Note. Do not attempt to crank the engine when the crankshaft/camshaft is locked. 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, the mounting holes are drilled in the toothed pulley (-Oh) camshaft (-ov) and on the back of the flywheel. The holes are used to confirm the correct position of the crankshaft and camshaft (-ov) when assembling the engine (to prevent possible collision of valves and pistons when installing the cylinder head) or installing a timing belt. When the alignment holes are aligned with the access holes in the cylinder head and front of the cylinder block, bolts/rods of the appropriate diameter can be inserted to lock the camshaft and crankshaft against unintended rotation. Then proceed as described below.
2. Remove the upper timing belt cover as described in paragraph 5.
3. On later engines with a plastic oil filter housing, access to the mounting hole in the flywheel can be improved by removing the oil filter (see chapter 1 A).
Engines 1.4 l
4. Now rotate the crankshaft until the alignment hole in the camshaft sprocket is aligned with the alignment hole in the cylinder head. The holes align when the hole in the camshaft sprocket is in position «2 hours», when viewed from the right end of the engine. The crankshaft can be turned with a wrench on the crankshaft sprocket bolt, but keep in mind that it should always be turned clockwise (viewed from the right side of the engine).
5. With the hole in the camshaft sprocket correctly positioned, pass a stud or rod with a diameter of 6 mm and a length of 90 mm (Ideally, the stud/rod should be welded to a piece of welding electrode bent into shape) through the hole on the front left flange of the cylinder block and insert it into the mounting hole on the back of the flywheel (pic. 3.5). A special tool is available from your dealer. Keep in mind that it may be necessary to turn the crankshaft slightly to align the holes.
Pic. 3.5. Insert a bolt/rod with a diameter of 6 mm (marked with an arrow) about the hole in the flange of the cylinder block and into the hole in the flywheel
6. With the flywheel correctly positioned, pass a 10 mm bolt or rod through the locating hole in the camshaft sprocket and insert it into the hole in the cylinder head (pic. 3.6).
Pic. 3.6. Lock the camshaft sprocket with a 10 mm bolt/rod (marked with an arrow) (engines 1.4 l)
7. The crankshaft and camshaft are now locked and prevented from turning unintentionally.
Engines 1.6 l
8. Turn the crankshaft so that the holes in the camshaft pulleys are aligned with the mounting holes in the cylinder head. The crankshaft can be turned with a wrench on the crankshaft sprocket bolt, but keep in mind that it should always be turned clockwise (viewed from the right side of the engine).
9. Having correctly positioned the holes in the camshaft pulleys, pass a stud or rod with a diameter of 6 mm and a length of 80 mm (ideally welded to a piece of welding electrode bent into shape) through the hole on the front left flange of the cylinder block and insert it into the mounting hole on the back of the flywheel (pic. 3.9, a, b). A special tool is available from your dealer. Keep in mind that it may be necessary to turn the crankshaft slightly to align the holes.
Pic. 3.9, a. Weld a rod/stud with a diameter of 6 mm and a length of 90 mm to a piece of welding electrode...
Pic. 3.9b....and insert it into the hole in the cylinder block flange (marked with an arrow)
10. With the flywheel correctly positioned, pass bolts or rods with a diameter of 10 mm through the mounting holes in the camshaft pulleys and insert them into the holes in the cylinder head (pic. 3.10).
Pic. 3.10. Use bolts/rods with a diameter of 10 mm (marked with arrows) for locking the camshaft pulleys (engines 1.6 l)
11 The crankshaft and camshafts are now locked and prevented from turning unintentionally.