Timing drive. Petrol engine 1.6 l ALZ
- 1 - Rotary lock. Turn counterclockwise to open
- 2 — the Top cover of a gear belt
- 3 - Bolt, 100nm
- 4 - Toothed belt wheel
- 5 - Combined screw, 10nm
- 6 — a back cover of a gear belt
- 7 - Screw with an internal hexagon, 15Nm
- 8 - O-ring. Be sure to replace. Moisten with G12 coolant when installing
- 9 - Coolant pump
- 10 - Toothed belt. If a used belt is used, mark the direction of rotation with chalk or a felt-tip pen before removing it. Don't bend the belt
- 11 - Crankshaft gear. Attention: The mating surface between the gear and crankshaft must be free of oil
- 12 - Bolt, 90Nm + 90°. Be sure to replace. Thread and bearing surface must not be lubricated
- 13 — the Bottom cover of a gear belt
- 14 - Bolts, 10nm
- 15 - Crankshaft pulley / vibration damper
- 16 - Screw, 25Nm
- 17 — the Central cover of a gear belt
- 18 - Tension roller
- 19 - Washer
- 20 - Nut, 20Nm
Withdrawal
1. Set the front panel to the service position, refer to Section Setting the Front Panel to the Maintenance Position.
2. Remove the engine top cover.
3. Remove the V-belt, refer to Section Removal and installation of a belt of a drive of auxiliary units.
4. Disconnect the V-belt tensioner.
Caution: Sketch the installation position of the upper toothed belt cover, in particular at the transition to the center cover.
5. Turn the swivel lock counterclockwise (arrow in fig. A) so that the slot of the screw is in a vertical position.
6. Disconnect the top cover of a gear belt. To do this, push up the locking tabs of the clamp (arrow in fig. IN).
7. Remove the top cover of a gear belt.
8. Apply the parking brake and place the gearbox in neutral.
9. Set the engine to TDC of the piston of the first cylinder. To do this, turn the crankshaft at the central gear bolt in the direction of engine rotation, i.e. clockwise so that the marks on the camshaft wheel and on the crankshaft match.
10. Manual gearbox: The TDC marks on the flywheel and drive disc must match.
11. AT: The TDC mark should be at the left edge of the window (arrow on accompanying illustration).
12. Turn away screws of fastening of a pulley of a cranked shaft and take out a pulley.
13. Disconnect the center and bottom timing belt covers (arrows) and take them out.
14. Use a chalk or felt-tip pen to mark the timing belt with an arrow indicating the direction of rotation.
15. Loosen the terminal nut (20) tension roller attachment (18). Turn the tensioning pulley clockwise with tool T10020 and thus loosen the toothed belt tension, see Timing drive. Petrol engine 1.6 l ALZ and accompanying illustration.
16. Remove a gear belt.
Installation (variable valve timing)
Caution: If the toothed belt is only removed from the camshaft wheel during repairs, the valve timing must be adjusted.
When turning the camshaft without a toothed belt, do not set any cylinder to the TDC position. There is a risk of damage to valves and/or piston crowns.
1. Turn the gears so that the marks on the camshaft wheel and the rear toothed belt cover and the marks on the crankshaft wheel and the lower toothed belt cover match. To do this, briefly install the crankshaft wheel.
2. Put the toothed belt on the crankshaft wheel.
Caution: Observe the direction of its rotation.
3. Replace the center and bottom toothed belt covers and secure them.
4. Install the crankshaft wheel so that the hole on the wheel matches the protrusion on the crankshaft wheel. Tighten the wheel in this position 25Nm.
5. Put on a gear belt on a tension roller and a camshaft wheel.
Toothed belt tension
Caution: The engine must be warmed up to a temperature no higher than hand temperature.
1. Check whether the marks on the camshaft wheel and toothed belt rear cover, as well as on the crankshaft wheel and toothed belt bottom cover, match.
2. Before tensioning the toothed belt, turn the tension roller on the eccentric using tool T10020 five times in both directions until it stops.
3. Turn the eccentric tool T10020 counterclockwise (arrow direction illustration) all the way.
4. Slowly tension the toothed belt until the mark (1) and pointer (2) stood opposite each other. If necessary, use a mirror to check.
5. Holding the idler in this position, tighten the fastening nut to the torque 20nm.
6. Turn the crankshaft further two turns in the direction of engine rotation so that the engine stops at TDC of the first cylinder. It is important that the last 45°of the rotation is made without stopping.
7. Check the toothed belt tension again: Pointer and mark must be opposite each other.
Further installation
1. Fix the top cover of a gear belt. Turn the swivel lock clockwise so that the slot of the screw is in a horizontal position.
2. Fasten the V-belt clamping element with torque 25Nm.
3. Put on the V-belt, refer to Section Removal and installation of a belt of a drive of auxiliary units.
4. Establish the top cover of the engine, address to the corresponding Section.
5. Set the front panel to the service position, refer to Section Setting the Front Panel to the Maintenance Position.
Petrol engines 1.8 and 2.0 l (AVJ, BFB, ALT)
Timing drive. Petrol engines 1.8 and 2.0 l (AVJ, BFB, ALT)
- 1 — the Bottom cover of a gear belt
- 2 - Bolt, 10nm. Screwed on sealant
- 3 — the Central cover of a gear belt. To remove, unscrew the V-belt tensioner
- 4 — the Top cover of a gear belt
- Engines AVJ, BFB: At installation carefully connect with the central cover of a gear belt.
- Engine ALT: 10Nm.
- 5 - Toothed belt
- 6 - Guide roller
- 7 - Terminal nut, 27Nm
- 8 - Bolt, 65Nm
- 9 — Wheel of a camshaft of final valves
- 10 - Tension roller
- 11 - Washer
- 12 — Device of a tension of a gear belt
- 13 - O-ring. Be sure to replace Moisten with coolant when installing
- 14 - Coolant pump
- 15 - Bolt, 15Nm
- 16 - Crankshaft toothed belt wheel. The mating surface between the gear and crankshaft must be free of oil
- 17 - Bolt, 90Nm + 90°. Be sure to replace. Don't grease
- 18 - Bolt, 15Nm
- 19 - Bolt, 25Nm
Position of the camshaft wheel. Narrow wall of camshaft wheel points outward (arrows), and the TDC mark of the first cylinder is visible from the front
Removal and installation procedures are similar to the 1.6L gasoline engine. Therefore, only the differences are described.
Withdrawal
Caution: Toothed belt tensioner tensioner (A) is oil damped and can only compress slowly and under a uniform load. Excessive compressive force can damage the idler pulley.
1. Insert the socket wrench all the way into the hex hole of the tension roller and turn the tension roller counterclockwise (according to the arrow in the accompanying illustration) so that the tensioner can be fixed with HAZET 2588-2 plates.
Caution: Turn the idler without applying excessive force.
Caution: Insert the socket wrench all the way so that when turning it does not damage the hexagon at the tension roller.
Warning: The toothed belt tensioner is oil damped. Press it slowly and evenly.
Warning: Do not bend the pusher foot (A) eccentric lever.
2. To tighten the toothed belt, loosen the nut (1) tension roller and turn the eccentric with the HAZET 2587-1 wrench in the direction of the arrow.
3. If a used toothed belt will be installed, mark the direction of rotation on it with chalk or a felt-tip pen.
4. Remove the toothed belt.
Installation (variable valve timing)
Installation is carried out similarly to the same procedure for a 1.6 liter gasoline engine.
Toothed belt tension
Caution: If the toothed belt tensioner is fully extended, it must be rotated back together with the tensioning roller in the installed position. This process can take up to 5 minutes. Excessive compression force can damage the idler.
1. With the toothed belt tensioner fully extended, press the tensioner roller counterclockwise with a socket wrench so that the tensioner piston can be locked by the HAZET 2588-2 locking plates.
Caution: Turn the idler evenly without applying much force.
Warning: Do not bend the stop nose (A) eccentric lever.
2. Turn the eccentric counterclockwise with the HAZET 2587-1 wrench so that the HAZET 2588-2 locking plate can be pulled out.
3. Then turn the eccentric clockwise so that a drill of size a = 8 mm can pass between the tension arm and tensioner body.
4. While holding the eccentric in this position, tighten the nut (1) tension roller attachment. Then remove the wrench to tighten the nut.
5. Rotate the engine two turns at the crankshaft center bolt (clockwise) and set it to TDC again.
6. Check the size with a drill (A) between tensioner arm and tensioner housing. The specified size should be 6 ÷ 10 mm.
7. If size (A) less, loosen the belt, compress the tensioner and tighten the toothed belt again.
8. If size (A) reached, complete the installation process.
Petrol engine 2.0 l AWA
Timing drive. 2.0L direct injection petrol engine AWA
- 1 — the Bottom cover of a gear belt
- 2 - Bolt, 10nm. Screwed in with locking agent
- 3 — the Central cover of a gear belt. To remove, unscrew the V-belt tensioner
- 4 — the Top cover of a gear belt. When installing, carefully connect to the center cover of the toothed belt and secure with a torque 10nm
- 5 - Bolt, 10nm
- 6 - Toothed belt
- 7 - Terminal nut, 27Nm
- 8 - Bolt, 65Nm
- 9 — Wheel of a camshaft of final valves
- 10 - Guide roller holder
- 11 - Washer
- 12 - Lock plate tension roller
- 13 - Bolt, 9Nm
- 14 - Guide roller
- 15 - Bolt, 40Nm
- 16 - O-ring. Be sure to replace. Moisten with coolant when installing
- 17 - Coolant pump
- 18 - Bolt, 15Nm
- 19 - Bolt, 40Nm
- 20 - Bolt, 15Nm
- 21 - Locking plate of the damper of the belt tensioner
- 22 - Bolt, 16Nm
- 23 - Damper belt tensioner
- 24 - Guide roller
- 25 - Bolt, 25Nm
- 26 - Crankshaft toothed belt wheel. The mating surface between the gear and crankshaft must be free of oil
- 27 - Bolt, 90Nm + 90°. Be sure to replace. Don't grease
Withdrawal
1. Removal and installation are similar to the same procedures for the 1.6L gasoline engine. Therefore, only the differences are described here (refer to illustration above).
2. Turn away bolts of fastening at the top and remove a cover of a gear belt. Note: To facilitate subsequent installation, mark the position at the transition point to the toothed belt center cover.
Caution: Toothed belt tensioner tensioner (A) is oil damped and can only compress slowly and under a uniform load. Excessive compressive force can damage the idler pulley.
3. Press the tension roller clockwise with a socket wrench (arrow on accompanying illustration) so that the piston can be fixed to the tensioner piston with a suitable pin, eg T40011.
Caution: Rotate the roller evenly without applying excessive force. If the old toothed belt will be installed, mark with chalk or a felt-tip pen in the direction of its rotation.
4. Unscrew the holder with guide roller (1). The arrow indicates the bolts for fastening the damper of the belt tensioner.
5. Remove the toothed belt.
Installation (variable valve timing)
Installation is carried out similarly to the same procedure for a 1.6 liter gasoline engine.
As a result, install and secure the holder with the guide roller and the spacer (11), refer to illustration Timing drive. 2.0L direct injection petrol engine AWA.
Toothed belt tension
1. Turn the tension roller clockwise with a socket wrench so that the lock pin can be removed.
2. Slowly turn the tension roller anti-clockwise with a socket wrench and thus tension the toothed belt.
Caution: If the toothed belt tensioner is fully extended, it must be rotated back together with the tensioning roller in the installed position. This process can take up to 5 minutes. Excessive compression force can damage the idler.
3. With the toothed belt tensioner fully extended, press the tensioner roller counterclockwise with a socket wrench so that the tensioner piston can be locked with the appropriate pin, eg T40011.
Caution: Turn the idler pulley evenly without applying much force
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