Table of contents: Camshaft drive ↓ Fuel injection pump drive ↓
Camshaft drive
1. Front camshaft gear; 2. Side plate; 3. Toothed belt; 4. Intermediate roller; 5. Fastening bolt, 7 Nm (insert with regular protective agent); 6. Upper timing belt cover; 7. Central element of the toothed belt casing; 9. Crankshaft gear; 10. Crankshaft belt pulley; 11. Cooling system pump belt pulley; 12. Tension roller; 13. Return spring
High pressure fuel pump drive TNVD
1. Toothed belt; 2. Spring; 3. Tension roller; 4. Segment key; 5. Timing belt cover; 6. Fuel injection pump gear; 7. Rear camshaft gear
Camshaft drive
Removal
1. Disconnect the ground cable from the battery.
Warning! This will erase the electronic memory, such as the radio code. Before disconnecting the battery, read the instructions in subsection 7.2.
2. Unscrew the cylinder head cover.
3. Set the piston of the 1st cylinder to the TDC position.
4. To do this, put the gearbox in neutral and apply the handbrake.
5. Turn the crankshaft by the central bolt in the direction of engine rotation (clockwise), so that the notch on the crankshaft belt pulley is opposite the arrow on the engine block.
6. At the same time, the camshaft should be positioned so that the cams of the 1st cylinder are facing upwards.
7. Otherwise, turn the crankshaft 1 revolution forward in the direction of engine rotation.
8. The second option for turning the crankshaft is to lift the front of the car on one side, engage 5th gear and turn the wheel by hand.
9. Raise the engine with a jack and shim to clear the front engine mount.
10. Unscrew the front integrated engine console.
11. Remove the alternator V-belt.
12. If present, remove the servo pump and air conditioning compressor V-belt.
Attention! After the engine is set to the TDC position, turn off the transmission and check again whether the mark on the crankshaft belt pulley matches the arrow on the engine block, adjust if necessary. If the marks match, do not change the engine installation under any circumstances.
13. Unscrew the water pump belt pulley.
14. Block the engine and unscrew the crankshaft belt pulley mounting bolt.
15. To immobilize the engine, engage 5th gear and ask an assistant to press the brake pedal.
16. Remove the crankshaft pulley using a standard puller.
Caution! The puller hooks must only engage the back side of the belt pulley.
17. Remove the upper and lower timing belt covers.
18. If the old belt is to be used again, it should be marked. An arrow should be put on the belt with a felt-tip pen indicating the direction of rotation. The engine rotates clockwise.
19. Turn the tension roller bolt with the Allen key - direction of the arrow (1), and the tension roller with the second key (2) counterclockwise until the toothed belt is loosened. Tighten the tension roller bolt back.
20. Unscrew the side plate from the camshaft gear.
21. Unscrew the intermediate roller.
22. Remove the timing belt from the crankshaft gear.
Caution! Do not change the TDC position of the camshaft and crankshaft any further. If you need to turn the camshaft with the timing belt removed, make sure that the crankshaft is not in the TDC position (otherwise there is a risk of damage to the valves and pistons). To do this, mark the position of the crankshaft gear (apply a color mark to the crankshaft gear and to the cylinder block). Then turn the crankshaft gear 1/4 turn (90°) forward or backward.
Installation
1. Check the condition of the timing belt.
2. Check the belt tensioner for rust, damage and ease of movement.
3. If removed, install the crankshaft gear side plate with the chamfered portion facing the engine.
4. Make sure that the camshaft and crankshaft are in the TDC position of the piston of the 1st cylinder. The woodruff key of the crankshaft in the TDC position points vertically upwards.
5. Screw on the intermediate roller with a torque of 40 Nm.
6. Install the toothed belt with the crankshaft gear. When doing this, take into account the rotation direction mark applied during removal. A used belt should only rotate in the same direction as before.
7. Tighten the crankshaft belt pulley to 150 Nm.
8. To hold, engage 5th gear and ask an assistant to press the brake pedal.
9. Align the white line on the timing belt with the mark on the camshaft and crankshaft gear (C). The marks (B) on the timing belt are 43 teeth apart (dimension A).
10. The arrow on the timing belt should point towards the casing.
11. Tighten the camshaft gear side plate to 7 Nm. Pre-coat the bolts with Loctite.
12. Loosen the belt tensioner clamp bolt so that the tensioner presses the belt.
13. Turn the crankshaft 2 turns clockwise, this will cause the tensioner to give the belt the correct tension.
14. Before the end of the 2nd revolution, insert the flat feeler gauge (1) from above, arrow between the toothed belt (3) and the intermediate gear (2). Dimensions of the feeler gauge: width – 12.5 mm, length – 150 mm, thickness – 0.3 mm.
15. Tighten the tension roller clamping screw to 40 Nm, while holding the roller from turning with a wrench, otherwise the belt tension may decrease.
16. Check the TDC position of the camshaft and crankshaft again. All TDC marks with the timing belt tensioned should coincide simultaneously; repeat the adjustment if necessary.
17. Turn the crankshaft slightly counterclockwise and remove the dipstick.
18. Screw the lower and upper casings with a torque of 5 Nm.
19. Tighten the crankshaft pulley using the central bolt with a torque of 120 Nm.
20. To lock the crankshaft, engage 5th gear and ask an assistant to press the brake pedal.
21. Tighten the coolant pump belt pulley to 10 Nm.
22. Install the V-belt.
23. Screw on the cylinder head cover.
24. Screw on the coolant pump belt pulley.
25. Bolt the front integrated engine console.
26. Connect the battery ground cable.
Fuel injection pump drive
Removal
1. Set the piston of cylinder 1 to the TDC position.
2. Remove the air duct with the air filter.
3. Unscrew the timing belt cover.
4. Loosen the tension roller nut with an offset spanner and press the tension roller in the direction of the arrow with a screwdriver until the timing belt is loosened.
5. Tighten the tensioner roller nut back.
Caution: To protect the tension roller, wrap the screwdriver in cloth.
6. Remove the belt.
Caution! Do not change the TDC position of the camshaft and the fuel injection pump gear when the timing belt is removed.
Installation
1. Check the condition of the timing belt.
2. Check the belt tensioner for rust, damage and ease of movement.
3. Make sure that the camshaft and fuel injection pump are in the TDC position of the piston of the 1st cylinder.
4. Install the timing belt.
5. Align the white lines on the belt with the marks on the camshaft gear and the fuel injection pump gear (C). The marks (B) on the belt are spaced at a distance of A - 23 teeth.
6. The arrow on the timing belt must point towards the casing.
7. Loosen the tensioner roller clamp nut to allow the tensioner to press on the belt.
8. Turn the crankshaft 2 turns clockwise, the tensioner will give the timing belt the correct tension.
Caution! Do not turn the engine by the camshaft gear, otherwise the timing belts will be overloaded.
9. Tighten the tension roller clamp nut to 20 Nm, while holding the tension roller with a screwdriver, otherwise the timing belt tension may decrease.
10. Check the TDC setting of the camshaft and the injection pump again. All TDC marks with the timing belt tensioned should coincide simultaneously; repeat the adjustment if necessary.
11. Tighten the timing belt cover with a torque of 5 Nm.
12. Install the air duct with air filter.