1. Lower engine and connect to clutch housing.
2. Check that the flywheel mark corresponding to the installation of the piston of the first cylinder at TDC is aligned with the pointer. The fuel pump pulley and camshaft are locked with the installation tools.
3. Loosen the camshaft pulley bolt half a turn, while using a wrench on the camshaft flats, keep the camshaft from turning. Remove the camshaft timing belt pulley from the camshaft alignment cone using a drift through the hole in the rear timing belt housing. Completely unscrew the pulley mounting bolt and remove the pulley.
4. Install the timing belt to the crankshaft pulley, idler pulley, water pump pulley, fuel pump pulley and tension pulley.
Warning: When reinstalling the toothed belt, install it so that the arrow on the belt, marked before removing the belt, matches the direction of rotation of the engine pulleys. If the toothed belt rotates in the opposite direction after installation, cracks in the belt and engine failure may occur.
5. Center the fuel pump pulley section in the elongated hole and tighten the 3 bolts securing the pulley section to 20 Nm.
6. Install the camshaft timing belt pulley together with the timing belt and hand-tighten the pulley bolt.
TDI diesel engine
7. Using a wrench (e.g. HAZET 2587), turn the toothed belt tensioner clockwise until the marks on the tensioner roller and tensioner hub are aligned (arrows).
SDI diesel engine
8. Using an Allen wrench, turn the timing belt tensioner clockwise until the pointer aligns with the center of the adjusting tongue.
9. Tighten the clamping nut of the tension roller to 25 Nm.
10. Check the mounting position of the tension roller. The locking tab must be in the recess in the cylinder head. Otherwise, tighten the tension roller holder in the appropriate direction.
11. Check that the flywheel alignment mark is aligned with the pointer.
12. Tighten the camshaft pulley bolt to 45 Nm, while holding the camshaft from turning with a wrench by the camshaft flats.
13. Remove the high pressure fuel pump blocking pin.
14. Remove the camshaft lock tool.
15. Rotate the engine two full revolutions in the normal direction of rotation and reset the No. 1 cylinder to TDC on the compression stroke. Check that the locking pin can be installed in the high pressure fuel pump pulley mounting hole. Check and, if necessary, readjust the toothed belt tension.
16. Check that the tension roller pointer is aligned with the alignment mark. In this position, tighten the tensioner roller nut to 20 Nm.
17. Reinstall and bolt the lower toothed belt guard.
18. Install the crankshaft pulley and secure it with bolts, tightening them to a torque of 25 Nm. Keep in mind that the pulley is installed in only one position.
19. Establish the top casing of a gear belt.
20. Install the cylinder head cover.
21. Install and bolt the vacuum pump for the brake booster to the cylinder head.
SDI diesel engine
22. Install the intake manifold.
23. Tighten the bolts securing the right support of the power unit to the engine to 45 Nm.
24. Using new bolts, attach the holder to the right support and body and tighten the bolts to the required torque:
- support to the body: 40 Nm + tighten by 90°;
- support to the engine: 60 Nm + tighten by 90°.
25. Remove the fixture supporting the engine.
26. Install the V-belt tensioner and secure it with the bolt, tightening it to 25 Nm.
27. Install poly V-belt.
28. Install the lower engine mudguard.
29. Reinstall the expansion tank and the power steering reservoir.
TDI diesel engine
30. Install the pipe connecting the charge air cooler and the intake manifold.
31. Install the right headlight.
32. Check the injection timing of the high pressure fuel pump.
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