Removal
Disconnect the cable from the negative battery terminal.
Caution! Disconnecting the negative battery cable will erase the memory of electronic memory devices, such as the radio receiver code.
Raise the vehicle and remove the right front wheel.
Remove the lower engine cover in the right wheel arch.
Figure 4.12. RF-N engine belt arrangement: 1 – idler pulley; 2 – left and right timing belt covers; 3 – crankshaft pulley; 4 – V-belt; 5 – side engine cover; 6 – V-belt idler roller; 7 – toothed belt; 8 – tension roller with spring
Remove the V-belt (figure 4.12).
Set the piston of the first cylinder to TDC in the compression stroke. To do this, check
Figure 4.13. Alignment of marks on the toothed belt pulleys when setting the piston of the first cylinder to TDC in the compression stroke
engine crankshaft until the mark on the crankshaft pulley is aligned with the mark on the front cover of the cylinder block (figure 4.13).
Secure the engine crankshaft from turning and unscrew the crankshaft belt pulley mounting bolts.
To lock the engine, engage 5th gear and have the assistant press the brake pedal.
Remove the crankshaft pulley.
Remove the bolts and the right and left timing belt covers.
Remove the engine mount.
Remove the glow plugs. To turn the engine crankshaft, apply the parking brake and move the gearshift lever to neutral. Using a ratchet and socket, turn the crankshaft from the right wheel arch side.
Caution! Never turn the crankshaft using the camshaft pulley via the belt drive.
Use chalk, marker or paint to mark the direction of rotation of the timing belt. If the timing belt rotates in the opposite direction during installation, it will be damaged. The engine pulleys rotate clockwise.
Figure 4.14. Loosening the bolt and moving the tension roller away from the timing belt
Loosen the tension roller mounting bolt and move the tension roller away from the timing belt (figure 4.14). After loosening the timing belt tension, tighten the tension roller mounting bolt again.
Unscrew the idler pulley.
Remove the timing belt. After removing the timing belt, do not turn the pulleys.
Caution! Before removing the timing belt, double-check that the mark on the camshaft pulley aligns with the edge of the cylinder head, and adjust the pulley position if necessary.
Caution! If it is necessary to turn the camshaft with the timing belt removed, none of the pistons should be at TDC, as otherwise serious damage to the pistons and valves may occur.
If it is necessary to turn the camshaft, first set all pistons to the middle of their stroke. To do this, use chalk to make a mark on the top of the crankshaft pulley, with the crankshaft in the TDC position of the first cylinder, then turn the crankshaft pulley 1/4 turn (90°) to the left or right. Now the mark should be directed to the left or right, respectively.
Caution! Do not bend or twist the timing belt. Be sure to replace belts that are dirty, damaged or worn. Check that the tension roller rotates evenly and easily.
[The text of the article is taken from the website MAZBOOK.RU]
Installation
Make sure that the mark on the crankshaft pulley aligns with the mark on the front cylinder block cover, and the mark on the camshaft pulley aligns with the mark on the rear timing belt cover. If necessary, rotate the pulleys until all marks are aligned.
Install the timing belt onto the pulleys. Lay the old belt in accordance with the previously applied arrow indicating the direction of belt rotation.
Install the idler pulley and secure it with the bolt, tightening it to a torque of 50 Nm.
Caution: Make sure the belt grips the pulleys securely and does not sag.
Adjusting the belt tension
Loosen the tension roller mounting bolt so that the roller can move toward the timing belt under the force of the spring. Turn the crankshaft two revolutions clockwise until the camshaft mark aligns with the mark on the rear timing belt cover. Double check that all the marks match.
Tighten the tension roller mounting bolt to 50 Nm.
Turn the crankshaft two revolutions in the direction of engine rotation and check the alignment of the marks again.
Figure 4.15. Location for checking the RF-N engine toothed belt deflection
The toothed belt branch between the pulleys of the high-pressure fuel pump and the camshaft should deflect by 9.0–11.0 mm when pressing on the belt with a force of 10 kgf (strong finger pressure) (figure 4.15). Otherwise, loosen the tension roller mounting bolt and adjust the belt tension again.
Install and bolt the right and left timing belt covers, tightening the bolts to a torque of 10 Nm.
Figure 4.16. Location of the bolt and nut for fastening the upper RF-N engine mount
Install the upper engine mount and tighten the bolt to 115 N·m and the nut to 90 N·m (figure 4.16).
Block the engine crankshaft from turning, tighten the crankshaft pulley mounting bolts to 30 Nm. To lock the engine, engage 5th gear and have an assistant press the brake pedal.
Screw in the glow plugs.
Install and tension the V-belt.
Install the cover in the right wheel arch.
Connect the cable to the negative terminal of the battery.
If you have a clock, set the time and enter the radio security code.