Removing the engine damper
Removal of fastening of a back casing of a gear belt
Unscrew the mount (1). loosen the nut (4) tension belt.
Toothed belt loosening
Turn the tension roller as far as possible with a screwdriver (1) to the right and tighten the nut (2) tension roller.
Suspension installation
Install the engine mount by tightening (A) with a force of 115 Nm. and a nut (IN) with a force of 90 Nm.
Toothed belt wear
Setting the valve timing should usually be done after repair work, in which the toothed belt was removed or the engine was disassembled. When checking the installation of the valve timing, all steps should be carried out except for replacing the toothed belt.
Removing
1. Disconnect the negative ground cable from the battery.
Attention! This erases the contents of electronic storage devices, such as engine defect memory or radio code. Read before disconnecting the battery subsection 2.11.
2. Raise the car and remove the right front wheel.
3. Remove the lower engine cover in the right wheel arch.
4. Remove the V-belt.
5. Block the engine. To lock the engine, engage 5th gear and have an assistant depress the brake pedal. Loosen the crankshaft pulley bolts.
6. Remove the crankshaft pulley.
7. Remove glow plugs.
8. To turn the engine crankshaft, apply the handbrake and place the transmission in neutral. Turn the crankshaft from the side of the right wheel arch using a wrench and socket.
Attention! Never turn the crankshaft at the camshaft wheel through the toothed belt drive.
9. Release the tension roller bolt and press the tension roller away from the toothed belt with a screwdriver until the tension of the toothed belt is loosened. Re-tighten the idler pulley bolt.
10. Remove the right and left toothed belt guard.
11. Remove the toothed belt. After that, do not turn the gear wheels.
Attention! Before removing, check once again whether the mark on the camshaft wheel coincides with the edge of the cylinder head, correct if necessary.
Attention! If it is necessary to rotate the camshaft with the toothed belt removed, neither piston should be at TDC. Otherwise serious damage to pistons and valves may occur.
12. If it is necessary to rotate the camshaft, set all pistons to half their stroke in advance. To do this, put a mark with chalk on top of the crankshaft wheel.
13. Set cylinder 1 to TDC before marking. To do this, turn the crankshaft until the marks match (1) on the camshaft gear (2) labeled on the front plate. Then rotate the crankshaft wheel 1/4 turn (90°) left or right. The label should now be facing left or right.
Installation
Attention! Do not bend or twist the toothed belt. Be sure to replace dirty, damaged or worn belts. Check up uniformity and ease of the course of a tension roller.
1. Check belt wear.
2. Apply toothed belt. When applying the old belt, apply according to the marked arrow in the direction of rotation.
Attention! Make sure the belt fits the rollers well and does not sag.
Tension
1. Loosen the idler pulley bolt just enough to allow the idler pulley to move against the toothed belt under spring force.
2. Turn the crankshaft two turns clockwise until the marks on the camshaft and front plate match. Check again that all labels match.
3. Tighten the tension roller bolt to 45 Nm.
4. Turn the crankshaft two turns in the direction of engine rotation and recheck the adjustment.
5. The section of the belt between the rollers of the water pump and the camshaft must bend by 10.5–12.0 mm from a force of 10 kg (strong finger pressure), if not, loosen the idler bolt and tighten the belt again.
6. Install and secure with a force of 10 Nm the right and left toothed belt covers.
7. Install and secure the engine damper.
8. Install the crankshaft pulley with washer and tighten the mounting bolts with a force of 30 Nm.
9. Install glow plugs.
10. Install and tension the V-belt.
11. Establish a casing in the right wheel arch.
12. Connect the negative ground cable to the battery.
13. If there is a clock, set the time and set the security code for the radio.