Removing
1. Remove V-belt (see subsection 2.12.1).
2. Set the crankshaft to TDC for cylinder 1 and do not change the position again.
Installing the engine at TDC for 1 cylinder
1. Remove upper toothed belt cover.
2. Remove the plug on the clutch housing.
3. Rotate the engine shaft until the TDC marks are aligned.
4. The rotation of the motor shaft can be carried out in various ways:
- lift one edge of the car so as to free the wheel and, having previously engaged 5th gear, rotate the front wheel;
- place the machine on a level surface. Engage 5th gear. Push the car forward or backward;
- put the gearbox in neutral position. Tighten the handbrake. Remove the lower engine mudguard. Rotate the crankshaft using the center bolt of the vibration damper.
Attention! Do not rotate the engine using the camshaft bolt, otherwise the toothed belt may be overloaded.
5. Rotate the engine until the camshaft reaches the TDC position for 1 cylinder. In this case, the mark on the camshaft drive gear must match the mark on the toothed belt housing. There are 2 versions (indicated by arrow A and arrow B).
6. In this case, the mark on the flywheel (0) or the clutch driven disk must match the TDC mark. Otherwise, rotate the crankshaft further.
7. Disconnect the vibration damper from the crankshaft.
8. Remove upper and lower toothed belt guard.
9. Loosen and remove toothed belt.
Installation
1. Check the TDC position of the camshaft, crankshaft and intermediate shaft, adjust if necessary.
2. Check the position of the camshaft at TDC for the first cylinder. The mark on the camshaft drive gear in this case matches the mark on the toothed belt guard. If necessary, carefully turn the camshaft with the toothed belt removed.
Attention! If it is necessary to rotate the camshaft with the toothed belt removed, no piston should be at TDC. To do this, apply a colored strip to the vibration damper and turn the crankshaft 90°forward or backward. Finally, if the camshaft was set to TDC for cylinder 1, set the crankshaft back to TDC for cylinder 1. A vibration damper is used to rotate the crankshaft.
3. At the same time, the crankshaft must be in the TDC position. In this case, the mark on the flywheel or clutch disc must match the TDC mark.
4. At the same time, the mark on the distributor slider must match the mark on the edge of the distributor housing. Otherwise rotate the intermediate gear accordingly. To perform this test, remove the distributor cap, remove the distributor runner, remove the dust cap, and finally reinstall the runner.
5. Check the simultaneous match of all 3 labels. In this case, the engine is in the TDC position for 1 cylinder.
6. Fit the timing belt to the crankshaft gear, camshaft drive gear and idler gear.
Attention! When installing a toothed belt, do not change the position of the camshaft, crankshaft or intermediate shaft. Failure to do so may result in severe engine damage or the engine will not develop full power.
Attention! After tensioning the belt, check the position of the camshaft, countershaft and belt pulley again. This means: if the mark on the camshaft drive gear matches the corresponding mark on the toothed belt housing, it must simultaneously match the mark on the flywheel and the mark on the ignition distributor. Otherwise, repeat the installation with the toothed belt removed.
7. Screw on the vibration damper.
8. Pull on toothed belt.
9. Turn the crankshaft twice in the direction of engine rotation and check the setting again.
10. Remove vibration damper.
11. Install the lower toothed belt cover.
12. Install the upper toothed belt cover.
13. Install vibration damper and tighten to 25 Nm.
14. Install the dust cap, then the distributor cap.
15. Install and tighten V-belt (see subsection 2.12.1).
16. Check ignition timing, adjust if necessary.
Attention! For repairs that require removal of the toothed belt from the camshaft drive gear only, adjust the toothed belt as described below.
17. The mark on the camshaft drive gear must match the mark on the cylinder head cover.
18. Loosen the toothed belt and remove the camshaft drive gear.
Attention! Do not change the position of the camshaft and intermediate shaft any more.
19. Put on and tension the toothed belt.
20. Remove the ignition distributor cap. Check the installation of the distributor on the slider and mark.
21. Turn the crankshaft 2 turns and check the alignment of the camshaft and crankshaft marks.
22. Check ignition timing, adjust if necessary (see subsection 2.14.6).
23. Let the engine run. If the toothed belt whistles, it will be over tightened.
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