20.8.1. Removing and installing the timing belt
When replacing the timing belt, the front right wheel must be raised.
- Disconnect the ground wire from the battery.
- Engage the highest gear to turn the crankshaft with the front wheel raised.
- Remove the oil pan under the engine.
- Using a 36 mm wrench, loosen the vibration damper nut (crankshaft belt pulley).
- Remove the timing belt covers.
- Unscrew the oil filler cap so that you can look into the hole. Turn the crankshaft to the position where the rocker arms of the first cylinder "intersect", that is, one rocker arm closes the valve, while the other rocker arm closes the corresponding valve. With the engine in this position, check that the line matches the mark on the cylinder block, as shown in Figure 355. The mark on the camshaft toothed pulley (A) in Figure 354 should be located opposite the bolt (2).
Figure 354 Timing belt application. References to numbers and letters are given in the text.
Figure 355 The marks on the flywheel and cylinder block must match.
- Loosen both tension rollers, push the rollers outward and tighten their fastening.
- Remove the timing belts and high pressure fuel pump drive belts.
- Installation of timing belts is carried out as follows.
- Turn the engine until the marks on the flywheel and cylinder block align, as shown in Figure 355 (if the engine was turning in the meantime).
- Turn the camshaft until the mark (A) in Figure 354 is positioned opposite the bolt (2).
- Place the toothed belt on the toothed pulleys. In this case, use Figure 354. After placing the toothed belt on the tension roller (1), 35 belt teeth should be located between mark (A) and mark (B).
- After this, tighten the timing belt. At service stations, a device is used that is inserted into the tension roller, as shown in Figure 356. In this case, the load is secured on the second groove. After releasing the device, it moves under the weight of the load and tightens the belt to a specified value. If such a device is not available, the roller should be moved so that the belt on the upper side can move a little more.
Figure 356. Tensioning the toothed belt to a specified value. The load (1) of the device must be installed with its side "a" on the second groove of the rod. The bent end of the rod is inserted into the tension roller.
- Tighten the top nut in Figure 356 to 32 Nm and then the bottom nut to 21 Nm.
- Check that the high pressure fuel pump is in the injection timing position and apply the belt. The belt should be tight on the side opposite the roller. With the belt in this position, loosen the tension roller nut and press the roller against the belt. Tighten the nut to a torque of 20 Nm.
- Turn the crankshaft two revolutions and check the position of all marks.
- Install the lower and then the upper timing belt cover. Tighten all bolts to a torque of 10 Nm.
- All other work is carried out in reverse order. The crankshaft pulley nut is tightened with a 36 mm socket wrench. Don't forget to install the oil pan.