Camshaft pulley
1 – pulley mounting bolts; 2 – pulley; 3 – camshaft stopper
Timing belt tension
1 – key; 2 – tension roller eccentric; 3 – locking plate; A, B – stops; C – eccentric projection; a – gap
Rear powertrain support
1 – support mounting bolt to the body; 2 – support; 3 – support bracket; 4 – bolt for fastening the support to the gearbox
1. Remove the alternator drive belt (see subsection 2.3).
2. Remove the right front fender liner.
3. Unscrew bolts 21 (see Camshaft drive parts), holding the crankshaft from turning, and remove pulley 20.
4. Loosen the mounting bolts and remove the lower 19 and middle 22 camshaft drive belt covers.
5. Remove the clamps and disconnect fuel supply hoses 1 and 2 from the fuel filter. Be careful - fuel may be under pressure.
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6. Remove the expansion tank without disconnecting the hoses from it and set it aside.
7. Attach the engine to a hoist and tighten the cables to relieve the load on the engine mounts.
8. Unscrew bolts 1 and 3 securing the right support of the power unit to the body and engine (2 – support).
9. Loosen the 4 bolts securing the rear support of the power unit to the gearbox (see Rear powertrain mount).
10. Unfasten the latches and remove the top cover 1 (see Camshaft drive parts) camshaft drive belt.
11. Lower the engine by approximately 35 mm and unscrew the lower bracket mounting bolt 24.
12. Raise the engine approximately 45 mm from its normal position and unscrew the two upper mounting bolts of bracket 24. Remove the bracket by first turning it in the direction of arrow A and then lifting it upwards.
13. Lower the engine to its normal position and set the piston of the first cylinder to TDC (see subsection 2.2.2). After this, the crankshaft and camshaft cannot be turned. At service stations, the MP 1-301 device is used to lock the camshaft, and the T 10050 device is used to lock the crankshaft.
14. Insert key 1 into the hexagonal hole of tension roller 2 and turn the tension roller counterclockwise so that locking plate 5 can be inserted (3 – tensioner; 4 – tensioner mounting bolt).
15. Unscrew the mounting bolts 4 and remove the tensioner 3.
16. Remove the camshaft drive belt.
Caution! The camshaft drive belt tension can only be adjusted when the engine is cold.
17. Loosen bolts 1 (see the figure Camshaft pulley) fastenings of pulley 2 and turn the pulley using the oval holes clockwise until it stops.
18. Using a special key 1 (see figure Timing Belt Tension) turn the eccentric 2 of the tension roller clockwise so that its protrusion C reaches the stop B.
19. Place the belt over the crankshaft pulley, then the tensioner pulley and camshaft pulley, and finally the water pump pulley.
20. Install the tensioner and tighten its mounting bolts.
21. Using key 1, turn eccentric 2 counterclockwise (projection C turns towards stop A) so that the locking plate 3 can be removed.
22. Using key 1, turn eccentric 2 clockwise (projection C turns towards stop B) until the gap a is equal to 4±1 mm. The gap size can be conveniently checked using a 4 mm diameter drill as a gauge.
23. Holding the tension roller in this position, tighten its mounting nut in two stages: 1st - tighten to a torque of 20 N·m; 2nd – turn it 45°.
24. Tighten bolts 1 (see the figure Camshaft pulley) tighten the camshaft pulley to 25 Nm. Remove the crankshaft and camshaft locking tools, if installed.
25. Turn the crankshaft two revolutions and set the piston of the first cylinder to TDC again.
26. Check the gap a (see figure Timing Belt Tension). If it differs from the specified (4±1) mm, adjust the gap again as described above. Check that the piston of the first cylinder is set to TDC.
27. Install all removed parts in reverse order.