Removing and installing timing belt. 1 - crankshaft pulley; 2 - a bolt of fastening of a pulley of a cranked shaft (М3=118 Nm); 3 - V-belt drive generator and coolant pump; 4 - protective cover No. 1 of the timing belt; 5 - protective cover No. 2 of the timing belt; 6 - protective cover No. 3 of the timing belt; 7 - timing belt; 8 - timing belt guide; 9 - engine wiring; 10 - protection of the motor wiring; 11 - hoses of the forced crankcase ventilation system; 12 - high voltage wires; 13 - spark plug; 14 - cylinder head cover; 15 - gasket; 16 - a gear pulley of a camshaft; 17 - a bolt of fastening of a gear pulley of a camshaft (М3=59 Nm); 18 - coolant pump pulley; 19 - tension roller of the timing belt; 20 - a bolt of fastening of a tension roller of a timing belt (M3 = 37 Nm); 21 - toothed pulley of the crankshaft for the timing belt; 22 - tension roller spring.
Removing the timing belt
1. Remove the alternator and coolant pump drive belt.
- A) Loosen the 4 coolant pump pulley bolts.
- b) Release a bolt of fastening of the generator and an adjusting bolt clamp.
- V) Loosen the adjusting bolt and remove the alternator and coolant pump drive belt.
- G) Turn out 4 bolts of fastening and remove a pulley of the pump of a cooling liquid.
2. Turn out the spark plugs, after removing the high voltage wires, holding them only by the rubber boots.
3. Remove the cylinder head cover.
- A) Disconnect:
- (1) generator connector.
- (2) generator wire.
- (3) emergency oil pressure sensor connector.
- (4) two cable ties.
- b) Turn away 2 bolts, fastenings and remove a protective cover of electroconducting.
- V) Disconnect the 2 hoses of the positive crankcase ventilation system from the cylinder head cover,
- G) Loosen the 4 cap nuts and remove the sealing washers, cover and cover gasket.
4. Set the piston of the first cylinder to the TDC of the end of the compression stroke.
- A) Turn the crankshaft pulley and align the groove on the pulley with the mark "ABOUT" on the protective cover No. 1 of the timing belt.
- b) Make sure the hole in the camshaft pulley aligns with the mark on its bearing cap.
Otherwise, crank the crankshaft one turn (360°).
5. Remove the crankshaft pulley.
- A) Using a suitable tool, remove the pulley fixing bolt.
- b) Remove with a puller (compress) crankshaft pulley.
6. Remove the timing belt guards.
7. Remove the timing belt guide.
8. Remove the timing belt.
Note: in case of reusing the belt, draw an arrow in the direction of the belt movement (in the direction of rotation of the crankshaft of the engine) and make marks on the belt and pulleys as shown in the pictures.
- A) Release the tension roller mounting bolt, move it all the way to the left and then temporarily fix it in this position with the same mounting bolt.
- b) Remove the timing belt.
9. Remove the tension roller and tension spring by completely unscrewing the tension roller mounting bolt.
10 If necessary, remove the crankshaft sprocket. In case of difficulty, use 2 screwdrivers.
Note: to prevent damage to the elements of the cylinder block, place a rag as shown in the figure.
11. If necessary, remove the camshaft drive gear pulley.
Holding the camshaft from turning, setting the adjustable wrench on its hex part, unscrew the fixing bolt and remove the pulley.
Note: when performing this operation, do not damage the block head with a wrench.
Timing belt installation
Note: Keep water or oil away from the camshaft and crankshaft pulleys and keep them clean.
1. Install the camshaft drive sprocket (if it was taken).
- A) Align the dowel pin on the nose of the camshaft with the groove of the toothed pulley and fit the pulley onto the camshaft.
- b) Temporarily install the pulley bolt.
- V) Holding the camshaft by its hex part with an adjustable wrench, tighten the camshaft pulley bolt (М3=59 Nm).
2. Install the crankshaft sprocket (if it was taken).
- A) Align the key on the crankshaft with the keyway on the toothed pulley.
- b) Push the pulley onto the toe of the crankshaft until it stops with the flare inward.
3. Temporarily install the tension roller and tension spring.
- A) Fasten the roller with a bolt, without tightening the latter.
- b) Install the tension spring.
- V) Pull the roller to the left until it stops and tighten the bolt.
4. Set the piston of the 1st cylinder to the TDC position at the end of the compression stroke.
- A) With an adjustable wrench on the hex section of the camshaft, turn it and align the mark on the camshaft bearing cap with the center of the small hole on the camshaft pulley.
- b) Using the crankshaft sprocket bolt, rotate the crankshaft and align the timing marks on the sprocket and on the oil pump housing.
5. Install the timing belt.
Warning: The engine must be cold.
Note: If the belt is to be reused, align the previously made marks on the pulleys and the belt and take into account the direction of rotation of the belt.
Install the timing belt, observing the marks and providing the necessary tension in the area between the toothed pulleys of the crankshaft and camshaft.
6. Check the correct installation of the belt (valve timing)
- A) Slowly loosen the idler pulley bolt.
- b) Slowly turn the crankshaft 2 turns clockwise from TDC to TDC after installing the toothed pulley mounting bolt.
- V) Make sure the timing marks on each pulley match up with the timing marks on the oil pump housing (for crankshaft pulley) and on the camshaft bearing cap as shown.
- G) Tighten the idler pulley bolt (М3=37 Nm).
- d) Temporarily loosen the crankshaft sprocket bolt
7. Check up a tension of a gear belt.
- Deflection of the timing belt under the action of a force of 20 N at the point indicated in the figure - 5-6 mm
If the deflection is out of specification, reposition the idler.
8. Install the toothed belt guide with the flare outwards as shown.
9. Install protective covers No. 1, NB2 and No. 3 of the timing belt.
- Bolt tightening torque - 7.4 Nm
10. Install the crankshaft pulley (for generator drive and coolant pump).
- A) Align the key on the crankshaft with the pulley groove and fit the pulley onto the shaft.
- b) Using a suitable tool, install and tighten the crankshaft pulley mounting bolt (М3=118 Nm).
11. Install the cylinder head cover (timing cover).
- A) Remove old sealant from surfaces.
- b) Apply fresh sealant to the areas shown in the illustration.
Note: If using an old gasket, apply sealant to the entire contact surface.
- V) Install the gasket on the timing cover.
- G) Replace the cover and secure it through the seals with 4 cap nuts (M3=6 Nm).
- d) Connect 2 hoses of the positive crankcase ventilation system to the cylinder head cover
- e) Fix the wiring protection with 2 bolts.
- and) Connect: alternator connector (1), generator wire (2), emergency oil pressure sensor connector (3), two cable ties (4).
12. Install spark plugs and connect high voltage wires.
13. Install the alternator and coolant pump drive belt.
- A) Temporarily secure the water pump pulley with 4 bolts.
- b) Put on the drive belt and fasten the adjusting bolt and the alternator mounting bolt. The locking bolt of the adjusting bolt should only be tightened after adjusting the tension of the alternator drive belt and coolant pump.
- V) Tighten the 4 pump pulley bolts.
14. Adjust the tension of the alternator drive belt and coolant pump (see chapter "General Inspection and Adjustment Procedures").