General information
See Bringing the piston of the first cylinder to the position of the top dead center of the compression stroke (TDC).
How to perform the procedure
Bringing any of the pistons to the TDC position is done by turning the crankshaft of the engine. When looking at the engine from the timing end, the normal direction of rotation of the crankshaft is clockwise. Remember that an attempt to turn the shaft counterclockwise can lead to a violation of the valve timing adjustments. The first is the cylinder, extreme from the side of the timing drive.
1. Disconnect the negative cable from the battery. Immobilize the ignition system (see chapter Engine electrical equipment).
2. Make sure the transmission is in neutral, then firmly apply the parking brake/chock the rear wheels of the vehicle. Jack up the front of the car, place it on jack stands and remove the right front wheel. If equipped, remove the crankcase protection.
3. To control the position of the working protrusions of the cams, remove the cover of the gas distribution mechanism. On 2.0 l models alternatively, the brake booster servo vacuum pump can be dismantled (see chapter Brake system). In order to provide access to the control hole on the camshaft trunnion).
4. On SOHC models unscrew the fixing bolts and remove the crankshaft pulley.
2. Using a wrench on the crankshaft gear / sprocket mounting bolt, turn the latter in the direction of normal rotation until the alignment mark of the gear / pulley is aligned with the mating mark on the base of the oil pump cover (models 1.7 l) / timing chain (2.0 L models - refer to accompanying illustration). The alignment of the alignment marks ensures that the pistons of the first and fourth cylinders are brought to the TDC position.
2 - Installation mark on the cover of the gas distribution chain (2.0 l models)
3 - Risk on the crankshaft pulley (2.0 l models)
3. Now you should check which of the pistons occupies the TDC of the end of the compression stroke.
4. On 1.7 SOHC engines check the position of the exhaust valve drive cam of the first cylinder (2 - extreme from the side of the timing drive), - in the TDC position of the end of the compression stroke of the first cylinder, this cam turns with the working ledge up. If the cam is turned with the working ledge down, the piston of the 4th cylinder is at the TDC of the end of the compression stroke and the crankshaft must be rotated 360°in the normal direction.
5. On 1.7L DOHC models the output to the required point of the piston of the 1st cylinder is accompanied by the combination of the installation marks of the gears of the camshaft and the high-pressure fuel pump with the threaded mounting holes in the cylinder head / block, in addition, the cams of the drive of both exhaust valves of the first cylinder should turn with the working projections up - make sure by looking into oil filler neck. If the risks of the gears turn out to be 180°relative to the marks, therefore, the piston of the 4th cylinder is in the TDC position of the end of the compression stroke, and to correct the situation, it is necessary to turn the crankshaft in the normal direction by another 360°.
1. On engines 2.0 l you should check the position of the cams, or the control hole in the end of the camshaft trunnion. In the TDC position of the end of the compression stroke of the piston of the first cylinder, the cams (1) the valve actuators of the first cylinder should turn their working projections symmetrically upwards at approximately 45°to the vertical.
In this case, the control hole in the shaft trunnion is in the position «at 12 o'clock». If the cams of the shaft are turned with the working lugs down, and the control hole on the pin is in the position «for 6 hours», the piston of the 4th cylinder is at the TDC of the end of the compression stroke and the crankshaft should be rotated in the normal direction by another 360°.
3. Fixing the pistons in the selected position on 1.7L SOHC models is produced by blocking the crankshaft using a special tool KM-951, which is a rod inserted into a recess in the flywheel ring gear through a hole in the transmission dome. In the absence of a special tool at hand, you can use a long bolt with a diameter of 8 mm (the bottom bolt of the steering column, the end of which is sharpened on a cone, is best suited for this purpose).
4. On 1.7 DOHC models the pistons can be fixed by blocking the gears of the camshaft and injection pump. The camshaft gear is locked using an M6 bolt, threaded through a round opening in the wheel spoke and screwed into a threaded hole in the cylinder head.
The injection pump gear is locked in a similar manner, with the only difference that an M8 bolt must be used.
6. On 2.0 l models the crankshaft can be blocked by inserting the KM-929 tool into the shaft position sensor hole (CKP) in front of the cylinder. If necessary, a suitable fixture can be made in-house in accordance with the illustrations Dimensional specifications of the crankshaft locking tool (mm) parameters. Remove the CKP sensor and make sure that the tool rod enters the mating cutout in the shaft body.
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