Removal the timing belt
1. Remove the right engine mount support by unscrewing the three bolts.
2 Remove the generator.
- a) Disconnect the wiring harness clamp from the clamp on the generator
- b) Disconnect the generator connector.
- c) Remove the rubber cap, unscrew the wire fastening nut and disconnect the generator wire.
- d) Loosen the lock bolt (models with air conditioning), adjusting bolt and hinge bolt.
- d) Remove the generator drive belt.
- e) Remove the adjustment lock bolt (models with air conditioning) or adjusting bolt (models without air conditioning) and the hinge bolt.
- g) Remove the generator.
3. Remove the spark plugs.
- a) Disconnect the high-voltage wires by the rubber caps. Do not pull the high-voltage wires.
- b) Remove the spark plugs.
4. Remove timing belt cover No.2 by unscrewing five bolts and remove two gaskets.
5. Set the piston of cylinder No.1 to TDC of the compression stroke
- a) Turn the crankshaft pulley and align its mark with the timing mark "0" on timing belt cover No.1.
- b) Check that the timing notch on the camshaft sprocket is aligned with the timing mark on the bearing cap. If not, rotate the crankshaft one revolution (360°).
6. Remove the timing belt from the camshaft sprocket.
Note: When reusing the timing belt, apply an arrow in the direction of rotation, marks on the timing belt and camshaft sprocket, and align them with the mark on the No.1 timing belt cover as shown in the figure.
- a) Loosen the tension roller mounting bolt and, being careful not to damage the belt, push the roller to the left as far as possible and temporarily tighten the bolt.
- b) Remove the timing belt from the camshaft toothed pulley.
7. If necessary, remove the camshaft toothed pulley by unscrewing the mounting bolt
8. Remove the crankshaft pulley.
- a) Using a special tool, loosen the pulley bolt.
Note:
- When reusing the timing belt, after loosening the crankshaft pulley bolt, check that the timing belt marks and timing belt cover No.1 are aligned when aligning the timing marks (the notch on the crankshaft pulley and "0" on the timing belt cover No.1).
- When the bolt is loosened, the crankshaft may turn and, since it is not synchronized with the camshaft, it may bend the valves under certain circumstances.
If the marks are not aligned, then do the following:
Note:
- The crankshaft can only be turned clockwise, but at small rotation angles it can also be turned counterclockwise.
- Align the alignment marks as shown in the figure.
- After aligning the marks, hold the timing belt and turn the crankshaft pulley, aligning its installation mark with the installation mark "0" on the timing belt cover No.1.
- c) Remove the pulley by unscrewing the bolt.
9. Remove timing belt cover No.1 by unscrewing four bolts and remove the gasket.
10. Remove the timing belt guide.
11. Remove the timing belt.
Note: When reusing the timing belt, mark it with an arrow in the direction of rotation and make marks on the timing belt and crankshaft sprocket.
12. Remove the tension roller and tension roller spring by unscrewing the bolt.
13. If necessary, remove the intermediate pulley by unscrewing the bolt.
14. If necessary, remove the crankshaft toothed pulley. If the pulley is difficult to remove by hand, use two screwdrivers.
Note: Place the rag as shown in the picture to prevent damage.
15. If necessary, remove the oil pump pulley by unscrewing the nut.
Installing the timing belt
1. Install the oil pump pulley if removed
- a) Align the pulley and shaft profiles and install the pulley.
- b) Tighten the oil pump pulley mounting nut.
- Tightening torque - 28 Nm
2. Install the crankshaft timing pulley (if it was filmed).
- a) Align the locating key on the crankshaft with the keyway in the pulley.
- b) Install the crankshaft timing belt guide pulley inside
3. Install the idler pulley. (If it was filmed).
- a) Install the pulley and tighten the bolt.
- Tightening torque - 42 Nm
Note: Use 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 42mm long bolt.
- c) Install the tension roller spring.
- d) 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) Turn the crankshaft by the pulley bolt and align the timing marks on the crankshaft toothed pulley with the marks on the oil pump housing.
- b) Remove any oil or water from the crankshaft pulley, oil pump pulley, coolant pump pulley, tensioner roller No.1 and No.2, if any.
- c) Install the timing belt on the crankshaft toothed pulley, oil pump pulley, tensioner roller No.1, coolant pump pulley and tensioner roller No.2.
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 with the front side facing out.
7. Install timing belt cover No.1.
- a) Install or glue the gasket onto the timing belt cover.
Note: If the gasket has swollen or changed size due to oil leakage, 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. Install the camshaft timing pulley.
- a) Align the camshaft dowel pin with the dowel hole and install the camshaft timing pulley.
- b) Tighten the pulley bolt.
- Tightening torque - 54 Nm
10. Set the piston of cylinder No.1 to TDC of the compression stroke.
- a) Turn the crankshaft pulley and align its mark with the installation mark "0" on the timing belt cover No.1.
- b) Using the special tool, turn the camshaft and align the hole in the camshaft toothed pulley with the timing mark on the bearing cap.
11. Install the timing belt onto the camshaft sprocket
Note: When reusing the timing belt
- Check that the marks on the timing belt and cover are aligned. If necessary, reinstall the timing belt until they are aligned
- Align the timing belt marks with the camshaft sprocket marks.
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- a) Remove any oil or water from the camshaft sprocket, if any
- b) Install the timing belt on the camshaft toothed pulley, checking the tension of the working branch between the crankshaft toothed pulley and the camshaft toothed pulley.
12. Check the valve timing.
- a) Loosen the tension roller by turning the bolt 1/2 turn.
- b) Slowly turn the crankshaft pulley two revolutions from TDC to TDC.
Note: Always turn the crankshaft pulley clockwise, otherwise the roller will 'play back', the belt will become slack and skip a tooth.
- c) Check that each pulley is aligned with the timing marks as shown in the illustration. If the timing marks are not aligned, remove the timing belt and reinstall it.
- d) Slowly turning the crankshaft pulley by 1 and 7/8 turns, align its mark with the 45° before TDC mark (for cylinder No.1) on cover No.1 of the timing belt.
Note: Always turn the crankshaft pulley clockwise.
- d) Tighten the tension roller mounting bolt.
- Tightening torque - 42 Nm
13. Install timing belt cover No.2
- a) Install the gasket on the N81 timing belt cover.
Note: It is better to glue the gasket so that it does not slip inside.
- b) Disconnect the wiring harness protector from the cylinder head and timing belt cover No.3.
- c) Install the timing belt cover by tightening the four bolts.
- d) Install the two wire harness clamps.
- d) Install the engine wiring harness protection clamps to the two timing belt cover #2 mounting bolts in the sequence shown in the figure.
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 support 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 on the adjusting bolt (models without air conditioning). Do not tighten the bolts.
- b) Install the generator drive belt and adjust its tension.
- c) Tighten all bolts.
- Tightening torque:
- hinge bolt - 54 Nm
- locking and adjusting bolt - 19 Nm
- d) Connect the generator connector.
- d) Connect the generator wire by tightening the wire fastening nut and install the rubber cap.
- e) Connect the wire harness clamp to the clamp on the generator.