A) Align the pulley and shaft profiles and install the pulley.
b) Tighten the oil pump pulley nut
- Tightening torque - 28 Nm
2. Install the crankshaft sprocket. (If it was taken).
A) Install the key into the keyway.
b) Install the crankshaft sprocket with the belt guide inward.
3. Install intermediate pulley (if it was taken).
A) Install the pulley and tighten the bolt.
- Tightening torque - 42 Nm
Note: Use a 35mm long bolt.
b) Check that the pulley rotates freely.
4. Temporarily install the tension roller and its spring.
A) Align the hole with the guide pin.
b) Install the tension roller and bolt. Do not tighten the bolt.
Note: Use a 42mm long bolt.
V) Install the tension roller spring.
G) Press the roller to the left as far as possible and tighten the bolt.
d) Check that the tension roller rotates freely.
5. Temporarily install the timing belt.
A) Rotate the crankshaft at the pulley bolt.
b) Align the timing marks on the crankshaft sprocket with the marks on the oil pump housing.
V) Remove any oil or water from the crankshaft pulley, oil pump pulley, water pump pulley, tensioner pulley and idler pulley.
G) Install the timing belt to the crankshaft sprocket, oil pump pulley, tensioner pulley, coolant pump pulley and idler pulley.
Note: When reusing the timing belt, align the marks made during removal and install the belt with the arrow pointing in the direction of rotation of the engine crankshaft.
6. Install the timing belt guide
7. Install the lower timing belt cover.
A) Install or glue the gasket to the timing belt cover.
Note: If the gasket is swollen or resized due to an oil leak, cut off the excess.
b) Install the timing belt cover and tighten the four bolts.
8. Install the crankshaft pulley.
A) Align the pulley key with the groove on the pulley and install the pulley.
b) Tighten the pulley bolt.
- Tightening torque - 108 Nm
9. Establish a gear pulley of a camshaft.
A) Align the camshaft locating pin with the pin hole, and install the camshaft sprocket.
b) Tighten the pulley bolt.
- Tightening torque - 54 Nm
10. Set the piston of cylinder No. 1 to TDC of the compression stroke.
A) Rotate the crankshaft pulley and align it with the alignment mark «0» on the lower timing belt cover.
b) Using the special tool, rotate the camshaft and align the camshaft sprocket bore with the bearing cap alignment mark.
11. Install the timing belt on the camshaft sprocket.
Note: When reusing the timing belt, check that the marks on the timing belt and cover are aligned.
Check the alignment of the marks on the timing belt and the camshaft sprocket.
If necessary, reinstall the timing belt until they are aligned.
A) Remove, if any, oil or water from the camshaft sprocket.
b) Install the timing belt on the camshaft sprocket while controlling the tension of the working branch between the crankshaft sprocket and the camshaft sprocket.
12. Check the valve timing, and) Loosen the tension roller by turning the bolt 1/2 turn.
b) Slowly turn the crankshaft pulley two turns from TDC to TDC.
Note: Always turn the crankshaft pulley clockwise, otherwise the roller will "will win back", the belt will get slack and slip a tooth.
V) Check that each pulley is aligned with the timing marks as shown in the illustration.
If the alignment marks are not aligned, remove the timing belt and reinstall it.
G) Tension the timing belt. Slowly turning the crankshaft pulley 1 and 7/8 turns, align it with the mark 45°to TDC (for cylinder #1) on the lower timing belt cover.
Note: Always turn the crankshaft pulley clockwise.
d) Tighten the idler pulley bolt.
- Tightening torque - 42 Nm
13. Install the timing belt top cover.
A) Install the gasket on the lower timing belt cover.
Note: it is better to glue the gasket so that it does not come off inside.
b) Disconnect the harness guard from the cylinder head and rear timing belt cover.
V) Install the timing belt cover by tightening the four bolts.
G) Install the two wire harness clamps.
d) Install the engine harness guard clamps to the two timing belt upper cover bolts in the sequence shown.
14. Install the spark plugs and connect the high voltage wires to the spark plugs.
- Tightening torque - 18 Nm
15. Install the right engine mount by tightening the three bolts.
- Tightening torque - 52 Nm
16. Install the generator.
A) Install the generator on the hinge, locking bolts (models with air conditioning) or adjusting screw (models without air conditioning). Do not overtighten the bolts.
b) Install the alternator drive belt and adjust its tension.
V) Tighten all bolts
Torque:
- hinge bolt - 54 Nm
- locking and adjusting bolt - 19 Nm
G) Connect the generator connector.
e) Connect the generator wire by tightening the wire fastening nut and install the rubber cap.
h) Connect the wire harness clamp to the clamp on the alternator.