Contents: Removal 🠛 Installation 🠛
Removal
- Place the vehicle on a two-post lift and raise the front wheels off the ground.
- Disconnect the cable from the negative battery terminal.
- Remove:
- right front wheel;
- protective shields under the engine;
- protective liner of the front right wheel arch
- Drain the oil from the gearbox (within 3 minutes).
- Remove the oil pipe mounting bracket from the oil filter base and plug the holes to prevent oil from leaking.
- Remove the thrust rod completely.
- Remove the intake pipe of the exhaust system.
On the right side of the car
- Remove:
- the front right floating bracket of the brake caliper and to protect the brake hose from damage, secure it to the suspension spring (fig. 3.26);
- unscrew the two bolts securing the intermediate support of the drive shaft in the support bearing (fig. 3.27);
- using the T.Av. 476 puller, the steering rod end (fig. 3.28);
- unscrew the lower shock absorber strut mounting bolts;
- wheel speed sensor.
- Loosen the lower ball joint tip fastening nut as much as possible and use a ball joint impact puller to press the tip out of the steering knuckle (fig. 3.29).
- Remove the drive shaft - steering knuckle - brake disc assembly. Do not damage the drive shaft corrugated boots.
On the left side of the car
- Remove the brake caliper floating bracket and secure it to the suspension spring
- Remove the three bolts securing the drive shaft corrugated boot.
- Using the Tav 476 puller, remove the tie rod end.
- Disconnect the wire from the brake pad wear sensor.
- Remove the lower shock absorber strut mounting bolts.
- Disconnect the steering rod ends and lower ball joints from the steering knuckles.
- Remove the drive shaft - steering knuckle - brake disc assembly.
- Install a universal support and lift the engine up until it is suspended (do it together).
- Remove the right engine swingarm mount bracket (4 bolts) together with the swingarm mount travel limiter.
- Unscrew the lower nut of the left pendulum suspension (1 bolt).
- Remove the upper accessory drive belt cover.
- Lower the power unit by 70 mm and move it to the left.
Caution: Monitor the air conditioning hoses between the air conditioning compressor and the receiver-dryer, as tension in these hoses will limit the downward movement of the power unit.
- Remove the accessory drive belt.
- Remove the accessory drive belt pulley from the crankshaft.
- Remove the timing belt covers.
- Remove the plug covering the hole for the TDC locking pin and insert the TDC locking pin Mot. 1318 or a 7 mm diameter rod.
Setting the valve timing
- Turn the crankshaft until the mark on the crankshaft pulley (C, Fig. 3.31) will not be directed downwards, and the mark (D) on the camshaft pulley will be on the left at an angle of approximately 45° (the internal mark A on the camshaft pulley must be opposite the mark on the cylinder head cover) and the mark (I) of the fuel injection pump pulley is opposite the mark on the fuel injection pump casing.
- Remove nut (B) and bolt (E) and loosen the timing belt.
- Remove the timing belt.
Installation
- Make sure that the TDC locking pin Mot. 1318 is in place.
- Install the tension roller in place.
- Install the timing belt, aligning the marks on the pulleys and belt.
Note: The following belt tension adjustment procedure must be strictly followed.
- Rotating the bolt (E. Fig. 3.31) tighten the timing belt, while the bracket-mark (H, Fig. 33) of the tension roller should be aligned with the stop (F) and, without applying much force, tighten the lock nut of the adjusting screw.
- Remove the TDC locking tool and rotate the crankshaft 3 full turns clockwise until the piston of the 1st cylinder is set to the TDC position. Re-insert the TDC locking tool.
- Loosen the adjusting bolt lock nut, then gradually bring the tension roller to the nominal position where the dash mark (G) passes through the center of the mark bracket (H). Tighten the lock nut to a torque of 30 N·m.
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Note: Do not rotate the crankshaft in the opposite direction to the working stroke.
- Check the injection phase setting of the high-pressure fuel pump
- Remove the TDC locking tool
- Clean the bearing surface of the crankshaft pulley
- Apply 2 drops of LOCTITE AUTOFORM locking agent to the crankshaft pulley bearing surface.
- Be sure to replace the crankshaft pulley bolt with a new one
- Further installation is carried out in the reverse order of removal