- 1. Support the car in front. Engage fifth gear, tighten the parking brake. Turn the suspended front wheel. In this case, the crankshaft of the engine will also rotate. An assistant is needed to turn the wheel.
- 2. Put the car on a flat surface. Engage fifth gear. Roll the car forward or backward.
- 3. Turn the crankshaft at the central bolt of the vibration damper (pulley) with a captive head. Put the gearbox in neutral position first.
Caution: Do not turn the engine over the camshaft sprocket bolt, as this can overload the toothed belt.
Rotate the crankshaft until the elongated hole in the injection pump sprocket is at the top in position A.
Rotate the crankshaft approximately 30°in the opposite direction (position B).
To accurately adjust the TDC position of the crankshaft, a special adjusting pin is required. In extreme cases, you can make it yourself, guided by the picture.
Unscrew the cap screw on the cylinder block (arrow). It is located at the front of the engine between the injection pump and the alternator.
Insert the adjusting pin into the hole.
Turn the crankshaft clockwise with a spanner until it rests on the adjusting pin. In this case, the crankshaft will be exactly in the TDC position.
Insert the camshaft locating pin or a suitable 6 mm diameter rod.
Insert the locating pin of the injection pump. This requires a special pin or rod with a diameter of 9.5 mm.
Loosen the timing belt tensioner bolt (E). Pull tensioner off toothed belt (A) and tighten the bolt back. This bolt requires a special key.
Attention: If a large force was used to unscrew the bolt or a chisel was used, the bolt and tensioner should be replaced. Otherwise, the tensioner may fail soon, resulting in serious engine damage. (C - oil filter holder).
Loosen the timing belt tensioner bolt (D). Pull tensioner off toothed belt (IN) and tighten the bolt back.
Loosen the four camshaft sprocket mounting bolts so that the sprocket moves freely inside the elongated holes.
Loosen the three bolts securing the injection pump sprocket so that it moves freely in the elongated holes. О Remove both toothed belts. The engine must not be turned after removing the camshaft timing belt, otherwise the valves and pistons may be damaged.
Rotate the belt tensioner and intermediate sprocket, check for cracks, scratches or other damage and replace parts if necessary. Check the bearing for ease of movement, seizing and, at high speeds, excessive noise and replace if necessary. Check plastic intermediate sprocket for tooth wear (the size in the middle is smaller than the size on the edges) and, if necessary, replace it.