Attention: The operation is described here only for the petrol engine.
4 cylinder petrol engine
Withdrawal
Remove V-belt.
Set the crankshaft to the TDC position of the piston of the 1st cylinder.
Unscrew both belt pulleys and vibration damper on the crankshaft.
Remove upper and lower toothed belt covers
Mark the direction of travel on the toothed belt.
Loosen and remove toothed belt.
Caution: The toothed belt must not be bent. A belt that has been bent once must be replaced without fail. in subsequent operation, such a belt may break, which will lead to serious engine problems.
Installation
Slide the toothed belt onto the gears of the crankshaft and auxiliary shaft.
Attention: If an old belt is installed, be sure to maintain the direction of travel Installing the toothed belt in the opposite direction of travel may cause it to break and, as a result, damage the engine.
Fasten the crankshaft pulley with one bolt for an injection engine, screw on the vibration damper with all 4 bolts.
Check that the camshaft is in the TDC position of the piston of the 1st cylinder. Otherwise, check the camshaft until the marks match (pic. A) with the cylinder head cover installed or fig. With cover removed.
Attention: In case the camshaft needs to be rotated through a larger angle. Make sure that none of the pistons is at TDC, otherwise valves or pistons may be damaged. Otherwise set the crankshaft to 90° (¼ turn) before or after TDC. In doing so, however, do not turn the belt pulley more than 90°.
115 hp engine, code AAD
Check that the camshaft is in the TDC position of the piston of the 1st cylinder. Otherwise, check the camshaft until the marks match (pic. A) with the cylinder head cover installed or fig. With cover removed.
Attention: In case the camshaft needs to be rotated through a larger angle. Make sure that none of the pistons is at TDC, otherwise valves or pistons may be damaged. Otherwise set the crankshaft to 90° (¼ turn) before or after TDC. In doing so, however, do not turn the belt pulley more than 90°.
Check the alignment of the markings on the crankshaft gear and the intermediate shaft. The engine is at the same time in the TDC position of the 1st cylinder.
Fit the toothed belt onto the camshaft wheel.
Attention: When putting on the belt, do not change the position of the crankshaft, camshaft and intermediate shaft. Otherwise, it may cause severe engine damage or reduce engine performance.
Attention: After tensioning the toothed belt, check again the installation of the camshaft and intermediate shaft. This means: If the marking on the camshaft sprocket matches the basic marking, then the marking on the crankshaft sprocket must also match the marking on the countershaft sprocket. Otherwise, change the installation of the wheels of the camshaft and crankshaft.
Tighten toothed belt
Check the crankshaft two turns in the direction of rotation and check the setting again.
Remove the crankshaft pulley.
Install the lower toothed belt cover.
Install the upper toothed belt cover.
Fit the crankshaft pulley and tighten to 20 Nm.
Install the V-belt and tension it.
Check ignition timing. Adjust if necessary.
Attention: When performing repairs that require the removal of the toothed belt from the camshaft wheel only, the installation of the toothed belt should be done as follows:
Install the crankshaft so that the piston of cylinder 1 is at TDC.
The mark on the camshaft gear must align with the cylinder head cover.
Loosen the toothed belt and remove it from the camshaft wheel.
Attention: Do not change the position of the crankshaft and intermediate shaft.
Put on the belt and tighten it.
Check that the distributor slider points to the output of the 1st cylinder on the distributor cap. If not, the distributor should be loosened and rotated so that the marks match. Otherwise, install the distributor again.
Turn the crankshaft twice, now the marks of the camshaft and crankshaft must match the pointers, otherwise the installation should be repeated.
Check ignition timing, adjust if necessary.
Start the engine. A whistling toothed belt usually indicates its excessive tension.
5 cylinder engine (2-valve)
Withdrawal
The order of work basically corresponds to a 4-cylinder engine. Below, only the differences are noted.
Remove the power steering pump.
Remove vibration damper.
Installation
Check that the mark on the camshaft gear aligns with the top edge of the cylinder head cover seal.
Put the toothed belt on the gear and put it together with the vibration damper on the crankshaft.
Caution: The toothed belt must not get stuck between the gear and the oil pump.
Attention: if an old toothed belt is used, the previous direction of travel must be taken into account. Installing the belt in reverse or bending the belt can cause it to break and damage the engine.
Attach vibration damper.
Check that the crankshaft is in the TDC position of the piston of the 1st cylinder. In the window of the clutch housing, the TDC mark -O- should be exactly under the pointer.
If the toothed belt is installed on a removed engine, the notch on the belt pulley must match the alignment mark on the pump housing. The crankshaft must be in the TDC position of the piston of the 1st cylinder.
Put on and tension the toothed belt.
Install the power steering pump.
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