Removing the timing belt (1.9 liter engines)
8. Square holes 10mm; 9, 10, 11. Adjusting bolts of the gas distribution mechanism; 12. Nut for fastening the pivot point of the tension mechanism; 13. Bolt fixing the tension mechanism
The timing belt drives the camshaft, fuel pump and water pump from the crankshaft pulley. If the timing belt breaks, the pistons and valves can collide, resulting in severe engine damage.
The toothed belt must be changed at the specified time interval, or sooner if it has been contaminated with engine oil.
After removing the toothed belt, check the condition of the water pump and its tightness (coolant leaks).
Removing
1.9 liter engines
1. Install the timing mechanism and fix it with rods or bolts. Disconnect the negative terminal from the battery.
2. Remove the remaining toothed belt covers.
3. Remove the right suspension bracket of the power unit. Loosen the timing belt tensioner pivot nut and fixing bolt, then turn the tensioner counterclockwise to release tension on the belt and re-tighten the fixing bolt. If possible, use a 10 mm square wrench to turn the tensioner.
4. Mark the direction of rotation of the belt with an arrow and remove the belt from the pulleys.
Engines 2.1 liters
5. Install the timing mechanism and fix it with rods or bolts. Disconnect the negative terminal from the battery.
6. Remove the remaining toothed belt covers.
7. Loosen the lock nut of the toothed belt tensioner pulley, located to the left of the suspension installation.
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8. Using a bent 5mm wrench inserted through the hole in the suspension setup, loosen the clamp bolt (IN) toothed belt tensioner (A - lock nut).
9. Using a 10mm key inserted through the same hole (indicated by an arrow), retract the tensioner by turning the shaft clockwise.
10. Mark the direction of rotation of the belt with an arrow and remove the belt from the pulleys.
Examination
Check the condition of the toothed belt for wear, separation and oil contamination. Pay special attention to the root of the teeth. If there is any defect, the belt must be replaced. If traces of oil are found on the belt, the source of the oil leak must be found and eliminated. Check the condition of the tension mechanism and the rotation of the idler pulley, which should rotate easily and evenly.
Installation and tension
1.9 liter engine models
1. Check for the presence of fixing bolts and rods on the timing mechanism.
2. Install the toothed belt on the crankshaft pulley, taking into account the direction of its rotation based on the previously made mark.
3. Install the toothed belt onto the pulleys in the following order:
- guide roller;
- high pressure fuel pump;
- camshaft;
- cooling pump.
4. When installing the belt on the fuel pump pulley, install it only half way and, after fitting it on the camshaft pulley, slide the belt over the fuel pump pulley.
5. Remove the fixing bolts from the camshaft and fuel pump pulleys and the flywheel fixing rod.
6. Loosen the pivot point nut and tensioner adjustment bolt and slowly release the tensioner until it contacts the timing belt. Retighten the adjustment bolt and pivot point nut.
7. Rotate the crankshaft two full turns in the running direction.
8. Loosen the tensioner mount and pivot point nut to allow the tensioner to tension the toothed belt. Retighten the adjustment bolt and pivot point nut.
9. Check that the mounting holes on the camshaft pulleys, fuel pump and flywheel are aligned. Otherwise, reinstall the toothed belt.
10. Further installation is carried out in the reverse order of removal.
2.1 liter engine models
11. Check for the presence of fixing bolts and rods on the timing mechanism.
12. Remove the toothed belt tensioner and tighten the lock nut. When using a 10mm wrench, loosen the tensioner by turning it counterclockwise.
13. Install the toothed belt on the crankshaft pulley, taking into account the direction of its rotation based on the previously made mark.
14. Install the toothed belt onto the pulleys in the following order:
- guide roller;
- high pressure fuel pump;
- camshaft;
- cooling system pump;
- tension roller.
15. When installing the belt on the fuel pump pulley, install it only half way, and after installing it on the camshaft pulley, slide the belt over the fuel pump pulley.
16. Loosen the tensioner pulley lock nut to allow the tensioner to tension the toothed belt.
17. Remove the fixing bolts from the camshaft and fuel pump pulleys and the flywheel fixing rod.
18. Rotate the crankshaft two full turns in the running direction.
19. Loosen the idler pulley lock nut, then turn the crankshaft two full turns.
20. Loosen the tensioner pulley lock nut so that the tensioner tensions the toothed belt, and tighten the lock nut and tensioner clamp bolt.
21. Check that the mounting holes on the camshaft pulleys, fuel pump and flywheel are aligned. Otherwise, reinstall the toothed belt.
22. Further installation is carried out in the reverse order of removal.