Table of contents: Removal 🠇 Installation 🠇 Pre-tensioning of the timing belt 🠇 Final tensioning of the timing belt 🠇 Checking the timing belt tension…🠇
Removal
Disconnect the cable from the negative battery terminal.
Remove the right front wheel.
Remove the right front wheel arch mudguard.
Remove the accessory drive belt.
Remove the decorative cover from the engine.
DW10ATED engine
Figure 4.43. Compressor location in the engine compartment with the DW10ATED engine: 1 - air conditioning compressor; 2 - jet bracket; 3 - air pipe at the outlet of the turbocharger; 4 - air cooler; 5 - shock absorber buffer 6 - engine subframe
Unscrew the nut, remove the bolt and remove the reaction bracket 2 (see figure 4.43) engine mounts.
Remove air pipe 4 to the air cooler.
Remove air pipe 3 at the outlet of the turbocharger.
All engines
Figure 4.42. Location of the air conditioning compressor in the engine compartment of the DW10TD engine: 1 - air conditioning compressor; 2 - jet bracket; 3 - shockproof reinforcement of the sub-engine frame; 4 - bump stop
Remove the bump stop 5 (see figure 4.43), 4 (see Figure 4.42).
Insert special tool 0188-F to prevent the flywheel from turning.
Remove the accessory drive belt pulley mounting bolt and screw the bolt back in place without the washer.
Remove special tool 0188-F, which secures the flywheel from turning.
Using pulley puller 0188-P, remove the accessory drive belt pulley.
Disconnect the turbocharger outlet pipe.
DW10ATED engine
Disconnect the fuel supply and return lines from the engine. Close the ends of the tubes with suitable stoppers.
Disconnect the particulate filter from the pre-catalytic converter.
All engines
Figure 4.49. Fastening the engine suspension reaction arm: 1 - reaction lever; 2 - bolt, 55 Nm; 3 - bolt, 40 Nm
Unscrew the bolts and remove the reaction bracket 1 (see figure 4.49) engine mounts.
Remove the air intake pipe.
Disconnect and set aside the hand pump for bleeding the fuel system.
Install crossmember 0911-AY to support the engine.
Protect the inside of the cooling system radiator with a sheet of cardboard cut to the size of the radiator.
Figure 4.57. Engine mount: 1 - support for the hand pump for bleeding the fuel system; 2 - bolts; 3 - toothed belt cover; 4 - right engine support bracket
Remove support 1 (figure 4.57) hand pump for bleeding the fuel system.
Remove the timing belt covers.
Remove bolts 2 and remove the right engine mount bracket.
Turn the engine crankshaft to a position where the piston of the 1st cylinder is set to the TDC position.
Using special tool 0188-Y, secure the crankshaft from turning.
Using special tool 0188-M, secure the camshaft pulley.
Figure 4.58. Fixing the camshaft pulley with special tool 0188-M (3) and the direction of rotation of the key (1) to loosen the tension roller fastening nut (2)
Loosen nut 2 (figure 4.58) tension roller mount and re-tighten it after the timing belt tension has been released as much as possible.
Remove the timing belt.
Installation
Caution! Do not twist or bend the timing belt. Prevent the timing belt from coming into contact with oil, coolant or fuel. If the outer surface of the timing belt is significantly worn or delaminated, check the condition of the idler and tension roller races. If there are any defects on the timing belt, replace it.
Check that the water pump, idler and tensioner rollers rotate smoothly and evenly.
If the guide roller was replaced, tighten the roller mounting bolt to 43 N·m.
Figure 4.59. Location of pulleys and rollers: 1 - guide roller; 2 - water pump pulley; 3 - tension roller; 4 - camshaft pulley; 5 - bolts
Remove bolts 5 (figure 4.59) fastening of pulley 4 of the camshaft.
Check that the timing belt pulley rotates freely on the camshaft.
Tighten bolts 5 of camshaft pulley 4 by hand.
Turn the pulley clockwise until it stops.
Figure 4.60. Location of the toothed belt on the pulleys: 1 - water pump; 2 - tension roller; 3 - camshaft pulley; 4 - high pressure fuel pump; 5 - guide roller; 6 - device 0188-K for maintaining the belt on the crankshaft pulley; a - angular displacement of the pulley
Install the timing belt on the crankshaft pulley and secure it with a special tool 6 (figure 4.60) 0188-K for supporting the belt.
Install, while simultaneously tensioning the toothed belt on the pulleys, in the following order:
- guide roller 5;
- pulley 4 of the high-pressure fuel pump;
- camshaft pulley 3;
- tension roller 2;
- pulley 1 of the water pump.
Install the previously removed belt in accordance with the marks applied.
When installing the timing belt on the camshaft pulley, first turn the pulley counterclockwise to the normal rotation of the engine to facilitate belt installation.
Attention! Angular displacement a (see Figure 4.60) the pulley's distance from the belt should not exceed the width of one tooth.
Position the tension roller against the timing belt and tighten the roller mounting bolt to 1 Nm.
Remove tool 6-0188-K, which supports the timing belt on the crankshaft pulley.
Pre-tensioning of the timing belt
Install the 0192 belt tension measuring device sensor on the toothed belt branch between the fuel pump and camshaft pulleys. Make sure that the sensor does not touch surrounding mechanisms.
Using lever 0188-J2, turn the tension roller counterclockwise until the belt tension is (98±2) units. In this position, tighten the tension roller mounting bolt to a torque of 23 N·m.
Remove the sensor from the 0192 belt tension measuring device.
Tighten the camshaft pulley mounting bolts.
Remove tools 0188-Y and 0188-M, which secure the camshaft and crankshaft.
Turn the engine crankshaft 10 revolutions.
Final tensioning of the timing belt
Using special tools 0188-Y and 0188-M, secure the crankshaft and camshaft pulley.
Remove bolts 5 (see Figure 4.59) camshaft pulley fastenings.
Tighten bolts 5 of camshaft pulley 4 by hand.
Loosen bolts 5 of the camshaft pulley by 1/6 of a turn.
Loosen the tension roller mounting bolt.
Install the 0192 belt tension measuring device sensor on the toothed belt branch between the fuel pump and camshaft pulleys.
Using lever 0188-J2, turn the tension roller counterclockwise until the belt tension is (54±2) units. In this position, tighten the tension roller mounting bolt to a torque of 23 N·m.
Tighten the camshaft pulley mounting bolts.
Remove the sensor from the 0192 belt tension measuring device.
Reinstall the 0192 belt tension gauge.
The tension value of the toothed belt should be within 51-57 units.
Caution: If the resulting belt tension value is outside the tolerance range, loosen the belt and repeat the belt tensioning operations.
Remove the sensor from the 0192 belt tension measuring device.
Remove tools 0188-Y and 0188-M, which secure the camshaft and crankshaft.
Checking the timing belt tension adjustment
Turn the engine crankshaft 10 revolutions.
Install special tool 0188-Y to lock the crankshaft.
Visually check that the difference between the hole in the camshaft flange and the hole for the corresponding retainer is no more than 1 mm.
Remove the crankshaft locking tool 0188-Y.
Install the timing belt covers.
Install the engine mount cushion.
Tighten the camshaft timing belt pulley mounting bolts to 61 N·m.
Install the hand pump support to bleed the fuel system.
Install special tool 0188-F to prevent the flywheel from turning.
Install the reaction bracket 1 in place (see figure 4.49) engine mounts and tighten the bracket mounting bolts: bolt 2 - to 55 Nm; bolt 3 - torque 40 Nm.
Install the accessory drive belt pulley.
Using an M16x150 tap, clean the threads in the crankshaft for the central pulley mounting bolt.
Apply LOCTITE FRENETANCH to the threads of the central crankshaft pulley mounting bolt to prevent them from loosening (blocking fluid), screw in the bolt and tighten it to a torque of 40 Nm, then turn it further to an angle of 51°.
Install the accessory drive belt.
Remove special tool 0188-F, which secures the flywheel from turning.
Further installation is carried out in the reverse order of removal.
Install the front wheels and secure them with bolts, tightening them to a torque of 90 Nm.
Perform programming of the engine control computer.