Removing
Remove cover downwards and to the left.
Remove the air filter see point 6.6.
Unscrew the upper part of the intake manifold from the lower part and from the holders. First unscrew the connection for the exhaust outlet and remove the ventilation and air inlet hoses.
Remove glow plugs see point 9.4.
Place a wooden jack under the oil pan and support the engine to allow the engine mount bracket to be removed.
Remove the V-belt see paragraph 1.21.
Loosen all adjusting bolts of the rocker arms so that the ends of the bolts protrude only 0+2 mm.
Set the crankshaft to the TDC of the piston of the 1st cylinder and complete the adjustment there.
Setting the piston of the 1st cylinder to TDC.
Unscrew the upper toothed belt cover.
Rotate the crankshaft clockwise until the camshaft wheel mark is at TDC.
You can turn the crankshaft in several ways:
1. Raise the car from the front side. Engage 5th gear, cock the handbrake. Turn raised front wheel. This causes the crankshaft to rotate. Assistance required to turn the wheel
2. Place the car on a level surface. Engage 5th gear. Move the car forward.
3. Turn the crankshaft at the central bolt of the belt pulley. Pre-engage neutral gear and cock the handbrake.
Attention: Do not turn the engine by the camshaft wheel mounting bolt. This will overload the toothed belt.
Turn the engine so that the mark on the camshaft wheel matches the pointer. The piston of cylinder 1 is at TDC.
Unscrew the crankshaft pulley. To hold the belt pulley, use tool MD-998747 with an old V-belt.
Attention: V-belt must not be damaged. After using it as an accessory, under no circumstances should the belt be reinstalled. If no special tool is available, engage first gear and, with the help of a second person, block the wheels with the brake.
Unscrew the lower toothed belt cover.
Mark the direction of movement of the toothed belt with chalk or felt-tip pen. The toothed belt rotates clockwise.
Loosen toothed belt tension.
Remove toothed belt.
Attention: Do not knock down the TDC position of the camshaft and crankshaft with the toothed belt removed. If it is necessary to rotate the camshaft with the toothed belt removed, make sure that the crankshaft is not in the TDC position (risk of damage to valves and pistons). To do this, mark the position of the crankshaft gear (apply paint markings on the crankshaft gear and on the engine block). Then turn the crankshaft wheel ¼ turn forward or backward.
Checking the condition of the toothed belt
Be sure to replace the toothed belt if the following defects are present:
Traces of oil or coolant on the toothed belt. As a rule, the reason for this lies in the leakage of the seals of the housing or camshaft or the leakage of the water pump.
Rubber hardening on the outside of the toothed belt. The belt thus becomes shiny, inelastic, and so stiff that there is no trace of a strongly pressed fingernail.
Gusts of rubber on the outer strap of the belt.
Tearing and tearing of fabric on the inside of the belt.
Gusts at the base of the teeth.
Gusts on the narrow side of the belt.
Severe wear on the narrow side of the belt.
Severe tooth wear. Fraying of the fabric on the loaded side of the teeth. Rubber peeling, color change to white. Reducing the width of the teeth. Chipped teeth.
Installation
Check the TDC position of the camshaft, fuel injection pump, oil pump and crankshaft, set if necessary.
Attention: If it is necessary to rotate the camshaft with the toothed belt removed, the crankshaft must not be in the TDC position.
Apply toothed belt. When doing so, the direction of rotation marking made during removal must be taken into account. A used toothed belt must only be refitted in the same direction of travel.
First put the toothed belt on the crankshaft gear, and then pass it through the idler roller, camshaft gear and oil pump gear. At the same time, make sure that the toothed belt fits between two adjacent gears in a tensioned state.
Attention: Align the TDC mark on the fuel injection pump gear with the mark on the engine using a bent spanner with the toothed belt applied.
Place the toothed belt on the tension roller.
Pull on toothed belt.
Rotate the toothed belt clockwise until all TDC markings match.
Attention: All TDC markings must match, otherwise repeat the installation.
Check toothed belt tension.
Adjust valve clearances see paragraph 1.18.
Screw on the cylinder head cover, first installing the gaskets, see point 1.10.
Install the upper and lower toothed belt covers. Insert the bolts according to their dimensions shown in the figure.
Install the V-belt see item 1 21.
Screw the upper engine mount, see item 1 4.
Install glow plugs see point 9.4.
Install the intake manifold top. To do this, insert new O-rings into the lower part of the manifold, fit the upper part and tighten the bolts alternately to 15 Nm. Fasten the collector to the holders with a force of 15 Nm. Fit the exhaust pipe with a new seal and tighten it with 20 Nm. Put on the ventilation and air intake hoses and secure them with clamps.
Install the air filter see point 6.6.
Install the bottom left cover.