Removal and installation
1. Remove the front mudguard (tORX bolts). For convenient work, remove the front wheel.
2. Remove the V-belt, see. Generator.
3. Remove the timing belt cover completely.
4. Remove the crankshaft V-belt pulley. When unscrewing the bolt, secure the crankshaft by engaging 5th gear or hold the flywheel toothed rim with a screwdriver for this purpose.
5. Set the engine to TDC position for cylinder 1.
6. Set the TDC position of the camshaft and crankshaft pulleys. The marks on the toothed belt, pulley and pulley housing should match. And the arrow showing the direction of belt movement should indicate the direction of engine rotation (that is, clockwise). In addition, the diesel engine's high-pressure fuel pump mark must match.
7. Diesel: to accurately establish the TDC position, a rod is inserted into the engine unit in the auto repair shop (diameter 8 mm). The hole for it is located next to the dipstick for measuring the oil level. Before inserting the rod, you need to pull out the plug. If there is no suitable rod, check the TDC position using the marks on the engine housing and flywheel. Be especially careful not to shift the TDC position.
8. 16-valve engine: to correctly set the TDC position of both camshaft pulleys, auto repair shops use a special tool (Mot. No.1196), which is inserted between both toothed drive belt pulleys. If this tool is not available, make sure that the TDC position does not change.
9. Loosen the tension roller lock nut. While doing this, hold the tension roller from turning.
10. Loosen the toothed drive belt by turning the tension roller to the right.
11. Remove the toothed drive belt from the pulleys.
12. Do not allow the pulleys to turn when the timing belt is removed.
13. Before installing a new timing belt, make sure that the camshaft and crankshaft TDC marks are in the correct position.
14. If the marks do not match, set the crankshaft to the TDC position.
15. Install the new belt starting from the crankshaft pulley in a counterclockwise direction.
16. Use the belt tensioner to set the belt tension as described above.
17. Turn the engine two revolutions so that the timing belt tensioner fits snugly on the back of the timing belt.
18. Check the timing belt tension again and adjust it if necessary.
19. Install the timing belt cover.
20. Install the V-belt pulley and put on the V-belt.
21. Tighten the V-belt, see. Generator.
22. Carry out further work in the reverse order of disassembly. Do not forget to remove, if any, the engine reinforcement (strut).
23. If possible, have the timing belt tension checked at a workshop.
Note: Recommendation: if it is necessary to turn the camshaft with the belt removed, none of the cylinders should be at the top dead center, otherwise the valves and pistons may be damaged. To avoid this, the crankshaft mark is set to a position no more than 90° (1/4 turn) before or after the TDC mark.