Contents: Removal ↓ Installation ↓
VC1.078. Timing drive for 1.6L petrol engines BGU, VSE, BCF:
1. Screw: 10 Nm
- Apply thread locking compound
2. Middle part of the timing belt cover
3. Engine mount bracket
4. Screw: 45 Nm
5. Upper part of the timing belt cover
6. Screw: 23 Nm
7. Washer
8. Semi-automatic tension roller
9. Screw: 100 Nm
10. Timing pulley of the camshaft
- The mounting position is determined by a woodruff key
11. Screw: 10 Nm
- Apply thread locking compound
12. Screw: 23 Nm
- Apply thread locking compound
13. Rear toothed belt cover
14. Segment key
15. Sealing ring
- Replace with a new one
16. Coolant pump
17. Screw: 15 Nm
18. Crankshaft toothed pulley
- There should be no oil on the mating surfaces of the toothed pulley and the crankshaft
- Installation is possible only in one position
19. Screw: 90 Nm and tighten by 90°
- Replace with a new one
- Do not lubricate
20. Toothed belt
- Before removing, mark the direction of belt movement with chalk or a felt-tip pen
- Check for wear
21. Lower timing belt cover
22. Screw: 10 Nm
- Apply thread locking compound
Removal
1. Remove the engine cover.
2. Remove the poly V-belt.
3. Remove the retainer.
4. Disconnect the upper hose from the expansion tank of the cooling system.
5. Remove the expansion tank and set it aside.
6. Remove the upper part of the timing belt cover by following these steps.
- Turn the fastening screw (1) so that its slot is vertical.
- Press the clamps (arrows) upward and remove the upper part of the timing belt cover.
7. Install the crossbar (1) with the support (2) and hang the engine so that its supports are not loaded.
8. Remove the lower noise-insulating casing.
9. Remove the damper (pulley) from the crankshaft pulley hub.
10. Remove the middle and lower parts of the timing belt cover.
11. Unscrew the lower mounting bolt (1) of the engine support bracket.
12. Unscrew the engine mount mounting bolts (arrows) and completely remove the mount.
Caution! When supporting the engine using a crossmember, pay special attention to ensure that no components or hoses are damaged, twisted, or torn out of place.
13. Raise the engine using a crossmember as far as possible so that both upper engine mount bracket mounting bolts (2) and (3) can be loosened and removed (see figure VC1.082).
14. Remove the engine support bracket by lifting it upwards.
15. Rotating the crankshaft, set the camshaft toothed pulley to the TDC position of the first cylinder.
The mark on the camshaft toothed pulley must match the arrow on the timing belt cover.
16. Mark the direction of movement of the toothed belt.
17. Loosen the tension roller and remove the timing belt.
18. After this, turn the crankshaft back slightly.
Installation
When the camshaft rotates, the crankshaft should not be at TDC. This could damage the valves and piston crowns.
1. Install the timing belt on the crankshaft timing pulley and on the coolant pump timing pulley (observing the correct direction of belt movement).
2. Set the camshaft in such a position that the marks on the toothed pulley and the toothed belt cover coincide.
3. Install the middle and lower parts of the timing belt cover.
4. Install the crankshaft pulley onto the hub using new screws. Tightening torque: 10 Nm + 1/4 turn (90°).
5. Using the marks on the crankshaft pulley, bring the crankshaft to the TDC position of the first cylinder (arrow).
6. Install the toothed belt on the tension roller and camshaft pulley.
Attention should be paid to the correct position of the tension roller in the cylinder head.
7. Tighten the timing belt. To do this, use the special key (3) to turn the eccentric counterclockwise until the arrow (2) is slightly higher than the mark (1) (the belt is too tight).
8. Repeat this action (belt tension exceeding the belt force) five times to ensure the belt is installed correctly.
9. After this, loosen the belt so that the mark (1) and arrow (2) are aligned.
10. Tighten the nut to a torque of 20 Nm.
11. Turn the crankshaft two revolutions in the direction of engine rotation and again set it to the position corresponding to TDC of the first cylinder. The last 45° (1/8 turn) the crankshaft should rotate without stopping (and without increasing the force).
12. Check the belt tension again. Correct position: the mark and the arrow should be aligned.
13. Check the timing belt installation again. If the marks do not match, repeat the timing belt adjustment.
14. Install the bracket (top) on the cylinder block and tighten both top screws to 45 Nm.
15. Lower the engine to its final mounting position.
16. Install the lower mounting screw and tighten it to 45 Nm.
17. Install the engine mount assembly.
18. Using new screws, screw the support to the engine bracket (arrows), while lowering the engine using a crossbar until the bracket comes into contact with the support. Tightening torque: 60 Nm and turn further by 90° (1/4 turn).
19. Remove the crossmember.
20. Install the upper part of the timing belt cover.
21. Install the poly V-belt.
22. Install the expansion tank of the cooling system.
23. Install the lower noise-insulating casing.
24. Install the engine cover.
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