Timing belt drive with double pulley injection pump

Engine 1Y

Removing

1. Remove the ribbed belt.

2. If installed, remove the ribbed belt tensioner.

3. Remove the upper part of the timing case and the cylinder head cover.

4. Align the TDC marks on the piston of cylinder No. 1 on the crankshaft (pic. 6.10).



5. Install adjuster 2068 A as shown in fig. 6.4. Set the adjusting device to 5mm (arrow A). Turn the crankshaft so that the TDC marks on the flywheel match the mark on the setting device (arrow B).

6. Lock the camshaft pulley with the lock (rice. 6.6).

7. Lock the injection pump pulley with locking pin 3359 (pic. 6.11). Loosen the bolts 1 for fastening the injection pump pulley.



8. Loosen the tension roller.

9. Remove the coolant pump pulley (use VAG 1590 to loosen and tighten the fixing bolt).


10. Remove the crankshaft pulley/damper.

11. Remove the lower part of the timing belt cover.

12. Mark the direction of movement of the timing belt.

13. Remove the intermediate roller.

14. Remove the timing belt.

Installation

15. Make sure that the TDC mark on the flywheel and the reference point are aligned.

16. Loosen the camshaft pulley bolt 1/2 turn (rice. 6.8). Disconnect the pulley from the hub using a hammer and punch.

17. Install the timing belt in the direction of travel and remove the injection pump pulley locking pin.

18. Install the intermediate roller. Tightening torque - 25 Nm.

19. Tighten the timing belt (rice. 6.9). Using a wrench, turn the tension roller in the direction of the arrow (clockwise) so that the marks (arrows) aligned.

20. Tighten the locking nut of the tension roller. The tightening torque is 20 Nm.

21. Make sure again that the TDC mark on the flywheel and the reference point are aligned.

22. Tighten the camshaft pulley bolt to 45 Nm. Tighten the injection pump pulley bolt to 25 Nm.

23. Remove the camshaft pulley retainer and the injection pump pulley locking pin.

24. Scroll the crankshaft two turns in the direction of rotation so that the TDC marks on the crankshaft are aligned.

25. Check the possibility of blocking the injection pump pulley using the locking pin (pic. 6.11).

26. If the injection pump pulley cannot be locked, loosen bolts 1, turn the pulley hub so that it is possible to insert the locking pin. Tighten the injection pump pulley bolt to 25 Nm.

27. Install the timing belt housing parts, damper and cylinder head cover.

28. Install the ribbed belt.