Attention! When the cable is disconnected from the negative battery terminal, the memory of electronic storage devices, such as engine trouble memory or radio code, is erased.
Front toothed belt
Removing
Disconnect the wire from the negative battery terminal.
Raise the car and remove the right front wheel.
Remove the lower engine cover in the right wheel arch.
Remove the V-belt.
Pic. 4.2. Removing the pulley from the crankshaft
Fix the crankshaft of the engine from turning and unscrew the bolts of the crankshaft belt pulley (pic. 4.2).
To block the engine, engage 5th gear, and the assistant must press the brake pedal.
Remove glow plugs. To crank the engine, apply the parking brake and place the transmission lever in neutral. Turn the crankshaft from the side of the right wheel arch using a wrench and socket.
Pic. 4.3. Removing the engine damper
Loosen the bolts and remove the engine damper (pic. 4.3).
Pic. 4.4. Removing the right and left toothed belt covers
Remove the right and left toothed belt covers (pic. 4.4).
Pic. 4.5. Label Alignment (1) on the toothed belt pulley with the mark (2) on the rear casing when the piston of the first cylinder is set to TDC on the compression stroke
Set the piston of the first cylinder to TDC on the compression stroke. To do this, turn the engine crankshaft until the mark on the camshaft pulley aligns with the mark on the rear toothed belt casing (pic. 4.5).
Attention! Never turn the crankshaft by the camshaft pulley through the belt drive.
Pic. 4.6. Deflection direction of the tensioner pulley to loosen the tension of the toothed belt
Loosen the tensioner roller mounting bolt and use a screwdriver to press the tensioner roller away from the toothed belt (pic. 4.6). After loosening the tension of the toothed belt, tighten the tension roller mounting bolt again.
Chalk, marker or paint mark the direction of rotation of the toothed belt. If the toothed belt rotates in the opposite direction during installation, this will lead to its destruction. The motor pulleys rotate clockwise.
Remove the toothed belt. After removing the toothed belt, do not rotate the pulleys.
If it is necessary to rotate the camshaft, first install all the pistons in the middle of their stroke. To do this, put a mark with chalk on top of the crankshaft pulley, while the crankshaft should be in the TDC position of the first cylinder, then turn the crankshaft pulley 1/4 turn (90°) left or right. Now the label should be directed respectively to the left or to the right.
Attention! Before removing the toothed belt, check again that the mark on the camshaft pulley matches the edge of the cylinder head, and if necessary, correct the position of the pulleys.
Attention! If it is necessary to rotate the camshaft with the toothed belt removed, no piston must be at TDC, otherwise the pistons and valves may be seriously damaged.
Attention! Do not kink or twist the toothed belt. Be sure to replace dirty, damaged or worn belts. Check up uniformity and ease of rotation of a tension roller.
Installation
Pic. 4.7. Label Alignment (1) on the crankshaft pulley with a mark on the front cover of the cylinder block
Make sure the mark on the crankshaft pulley matches the mark on the front cover of the cylinder block (pic. 4.7), and the mark on the camshaft pulley matches the mark on the rear toothed belt guard. If necessary, turn the pulleys until all marks are aligned.
Install the toothed belt onto the pulleys. Apply the old belt in accordance with the previously applied arrow indicating the direction of rotation of the belt.
Attention! Make sure the belt fits the pulleys well and does not sag.
Belt tension adjustment
Loosen the tensioner pulley mounting bolt just enough to allow the pulley to move against the toothed belt under spring force. Rotate the crankshaft two turns clockwise until the camshaft mark is aligned with the mark on the rear toothed belt guard. Check again that all labels match.
Tighten the tension roller mounting bolt to 45 Nm.
Turn the crankshaft two turns in the direction of engine rotation and recheck the alignment of the marks.
Pic. 4.8. Check point for toothed belt deflection
The branch of the toothed belt between the pulleys of the water pump and the camshaft should bend by 10.5–12.0 mm when the belt is pressed with a force of 10 kgf (strong finger pressure) (pic. 4.8). Otherwise, loosen the idler pulley mounting bolt and adjust the belt tension again.
Install and bolt the right and left toothed belt guards by tightening the bolts to 10 Nm. Install and secure vibration damper (shock absorber) engine.
Install the crankshaft pulley with washer and secure with bolts, tightening them with a torque of 30 Nm.
Screw in glow plugs.
Install and tension the V-belt.
Establish a casing in the right wheel arch.
Connect the wire to the negative battery terminal.
If you have a clock, set the time and enter the security code into the radio.
Rear toothed belt
Removing
Disconnect the wire from the negative battery terminal.
Attention! When the cable is disconnected from the negative battery terminal, the memory of electronic storage devices, such as the radio code, is erased.
Remove glow plugs.
Pic. 4.9. Rear toothed belt: 1 – a cover of a head of the block of cylinders; 2 – a nut of fastening of a tension roller; 3 – a casing of a gear belt
Turn out bolts and remove a casing of a back gear belt (pic. 4.9).
Loosen the toothed belt tensioner nut.
Pic. 4.10. Releasing tension on the rear toothed belt: 1 - screwdriver; 2 - hex key
Use a screwdriver to remove the tension roller from the toothed belt and tighten the nut (pic. 4.10).
Chalk, marker or paint mark the direction of rotation of the toothed belt. If the toothed belt rotates in the opposite direction during installation, it will collapse. The motor pulleys rotate clockwise.
Attention! Do not kink or twist the toothed belt. Be sure to replace dirty, damaged or worn belts. Check up uniformity and ease of rotation of a tension roller.
Installation
To turn the crankshaft of the engine, lift the front wheel of the car, engage 5th gear and turn the wheel by hand.
Attention! Never turn the engine crankshaft by the camshaft pulley to avoid overloading the front timing belt.
Pic. 4.11. Label Alignment (3) on the camshaft pulley (2) and high pressure fuel pump (1) with markings on the rear toothed belt guard
Rotate the camshaft and fuel pump pulleys so that the marks on the pulleys line up with the marks on the rear toothed belt guard (pic. 4.11).
Install the toothed belt onto the pulleys. Apply the old belt in accordance with the previously applied arrow indicating the direction of rotation of the belt.
Attention! Make sure the belt fits the pulleys well and does not sag.
Belt tension adjustment
Loosen the tensioner pulley mounting bolt so that the pulley can move against the toothed belt under spring force. Rotate the crankshaft two turns clockwise until the camshaft mark is aligned with the mark on the rear toothed belt guard. Check again that all labels match.
Tighten the tension roller mounting bolt to 25 Nm.
Turn the crankshaft two turns in the direction of engine rotation and recheck the alignment of the marks.
The branch of the toothed belt between the pulleys of the high pressure fuel pump and the camshaft must bend by 9.5–12.0 mm when the belt is pressed with a force of 10 kgf (strong finger pressure). Otherwise, loosen the idler pulley mounting bolt and adjust the belt tension again.
Install and bolt the toothed belt guard by tightening the bolts to 10 Nm.
Screw in glow plugs.
Connect the wire to the negative battery terminal.
If you have a clock, set the time and enter the security code into the radio.