KV - Crankshaft
RV - Camshaft
VN - Water pump
HPFP - High pressure fuel pump
R - Roller
H - Tensioner
The timing belt must be removed when the engine is cold!
Do not crank the engine with the timing belt removed!
SOHC equipped models will require a new camshaft sprocket bolt.
Engine 1.7 l SOHC
For 1.7L DOHC diesel engines, the procedure is the same as for DOHC gasoline engines (see In-Vehicle DOHC Gasoline Engine Repair Procedures).
Removing
See illustration Timing Belt Replacement.
1. Disconnect the negative cable from the battery.
2. Remove the air cleaner with intake duct and air mass sensor (MAF).
3. Remove the top timing cover [1].
4. Remove the belt (And) accessory drives.
5. Apply the parking brake, jack up the front of the vehicle and place it on jack stands. Remove the right front wheel. If equipped, remove the crankcase protection.
6. Remove the fixing bolts [2] and remove the crankshaft pulley [3].
7. Support the engine using the KM-6001 fixture and install the KM-909-B centering tool.
8. Remove the right powertrain mount with its bracket.
9. Remove the accessory drive belt tensioner.
10. Remove the timing cover (see Removing and installing timing cover).
11. After turning the crankshaft, bring the engine to the position 90°before the TDC of the end of the compression stroke of the piston of the first cylinder [5].
12. Make sure that the cam of the exhaust valve actuator of the first cylinder is turned with the working lug vertically upwards [6].
13. Loosen the high pressure fuel pump sprocket mounting bolts [7] and hand-tighten them.
14. Loosen the tensioner bolt [8], using a bar wrench (Allen) [10] rotate the latter clockwise until the left stop is brought into the corresponding position [9].
15. Lightly tighten the tensioner bolt and remove the timing belt. Unscrew the camshaft gear mounting bolt [11], - the bolt must be replaced without fail.
16. Screw in a new bolt of fastening of a cogwheel of a camshaft and by hand tighten it, make sure that the wheel can turn.
If the belt is in good condition and is subject to further use, mark with chalk or paint the original direction of its rotation.
Installation
See illustration Timing Belt Replacement.
1. Make sure that the cam of the exhaust valve actuator of the first cylinder is turned with the working lug up [6].
2. Make sure the engine is at 90°before TDC of the end of the compression stroke of the No. 1 cylinder [5].
3. Install the KM-661-1 measuring frame [12] and make sure that its left mounting pins fit the holes in the timing drive mechanism housing.
4. Install the MKM-571-B dial gauge, resting its plunger against the heel of the intake valve drive cam of the first cylinder (second from the front) [13a].
A nozzle with a flat cylindrical base with a diameter of 10 mm should be placed on the meter leg. The preload must not exceed 0.50 mm.
5. Zero the meter, then move the KM-611-1 measuring frame to the left so that the right landing pins fall into the receiving sockets in the timing drive mechanism housing, and the meter nozzle is in position [13b].
6. Install holder KM-661-2 on cylinder No. 4 [14].
7. Using a wrench, adjust the position of the camshaft so that the dial gauge reads approximately 0.80 mm [15].
8. Turn the screw [16] to fine-tune the camshaft so that the meter reading does not go out of range 0.60—0.64 mm.
9. Using the wrench [17], slowly turn the gear wheel of the injection pump and insert the locking tool KM-6011 [18] into the body of the latter.
10. Turning the crankshaft clockwise, bring the engine to the TDC position of the end of the compression stroke of the piston of the first cylinder (see Bringing the piston of the first cylinder to the position of the top dead center of the end of the compression stroke (TDC). Make sure that the alignment marks [19] are aligned correctly.
11. Pass the locking tool KM-951 into the flywheel housing [20].
Fixing can be done by installing a distribution pin spring on the bolt [21].
12. Starting at the crankshaft sprocket and working counterclockwise, install the timing belt. Make sure the belt is tight in the areas between adjacent wheels.
13. Loosen tensioner bolt [8].
14. Use a spanner [10] to turn the tensioner counterclockwise until the pointer near the right stop is in the desired position [22].
15. Tighten the tensioner bolt with force 25 Nm.
16. With the camshaft sprocket locked, tighten the bolt [11] to 75 Nm, then drag it first to 69°, then another 5°.
17. After blocking the gear wheel of the injection pump, tighten the bolts [7] with force 25 Nm.
18. Remove the locking tool [14].
19. Carefully remove the KM-661-1 measuring frame [12] — try not to move the dial gauge.
20. Remove the flywheel blocking rod [20] and stop rod [18].
21. Slowly rotate the crankshaft two full turns clockwise and bring it to the TDC position of the end of the compression stroke of the piston of the first cylinder - make sure that the alignment marks are aligned correctly [19].
22. Loosen the tensioner bolt [8] and turning it clockwise until the pointer [23] - new belt or [24] - used belt is aligned as required.
23. Tighten the tensioner bolt with force 25 Nm.
24. Slowly rotate the crankshaft two full turns clockwise and bring it to the TDC position of the end of the compression stroke of the piston of the first cylinder - make sure that the alignment marks are aligned correctly [19].
25. Check the correct position of the tensioner pointer (see paragraph 22 above). Repeat the belt tension adjustment procedure if necessary.
26. Turn the crankshaft two full turns clockwise - make sure that the alignment marks [19] are aligned correctly and install the KM-951 camshaft pin [20] into the flywheel housing.
27. Insert the locking pin KM-6011 into the injection pump [18].
28. Install the KM-661-1 measuring frame [12] and make sure that its mounting pins are in the receiving slots in the timing drive mechanism housing [13b] — the dial gauge should record the reading 0.55±0.03mm. Repeat the installation procedure if necessary.
29. Reinstall the removed components in the reverse order of removal.
30. Tighten the crankshaft pulley bolts [2] to 20 Nm.
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