crankshaft pulley bolt [2] .
15. Hold crankshaft pulley [3] . Use tool No.09330-00021.
16. Tighten crankshaft pulley bolt [2] . Use new bolt. Tightening torque: 35 Nm + 190°.
17. Install components in reverse order of removal.
18. Refit engine and transmission assembly. Reconnect hoses, cables and ancillaries.
19. Refill and bleed cooling system.