Removing
1. Place the machine on stands.
2. Remove the lower engine compartment cover.
3. Take the car off the stands.
4. Remove V-belt.
5. Set the crankshaft to TDC for the first cylinder. Rotate the crankshaft clockwise.
6. The crankshaft is at TDC if the camshaft gear mark matches the mark on the rear toothed belt cover.
7. At the same time, the mark on the flywheel or clutch disc must match the TDC mark. The figure shows both corresponding marks on the vibration damper and on the toothed belt guard. These marks are used to adjust the TDC on the removed engine.
8. Remove upper toothed belt cover. Using a felt-tip pen or a grease pencil, mark an arrow on the belt in the direction of its movement. The engine rotates when viewed from the front, clockwise to the right.
9. Loosen toothed belt (see subsection 2.5.1.3).
10. Unscrew the vibration damper from the crankshaft timing belt gear by unscrewing 4 M8 bolts.
11. Remove toothed belt.
Attention! The toothed belt must not have cuts. A toothed belt with cuts must always be replaced, as it can break during operation, which will lead to severe engine damage.
12. Do not change the position of the toothed belt gears if possible.
Installation
Attention! If an old toothed belt is to be installed, be sure to pay attention to the direction of travel. Installing the toothed belt in the opposite direction can cause it to break and cause engine damage!
1. Fit the toothed belt over the crankshaft gear, idler pulley and water pump.
2. Screw the vibration damper with 4 bolts to a torque of 20 Nm.
3. Screw on the lower toothed belt cover. If not, turn the camshaft until the mark on the camshaft drive gear is aligned with the upper edge of the cylinder head cover gasket.
Attention! If the camshaft rotates with the toothed belt removed, then not a single piston should be at TDC. Otherwise severe damage to the pistons or valves may occur.
Attention! If it is necessary to rotate the camshaft, first set all pistons to the same height. To do this, put a chalk mark on top of the crankshaft pulley (precondition: crankshaft in TDC position for 1 cylinder), then rotate the crankshaft pulley 1/4 turn (90°) left or right, guided by the chalk mark.
4. Check the position of the crankshaft at TDC for the 1st cylinder. The TDC mark should be visible in the inspection hole of the clutch housing (0) on the flywheel, standing exactly next to the mounting edge.
5. If the toothed belt is to be installed on a removed engine, then the notch on the belt pulley must match the alignment mark on the cylinder head cover. In this case, the crankshaft is in the TDC position for 1 cylinder.
6. Put on the toothed belt.
Attention! When installing a toothed belt, do not change the position of the camshaft and crankshaft. Otherwise, the engine may be severely damaged or may not develop full power. After tensioning the toothed belt, check the position of the camshaft and crankshaft again. This means: if the mark on the camshaft gear coincides with the upper edge of the cylinder head cover gasket, then at the same time the TDC mark on the flywheel must coincide with the corresponding mark. Otherwise, repeat the adjustment of the camshaft drive gear and crankshaft gear.
7. Pull on toothed belt.
8. Rotate the crankshaft 2 turns in the direction of rotation and recheck the adjustment and tension.
9. Install the upper toothed belt cover.
10. Screw on the V-belt tensioner.
11. Install and tighten the V-belt.
12. Install the engine mudguard.
13. For repairs that require the toothed belt to be removed from the camshaft gear only, adjust the toothed belt as follows:
- set the crankshaft to TDC for 1 cylinder;
- loosen and remove the toothed belt from the camshaft gear;
- put on and tighten the toothed belt;
- Do not change the position of the camshaft and crankshaft during repairs.
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