Removal and installation
1. Remove the front mudguard (TORX bolts). Remove the front wheel for easy operation.
2. Remove the V-belt, see Generator.
3. Completely remove the toothed drive belt cover.
4. Remove the crankshaft V-belt pulley. When unscrewing the bolt, fix the crankshaft by turning on the 5th gear or hold the gear rim of the flywheel with a screwdriver for this purpose.
5. Set the engine to the TDC position for the 1st cylinder.
6. Set the TDC position of the camshaft and crankshaft pulleys. In this case, the marks of the toothed belt, pulley and pulley casing must match. And the arrow showing the direction of movement of the belt should indicate the direction of rotation of the engine (i.e. clockwise). In a diesel engine, in addition, the label of the high pressure fuel pump must match.
7. Diesel: to accurately determine the position of TDC in a car repair shop, a rod is inserted into the engine assembly (diameter 8 mm). The hole for it is located next to the dipstick for measuring the oil level. Before inserting the rod, you must pull out the plug. In the absence of a 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: for the correct setting of the TDC position of both camshaft pulleys in car repair shops, a special tool is used (Mot. No. 1196), which is inserted between both pulleys of the toothed drive belt. In the absence of this tool, make sure that the TDC position does not change.
9. Loosen the tension roller locknut. At the same time, keep the tension roller from turning.
10. Loosen the toothed drive belt. To do this, turn the tension roller to the right.
11. Remove the toothed drive belt from the pulleys.
12. Do not allow the pulleys to rotate when the toothed belt is removed.
13. Before installing a new toothed drive belt, make sure that the TDC marks on the camshaft and crankshaft are in the correct position.
14. If the marks do not match, set the crankshaft to TDC.
15. Put on a new belt, starting from the crankshaft pulley counterclockwise.
16. Use the belt tensioner to set its tension as described above.
17. Rotate the engine two turns until the toothed belt tensioner is firmly «lay down» on the back of the toothed belt.
18. Check up a tension of a gear belt once again and if necessary adjust it.
19. Establish a casing of a gear drive belt.
20. Install the V-belt pulley and put on the V-belt.
21. Tension the V-belt, see Generator.
22. Perform further work in the reverse order of disassembly. Do not forget to remove, if any, engine reinforcement (spacer).
23. If possible, have the toothed belt tension checked by a workshop.
Note. Recommendation: if you need to turn the camshaft with the belt removed, then none of the cylinders should be at top dead center, otherwise the valves and pistons may be damaged. In order to avoid this, the crankshaft mark is placed in a position of no more than 90° (1/4 turn) before or after the TDC mark.