Removing
Attention! Precise observance of valve timing is very important, but for DOHC engines it is extremely important. Incorrect phase setting can seriously damage the motor. Be careful when installing the timing belt and before the first start after repair, check the coincidence of the marks again.
Timing drive assembly
1. Disconnect the negative cable from the battery.
Attention! If the stereo system installed in the car is equipped with a security code, before disconnecting the battery, make sure that you have the correct combination to activate the audio system!
2. Remove the crankcase protection.
3. Drain the coolant from the radiator and engine block (see chapter Engine cooling, interior heating and air conditioning systems).
4. Remove the radiator (see chapter Engine cooling, interior heating and air conditioning systems).
5. Remove the throttle body cover.
6. Remove the intake duct.
7. Remove the drive belt with the clutch and the crankshaft pulley.
8. Without disconnecting the hydraulic pipes, remove the power steering pump, take it aside and tie it up so that it does not interfere.
9. Having unscrewed a bolt, then having removed a cover, remove an intermediate roller of a driving belt (refer to illustration above).
10. Remove the right cover (right №3) timing belt.
11. Remove the left cover (left №3) timing belt. Be careful when disconnecting the camshaft position sensor wiring (CMP).
12. Remove the next timing belt cover (cover #2).
13. Without disconnecting the A/C pipes, remove the A/C compressor, move it aside and tie it up so that it does not interfere.
14. Remove the fan bracket. For its fastening, bolts of different sizes are used - fold them so as not to be confused during installation.
15. If the timing belt is to be reinstalled, locate the three alignment marks on it by turning the crankshaft clockwise. Locate the marks on the crankshaft and camshaft gears. If the marks on the belt are worn, apply new ones to make installation easier (refer to accompanying illustration).
16. Loosen but do not remove the crankshaft pulley bolt. To hold the crankshaft from turning, you will need a special tool.
17. Set the piston of cylinder No. 1 to TDC of the compression stroke.
- Turn the crankshaft pulley so that its notch is aligned with the mark She on the cover No. 1 of the timing belt.
- Check the alignment of the marks on the camshaft gears with the marks on the rear timing belt covers. If the marks do not match, the piston of cylinder No. 1 is not installed at the TDC of the compression stroke. Turn the crankshaft exactly one turn until the pulley mark next aligns with the 0 mark on the timing belt cover #1.
- Loosen the crankshaft pulley bolt, being careful not to knock off the marks. Do not rotate the crankshaft pulley.
18. Having unscrewed two bolts, remove the timing belt tensioner and anther. If only the belt tensioner is being replaced, secure the belt to the pulley with wire. Mark the belt and right camshaft sprocket.
19. Remove the belt from the camshaft gears. To do this, loosen the belt tension between the camshaft gears by putting a spanner wrench on the left camshaft sprocket mounting bolt and turning it slightly clockwise.
20. To remove the camshaft gears with a fork tool, fix the gear from turning and unscrew the central bolt (refer to accompanying illustration). Try not to turn the gears.
21. Remove the generator.
22. Remove the drive belt tensioner.
23. To remove the crankshaft pulley, the central bolt must already be unscrewed. Pull the pulley off the crankshaft with a suitable puller. Do not turn the crankshaft so as not to knock down the TDC setting.
24. Remove the lower timing belt cover (cover #1).
25. Remove the guide washer and cover spacer.
26. Remove the timing belt from the engine. If the belt is to be reinstalled and the alignment marks on it have been erased, apply new ones relative to the dot mark on the crankshaft gear.
27. If necessary, remove the intermediate rollers and check for smooth rotation.
28. If it is necessary to remove the crankshaft gear, pull it off with a suitable puller. Try not to move the crankshaft from TDC.
Examination
1. Check the condition of the timing belt. Do not bend it at an acute angle and do not turn it inside out. Keep the belt away from oil, water, antifreeze or solvents. If there is damage to the belt teeth, check if the camshafts are blocked. If there is noticeable wear or cracks on the back of the belt, check for damage to the surface of the rollers and the water pump pulley. If one-sided wear of the belt is detected, check the parallelism of the pulleys and their axes, the guide washer. If there is noticeable wear on the belt teeth, the belt covers or gear teeth may be damaged. To loosen the bolts for fastening the gears of the camshafts, do not use the tension of the timing belt.
2. Check the condition of the intermediate rollers. Check the integrity of their bearing seals. Replace rollers if necessary. Check for tensioner leaks. Try to push the stem - it should not move. If the stem can be pushed in, replace the tensioner. Measure the protrusion of the rod - it should be equal to 10.5–11.5 mm (refer to accompanying illustration).
3. Check that the water pump is not leaking. The pump must rotate smoothly, without play.
Installation
1. If removed, install the crankshaft sprocket by aligning the key on it with the groove. It may be necessary to carefully press the gear onto the shaft using a suitable piece of pipe.
2. Install intermediate rollers. Apply a few drops of Loctite 242 or equivalent to the bolt threads. Tighten the bolts to 35 Nm. Check the smooth rotation of the rollers.
3. Temporarily install the timing belt. Thoroughly clean the gears and rollers from oil and water, wipe them with a clean, dry cloth. Do not use solvents. Align the timing mark of the belt with the mark of the crankshaft gear. Slide the belt over the crankshaft sprocket and idler pulleys.
4. Install the timing belt cover spacer.
5. Install the guide washer with the convex side facing out.
6. Install the timing belt cover and secure it with four bolts.
7. Install the crankshaft pulley. Align the key with the slot and install the pulley. To do this, you may have to press the pulley with a piece of suitable pipe.
8. Install the drive belt tensioner (not timing belt). Bolt 106 mm long and nuts tighten with a force of 16 Nm.
9. Install the generator.
10. Check the position of the crankshaft pulley. The notch on the pulley should line up with the 0 mark on the timing belt cover.
11. Install the camshaft gears. Fit the gears, aligning their holes with the camshaft pins. While holding the gears from turning with a fork tool, tighten their fastening bolts to 108 Nm. Thoroughly clean the gears and dry them with a clean cloth. Do not use solvents.
12. Install the belt on the gears of the camshafts:
- Turn the left camshaft sprocket until its timing mark is aligned with the alignment mark on the timing belt. Put the belt on the gear wheel.
- Turn the left camshaft sprocket counterclockwise to introduce belt tension on the shoulder between the left camshaft sprocket and crankshaft.
- Turn the gear wheel of the right camshaft until the alignment mark of the belt is aligned with the timing mark of the gear wheel. Put the belt on the gear wheel.
13. Using a press, press in the tensioner rod. This will require a force of about 981-987 N. Align the holes of the stem and tensioner body and insert a pin with a diameter of 1.27 mm to fix the stem. Release the press and put on the boot. Install the tensioner on the engine and alternately tighten the bolts of its fastening to a torque of 26 Nm. After installing the tensioner, remove the pin with pliers.
14. Check the timing marks. Temporarily install the crankshaft pulley bolt. Slowly turn the crankshaft clockwise two full turns. Check the coincidence of the timing marks on the gears and the pulley.
15. If the timing marks match, tighten the pulley mounting bolt to 245 Nm. A fork tool is required to keep the pulley from turning.
16. Install the fan bracket. Install the bracket mounting bolts in place. The bolts are tightened as follows:
- Bolts with 12 mm heads tighten with a force of 16 Nm.
- Bolts with 14 mm heads tighten with a torque of 32 Nm.
17. Install A/C compressor (with appropriate equipment).
18. Install cover No. 2 of the timing belt and tighten the two bolts of its fastening with a force of 16Nm.
19. Install the right timing belt cover. Tighten the bolts and nut to 7.5 Nm.
20. Install the left timing belt cover:
- Install the oil cooler tube, securing it with a nut and bolt.
- Route the CMP sensor wiring through the hole in the cover.
- Install the timing belt cover, aligning it with the fan bracket.
- Tighten the bolt and nut to 7.5 Nm.
- Install the sensor wiring seal in the cover, attach the connector and attach it to the bracket.
- Fasten the motor wiring.
21. Install the drive belt intermediate roller and tighten its bolt to 39 Nm.
22. Install the power steering pump and tighten the bolts to 17 Nm.
23. Install the remaining components in the reverse order of their dismantling.
24. Start the engine and make sure there are no leaks or strange noises.