Note. Do not attempt to crank the engine when the crankshaft/camshaft/high pressure fuel pump is stuck. If the engine is to be left in this state for an extended period of time, it is recommended that warning labels be placed on the front panel and in the engine compartment. This will reduce the risk of accidental cranking of the engine by the starter, which can damage the engine if the shafts are locked.
1. On all models, mounting holes are drilled in the camshaft sprocket and flywheel. The holes are used to set the correct position of the crankshaft, camshaft and high pressure fuel pump and to prevent possible collision of valves and pistons when installing the cylinder head or installing the timing belt. When the mounting holes are aligned with the access holes in the cylinder head and cylinder block (whichever is applicable), bolts/rods of the appropriate diameter can be inserted to lock the camshaft, crankshaft and high pressure fuel pump against unintended rotation. Then proceed as described below. Note. When the dowel holes are aligned, cylinder #4 is at TDC on the compression stroke.
2. Remove the upper timing belt covers as described in paragraph 6.
3. Fully apply the parking brake. Raise the front of the vehicle and securely jack stands under it (see «Lifting and placing the car on supports»). Remove the right front wheel.
4. Now rotate the crankshaft so that the three alignment holes in the camshaft pulleys and the high pressure fuel pump (one hole in the camshaft sprocket and two holes in the high pressure fuel pump sprocket) were aligned with the corresponding holes on the engine front plate. To gain access to the right end of the engine, the plastic wheel arch locker must be removed. The locker is fixed with various screws and clamps. Release all fasteners and remove the locker from under the front fender. If necessary, release the coolant hoses under the fender to facilitate further access. The crankshaft can then be turned using a suitable socket and extension for the pulley bolt. Keep in mind that the crankshaft should only be turned clockwise (when viewed from the right side of the car).
5. Insert a 8 mm rod or drill through the hole in the left flange of the cylinder block near the starter. If necessary, carefully rotate the crankshaft until the pin is seated in the mounting hole in the flywheel (pic. 3.5, a, b).
Pic. 3.5, a. Set of tools for locking the engine in the TDC position
Pic. 3.5b. Kernel (marked with an arrow), inserted through the flange on the cylinder block into the mounting hole in the flywheel
6. Pass three bolts with a diameter of 8 mm through the holes in the toothed pulleys of the camshaft and high pressure fuel pump and screw them into the engine by hand (pic. 3.6, a, b).
Pic. 3.6, a. Bolt (marked with an arrow), inserted through the locating hole in the camshaft sprocket
Pic. 3.6b. bolts (marked with arrows), inserted through the mounting holes in the high pressure fuel pump sprocket
7. The crankshaft, camshaft and high pressure fuel pump are now locked and prevented from turning unintentionally.