Removal and installation of a gear belt (diesel)

The diesel engine is equipped with two toothed belts. Before removing the belt -B- for the injection pump, the belt -A- for the camshaft drive must be removed. After installing one or both belts, check and, if necessary, repair. adjust the gas distribution mechanism. To do this, you need three adjusting mandrels that you can make yourself. The toothed belt can only be removed from a cold engine.

Withdrawal

Disconnect the ground wire (-) from the battery.

Attention! As a result, data in electronic storage devices, such as an engine fault memory or a radio code, are erased. Please read the section carefully "Removing and installing the battery", before disconnecting it.

Disconnect the multi-pin connector of the power steering pressure sensor. The sensor is located at the top next to the toothed belt cover.

Unscrew the return and pressure hoses from the power steering oil pump.

Attention! Collect hydraulic oil. Close the holes with suitable plugs.

Unscrew the power steering pump pulley from the high pressure fuel pump sprocket.

Remove all V-belts (air conditioner, generator, power steering), see paragraph 1.19.




Raise the car on the goats. Unscrew the wheel arch trim -1-. Unscrew the protective cover of the V-belt pulley -2-.



Detach upper toothed belt guard -arrow-. Unscrew the bolt above the high pressure fuel pump and remove the cover.

Raise the vehicle. Disconnect the bottom protective cover of the toothed belt from the bottom of the car, to do this, unscrew the two bolts.

Rotate the crankshaft until it is at TDC on cylinders 1 or 4. To do this, shift the gearbox to the neutral position. Apply the parking brake. On the center bolt of the crankshaft belt pulley, place a SW32 bent ring wrench and turn the belt pulley clockwise. Other methods of cranking the engine: Engage 5th gear and drive the vehicle on a level surface.




The crankshaft is exactly at TDC in the first or fourth cylinder if the adjusting pins can be installed. The adjusting pins for the camshaft sprocket and the high-pressure fuel pump gear from Bosch have a diameter of 6 mm. If a Lucas high pressure fuel pump is used, a 9mm adjusting pin is used for the high pressure fuel pump gear.

Release fixing bolts of devices of a tension of gear belts - D - and - Е -, see fig. R-1037. The belt tensioner -D- requires a T50 Torx screwdriver.

Remove toothed belts. After removing the camshaft timing belt, the engine can no longer be cranked. otherwise the pistons and valves will be damaged.

Installation

Lay both toothed belts without turning the toothed belt sprockets.

Attention! The arrows on the timing belts must match the direction of rotation of the engine (right). If the timing belts are worn or oily, they must be replaced.

Start laying the belts from the sprockets on the crankshaft and continue to lay them counterclockwise, i.e. in the following sequence: crankshaft sprocket, camshaft or high pressure fuel pump sprocket, tension sprocket. As a result, a freer branch of the toothed belt will come to the tension rollers, which are under the influence of the spring.


Let the spring press the tensioning rollers against the toothed belts, tighten the tensioning roller bolts -D- and -E- to 50 Nm.

In conclusion, check the gas distribution mechanism, if necessary, adjust it, see the next section.

Remove the adjusting pins.

Install the lower and upper timing belt covers.

Screw the V-belt pulley with three bolts to the high pressure fuel pump sprocket. Install the V-belt see paragraph 1.19.

Screw the pressure and return hoses to the brake booster oil pump.

Connect the multi-pin plug to the pressure sensor.

Connect the ground wire to the battery. Set the clock, set the anti-theft code for the radio.

Pour hydraulic oil into the power steering reservoir and pump it see point 28.4.