Pic. 415. The upper figure shows the adjusting gauge 1 mounted on the camshaft. The lower figure shows how the flywheel with the TDC mark should be located
When installing a new drive belt or reinstalling an old belt, first make sure the flywheel is in the position shown in fig. 415.
Loosen 1/2 turn the camshaft gear bolt (without turning the shaft) and hit it with a plastic or rubber mallet to loosen the bevel fit of the gear on the shaft. When using an old drive belt, install it in accordance with the marking regarding the direction of travel.
Screw the toothed belt guide roller (25 Nm) and remove the thrust pin from the injection pump gear.
Pic. 419. Installing a toothed belt. Pay attention to the coincidence of marks on the tension roller (inset with an arrow in the figure). Instead of a special tool, beveled pliers can be used to remove the snap rings: 1 - running roller; 2 - a special tool or wire cutters for removing spring retaining rings; 3 - tension roller; 4 - locking pin
Check the tension roller. It has a rib and a groove that must match each other. On fig. 419 shows what the belt looks like at this stage of installation.
Now press the tension roller with the circlip pliers against the tension of the spring (direction 3 in fig. 419) and tighten the tension roller nut to 20 Nm.
Fix the camshaft gear in a fixed position and tighten the bolt to 45 Nm.
Remove the adjusting gauge from the other side of the engine.
Reinstall all parts. Raise or lower the vehicle to the ground in order to be able to reach individual parts.
Turning the crankshaft pulley rotate the engine two full turns. After that, check if the TDC position is still correct.
After adjusting the drive belt, check the injection adjustment.
Install lower toothed belt guard (3 bolts).
Screw the crankshaft pulley with vibration damper onto the timing gear and tighten the four bolts to 25 Nm. The dowel pin on the crankshaft sprocket must fit into the hole on the vibration damper. When tightening the connection, fix the crankshaft in a stationary position (you can turn on the transmission).
Install the top toothed belt guard. It should enter the groove of the lower protection.
Install the belt drive, as well as the V-belt of the power steering pump and adjust their tension.
Pic. 393. Turn away bolts 1 and 2
Reinstall the front engine mount yoke (large bolts are tightened to 58 Nm, small bolts to 23 Nm) and engine mount. On fig. 393 shows the engine mount from the front.
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