Removing
Attention: risk of fuel leakage! The fuel in the power system is under pressure. Before disconnecting the elements of the system, the connection point must be wrapped with rags. Then, carefully loosening the connection, you need to relieve pressure.
Attention: the adjustment of the toothed belt is carried out only on a cold engine, because The adjustment position of the tensioner changes depending on the temperature.
1. Remove the engine cover. For this engine cover in front (arrow A) pull sharply from the rear mount up and then forward (arrow B).
2. Disconnect the fuel injection hose (2), fuel return hose (1), as well as the coolant hose (3).
3. Remove the connecting pipe between the charge air cooler and the exhaust pipe, to do this, slightly lift the clamps (arrows).
4. After pulling out the latches, disconnect the pressure (3) and reverse (2) fuel lines.
5. Remove the fuel filter from the bracket (arrow).
6. Unscrew the bolt on the neck (1) washer tank.
7. Unscrew the bracket (3) fuel filter.
8. Disconnect the electrical connector on the coolant expansion tank (1),
9. Unscrew expansion tank (Do not disconnect the hoses that are connected to it) and take him aside.
10. Remove poly V-belt.
11. Remove the poly V-belt tensioner.
12. To remove the top protective casing of a gear belt.
13. Remove the fender liner of the front right wheel arch.
14. Remove the crankshaft pulley.
15. To remove the bottom and average casings of a gear belt.
16. Bring the crankshaft to the TDC position of the first cylinder.
17. Turn the crankshaft until the mark on its toothed pulley and the toothed segment of the camshaft pulley are in the upper position. In this case, the mark on the camshaft pulley must match the mark on the timing belt housing behind the pulley (arrow).
18. Fix the hub with the clamp. To do this, insert the retainer into the hole in the cylinder head through the free concentric groove on the left side of the camshaft sprocket.
19. Fix the crankshaft sprocket. The marks on the crankshaft sprocket and on the crankshaft retainer must match. In this case, the latch pin must enter the hole in the front cover of the cylinder block.
20. Mark the direction of travel of the toothed belt.
21. Loosen the fastening screws (1) camshaft pulley so that it can rotate in concentric grooves.
22. Loosen the nut (1) tension roller attachment.
23. Rotate the tension roller eccentric with a socket wrench counterclockwise (arrow) until the tensioner roller can be secured with the retainer.
24. Turn the eccentric of the tension roller clockwise (arrow) to the stop and tighten the fixing nut (1) by hand.
25. Remove the toothed belt first from the coolant pump pulley, and then from the remaining toothed pulleys.
Installation
1. Fix the camshaft with a retainer (1).
2. Fix the crankshaft with the crankshaft lock.
3. Fix the tension roller with a retainer and secure with a nut in the extreme right position.
4. Turn the camshaft pulley so that it takes a middle position in the concentric grooves (arrows).
5. Pass the toothed belt between the motor support and the motor.
6. Install the toothed belt on the crankshaft pulley, idler pulley, camshaft pulley and idler pulley.
7. Lastly, the belt is installed on the coolant pump pulley.
8. Ensure the correct position of the tensioner roller in the rear toothed belt housing (arrow).
9. To take a clamp from a tension roller.
10. Loosen the fixing nut (1) tension roller.
11. Turn the eccentric of the tension roller with a socket wrench clockwise (arrow) until the pointer (2) will not be in the middle of the hole in the base. The fastening nut must not rotate.
12. Holding the tension roller in this position, tighten the fixing nut as follows: 20 Nm and tighten 1/8 turn (45°).
13. Install the camshaft sprocket retainer with pins as shown.
14. Apply force to the retainer in the direction of the arrow to hold the toothed pulley.
15. Tighten in this position the fixing screws of the camshaft pulley (1) torque 25 Nm.
16. Remove the locking pin of the camshaft hub and the crankshaft retainer (T10050 or T10100).
17. Fix the camshaft hub with a clamp.
18. Check if it is possible to fix the crankshaft in this position with a clamp (Т10050 or 710100). If the crankshaft cannot be fixed, then the following steps must be performed..
- Loosen the fixing screws (1) camshaft pulley.
- Slightly rotate the crankshaft in the opposite direction until the detent pin is almost at the corresponding hole in the crankshaft cover (arrow).
- Rotate the crankshaft in the running direction so that the lock pin enters the hole during rotation.
19. Install the toothed pulley retainer (2) camshaft with pins (3), as it shown on the picture.
20. Apply force to the retainer in the direction of the arrow to hold the toothed pulley.
21. Tighten in this position the fixing screws of the camshaft pulley (1) torque 25 Nm.
22. Remove the locking pin of the camshaft hub (4) and crankshaft lock (T10050 or T10100).
23. Turn the crankshaft two turns in the direction of engine rotation so that the piston of the 1st cylinder takes a position close to TDC.
24. Repeat the check and, if necessary, adjust.
25. Install the middle and bottom casings of the toothed belt.
26. Install vibration damper/pulley. Tightening torque: 10 Nm + 90° (1/4 turn).
27. Install poly V-belt.
28. To establish the top protective casing of a gear belt.
29. Install the right front fender liner.
30. Install the expansion tank of the cooling system.
31. Screw the fuel filter bracket to the engine support with a torque of 8 Nm (arrows).
32. Fix the fuel filter in the bracket.
33. Screw the neck of the washer reservoir.
34. Install the engine cover.
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