Camshaft drive
1. Front camshaft gear; 2. Side plate; 3. Toothed belt; 4. Intermediate roller; 5. Mounting bolt, 7 Nm (insert with normal protective agent); 6. Upper casing of the toothed belt; 7. The central element of the casing of the toothed belt; 9. Crankshaft gear; 10. Belt pulley of the crankshaft; 11. Belt pulley of the pump of the cooling system; 12. Tension roller; 13. Return spring
High pressure fuel pump drive
1. Toothed belt; 2. Spring; 3. Tension roller; 4. Segment key; 5. Timing belt cover; 6. High pressure fuel pump gear; 7. Rear camshaft gear
Camshaft drive
Removing
1. Disconnect the ground cable from the battery.
Attention! As a result, the electronic memory, such as the radio code, is erased. 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, place the transmission in neutral and apply the handbrake.
5. Turn the crankshaft at the central bolt in the direction of engine rotation (clockwise), so that the notch on the crankshaft pulley is opposite the arrow on the engine block.
6. At the same time, the camshaft must be positioned so that the cams of the 1st cylinder are facing up.
7. Otherwise turn the crankshaft 1 turn forward in the direction of engine rotation.
8. The second possibility of turning the crankshaft: raise the front of the car on one side, engage 5th gear and turn the wheel by hand.
9. Raise the engine with a shim jack to free the front engine mount.
10. Unscrew the front integrated engine console.
11. Remove the alternator V-belt.
12. If so, remove the V-belt for the servo pump and A/C compressor.
Attention! After the engine is set to TDC, turn off the gear and check again whether the mark on the crankshaft pulley matches the arrow on the engine block, correct if necessary. If the marks match, do not change the engine setting in any case.
13. Unscrew the water pump pulley.
14. Block the engine and unscrew the crankshaft pulley bolt.
15. To block the engine, engage 5th gear and ask an assistant to press the brake pedal.
16. Remove the crankshaft pulley with a conventional puller.
Attention! The puller hooks must only engage on the reverse side of the belt pulley.
17. Remove the top and bottom timing belt guards.
18. If the old belt is used again, it should be marked. An arrow should be marked on the belt with a felt-tip pen indicating the direction of rotation. The motor rotates clockwise.
19. Turn the idler pulley bolt with an Allen key - direction of the arrow (1), and the tension roller using the second key (2) counterclockwise until the toothed belt is loosened. Retighten the idler pulley bolt.
20. Unscrew the side plate from the camshaft gear.
21. Unscrew the intermediate roller.
22. Remove the toothed belt from the crankshaft gear.
Attention! Do not change the TDC position of the camshaft and crankshaft any more. If you need to turn the camshaft with the toothed belt removed, make sure that the crankshaft is not in the TDC position (otherwise there is a risk of damage to valves and pistons). To do this, mark the position of the crankshaft gear (put a color mark on the crankshaft gear and on the cylinder block). Then turn the crankshaft gear 1/4 turn (90°) forward or backward.
Installation
1. Check the condition of the toothed belt.
2. Check the belt tensioner for rust, damage and ease of movement.
3. If removed, install the crankshaft gear side plate with the beveled 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 crankshaft key at TDC points vertically upwards.
5. Screw the intermediate roller with a force of 40 Nm.
6. Install the timing belt with the crankshaft gear. Pay attention to the marking for the direction of rotation made during removal. A used belt should only rotate in the same direction as before.
7. Tighten the crankshaft pulley to 150 Nm.
8. To hold, turn on the 5th gear and ask the assistant to press the brake pedal.
9. Align the white dash on the timing belt with the mark on the camshaft and crankshaft gear (WITH). Tags (IN) 43 teeth apart on toothed belt (size A).
10. The arrow on the timing belt must point towards the cover.
11. Screw in the camshaft gear side plate to 7 Nm Pre-coat the bolts with a protective agent "Loctite".
12. Loosen the belt tensioner clamping bolt so that the tensioner presses the belt.
13. Turn the crankshaft 2 turns clockwise, while the tensioner will give the belt the correct tension.
14. Before the end of the 2nd revolution, insert a flat feeler (1) top, arrow between toothed belt (3) and intermediate gear (2). Probe dimensions: width - 12.5 mm, length - 150 mm, thickness - 0.3 mm.
15. Tighten the clamping screw of the tension roller with a force of 40 N.m, while keeping the roller from turning with a wrench, otherwise the belt tension may decrease.
16. Recheck the TDC position of the camshaft and crankshaft. All TDC marks with a tensioned, toothed belt must match at the same time, repeat the adjustment if necessary.
17. Turn the crankshaft slightly counterclockwise and pull out the dipstick.
18. Screw the lower and upper casing with a force of 5 Nm.
19. Screw the crankshaft pulley to the central bolt with a force of 120 Nm.
20. To fix the crankshaft, turn on the 5th gear and ask the assistant to press the brake pedal.
21. Screw the belt pulley of the coolant pump with a force of 10 Nm.
22. Install the V-belt.
23. Screw on the cylinder head cover.
24. Screw on the water pump pulley.
25. Screw on the front built-in engine console.
26. Connect the battery ground cable.
HPFP drive
Removing
1. Set the piston of cylinder 1 to the TDC position.
2. Remove the air duct with the air filter.
3. Unscrew the toothed belt cover.
4. Loosen the tensioner nut with a bent ring wrench and press the tensioner with a screwdriver in the direction of the arrow until the toothed belt is loose.
5. Retighten the idler nut.
Attention! Wrap a cloth around the screwdriver to protect the tensioner.
6. Remove the belt.
Attention! Do not change the TDC position of the camshaft and injection pump gear with the toothed belt removed.
Installation
1. Check the condition of the toothed belt.
2. Check the belt tensioner for rust, damage and ease of movement.
3. Make sure that the camshaft and high pressure pump are in the TDC position of the piston of the 1st cylinder.
4. Install the toothed belt.
5. Align the white marks on the belt with the marks on the camshaft gear and injection pump gear (WITH). Tags (IN) on the belt they are separated by a distance A - 23 teeth.
6. The arrow on the toothed belt must point towards the cover.
7. Loosen the tensioner clamp nut so that the tensioner presses on the belt.
8. Turn the crankshaft 2 turns clockwise, while the tensioner will give the toothed belt the correct tension.
Attention! Do not turn the engine by the camshaft gear, otherwise the timing belts will be overloaded.
9. Tighten the clamping nut of the tensioner roller with a force of 20 N.m, while holding the tensioner roller with a screwdriver, otherwise the toothed belt tension may decrease.
10. Check the TDC setting of the camshaft and injection pump again. All TDC marks with the toothed belt tensioned must coincide at the same time, repeat the adjustment if necessary.
11. Screw the toothed belt cover with a force of 5 Nm.
12. Install the air duct with the air filter.