Engine 1.8-I / 125 hp
Engine 1.8-1/125 hp Equipped with a thermo-tensioner for the toothed belt, which ensures a constant tension of the toothed belt regardless of temperature. This ensures the durability and smooth operation of the belt.
Instruction. Depending on the model, the water pump is driven by a toothed or V-belt.
Withdrawal
Set the front panel of the body to the service position.
On vehicles with air conditioning, loosen the V-ribbed belt tension.
Remove the radiator fan with visco clutch and belt pulley.
On a 150 hp engine. V-belt driven water pump, remove the V-belt.
Setting the piston of the first cylinder to top dead center (TDC)
Remove the top casing of a gear belt.
Mark the direction of rotation of the toothed belt with a marker or paint. When viewed from the front of the engine, the engine pulleys rotate clockwise.
Turn the engine so that the piston of the first cylinder is at top dead center.
Attention. Do not rotate the engine by the camshaft pulley bolt, otherwise the load on the toothed belt is maximum.
You can turn the crankshaft of the engine in the following ways.
1. Raise the front of the car and secure it on stands. Engage fifth gear and tighten the handbrake. While holding one front wheel from spinning, manually turn the other front wheel. In this case, the crankshaft of the engine will rotate.
2. Park the vehicle on level ground, then engage fifth gear and manually move the vehicle forward or backward.
3. Place the transmission in neutral and apply the handbrake. Using a wrench, turn the engine crankshaft at the crankshaft pulley bolt.
Turn the engine crankshaft until the mark on the camshaft pulley aligns with the TDC indicator on the cylinder head cover (see fig. 2.7). Check that the mark on the crankshaft pulley is aligned with the pointer on the lower timing belt housing. When the marks are aligned with the pointers, the piston of the first cylinder is at TDC on the compression stroke.
Unscrew the four bolts securing the belt pulley (vibration damper) to the crankshaft (see fig. 2.8). At the same time, with an additional key, hold the crankshaft from turning by the central bolt of the pulley. Remove the pulley from the crankshaft.
Unscrew the bolts and remove the lower casing of the toothed belt (see fig. 2.9). Depending on the type of engine, the attachment points for the lower toothed belt guard may vary.
Toothed belt tensioner type 1
Loosen the tensioner bolt, press the roller down and loosen the tension of the toothed belt (see fig. 2.10).
Toothed belt tensioner type 2
Screw in threaded rod 1 (pic. 2.11) M5x55 into the toothed belt tensioner.
Screw the nut 2 with washer 3 onto the stud and compress the piston of the toothed belt tensioner.
Squeeze the piston of the timing belt tensioner until the holes in the piston and housing align, and insert a wire clamp or a 1.5 mm drill shank into the holes. In this position, the toothed belt tension is loosened.
Toothed belt tensioner type 3
Using an 8mm Allen wrench, slowly turn the timing belt tensioner counterclockwise until holes 2 are aligned (pic. 2.12) in the piston and body. Insert a steel rod or a 1.5 mm drill shank into the aligned hole. Do not unscrew bolt 3 (see fig. 2.12).
Remove toothed belt from engine pulleys.
Attention. Do not bend the toothed belt sharply, as during operation the toothed belt may break at the point of a sharp bend, which will damage the engine.
After removing the toothed belt, do not change the position of the toothed belt pulleys.
Attention. If the engine crankshaft is rotated after the toothed belt has been removed, the pistons will hit the valves, causing damage to the valves and requiring major engine repairs. Mark the position of the crankshaft pulley by marking the pulley and engine block with paint. If necessary, you can turn the engine crankshaft 90°clockwise or counterclockwise.
Check the toothed belt for wear, splitting or oiling. If there are traces of oil on the toothed belt, find the source of the oil leak and repair it before installing a new belt.
Examination
If toothed belt teeth are chipped, the ignition distributor, water pump, oil pump, or camshaft may be stuck.
If there is significant wear or delamination on the outer surface of the timing belt, check the condition of the idler treadmill.
If there is wear or damage on only one side of the belt, check the toothed belt guide and the alignment of the toothed belt pulleys.
If there are any defects on the toothed belt, it must be replaced.
Installation
Check that the mark on the camshaft pulley is aligned with the TDC indicator on the cylinder head cover.
Install the toothed belt on the crankshaft and intermediate shaft pulleys and, depending on the type of engine, on the water pump pulley.
Attention. When reinstalling the toothed belt, install it so that the arrow on the belt, marked before removing the belt, matches the direction of rotation of the engine pulleys. If, after installation, the toothed belt rotates in the opposite direction, cracks in the belt may occur and engine failure.
Reinstall and bolt the lower toothed belt guard. Before installing, apply LOCTITE 243 locking compound to the bolt threads and tighten the bolts to a torque of 10 Nm and the M8 bolts to a torque of 20 Nm.
Install the crankshaft belt pulley and at this stage, secure it with one bolt, tightening it just enough. Keep in mind that the pulley is installed in only one position.
Check that the marks on the camshaft and crankshaft pulleys are aligned with the pointers, while the piston of the first cylinder should be at TDC.
Put the toothed belt on the tension roller and the camshaft pulley.
Toothed belt tensioner type 1
Using wrench B (pic. 2.13) or a special key HAZET 2587 turn the holder A of the toothed belt tensioner pulley clockwise so that the piston 1 comes out to the stop, and the piston 2 rises 1 mm above the housing. While holding the toothed belt tensioner in this position, tighten bolt 3 to 25 Nm.
Turn the engine crankshaft 2 turns clockwise and check that the marks on the crankshaft and camshaft pulleys are aligned with the pointers.
Check the location of the elements of the toothed belt tensioner. Size A (pic. 2.14) must align with the top edge of the piston. Dimension D should be in the range of 25-29 mm. In this case, the toothed belt tension is correctly adjusted.
If the top edge of the piston is within dimension B, the belt tension is correct and no adjustment is required. If the top edge of the piston is within dimension C, the toothed belt tension must be re-adjusted and the condition of the toothed belt and idler roller checked.
Tighten bolt 3 (pic. 2.13) fastening the tension roller with a torque of 25 Nm, while holding the roller from moving with the key B.
Toothed belt tensioner type 2
Remove the lock with a diameter of 1.5 mm and unscrew the threaded rod 1 (pic. 2.11), while the piston will ensure the correct tension of the toothed belt.
Toothed belt tensioner type 3
Using an 8mm Allen wrench, press the timing belt tensioner counterclockwise and remove the steel rod, the piston will maintain the correct tension on the timing belt (see fig. 2.12). If necessary, use a hex wrench to turn the idler pulley clockwise until the piston is fully released. Release the tension roller and remove the hex wrench.
Turn the engine crankshaft two turns clockwise and check that all alignment marks are aligned with the pointers. Otherwise remove a gear belt and make its repeated installation.
Screw in the four bolts of the crankshaft belt pulley and tighten them to a torque of 40 Nm.
Establish the top casing of a gear belt.
On a 150 hp engine. V-belt driven water pump, install the V-belt.
Install the radiator fan with visco clutch and belt pulley.
On vehicles with air conditioning, install and adjust the tension of the V-ribbed belt.
Establish the forward panel of a body in normal position.
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