Removing
Removal in the following order:
- turn off the ignition and disconnect the wire «masses» from the storage battery;
- tighten the parking brake and block the rear wheels with stops;
- Loosen the right front wheel nuts. Raise the front of the car and place it on stands. Remove the right front wheel and the right front wheel arch mudguard;
- remove the power steering fill tank together with the bracket. If the vehicle is equipped with an anti-lock brake system (ABS), remove the ABS unit together with the bracket;
Pic. 3.11. Timing gear drive: 1 - crankshaft pulley; 2 – the bottom casing of a gear belt; 3 – the top casing of a gear belt; 4 - toothed belt; 5 - toothed belt guide; 6 - high-voltage wires with candle tips; 7 - spark plug; 8 - spring; 9 – a pulley of a gear belt of a cranked shaft; 10 - oil pump pulley; 11 - idle roller; 12 - tension roller; 13 – a pulley of a gear belt of a camshaft; 14 - protective box for wiring harness
- pulling up and turning at the same time, remove the tips with high-voltage wires 6 (pic. 3.11) with spark plugs;
- clean the spark plugs with a jet of compressed air, which will prevent dirt from entering the engine cylinder after the spark plugs are turned out. Remove the spark plugs;
- remove poly V-belts for driving mounted units;
- remove the generator and the generator bracket;
- separate the protective box 14 for the wiring harness from the front of the engine;
- jack through a wooden block, support the engine by the oil pan. Turn out 3 bolts and remove the right support of the engine;
- unscrew the screws, disconnect the rods and wires and remove the upper casing 3 of the toothed belt and the gasket;
Pic. 3.12. TDC mark on the cylinder head cover, seen through the small hole in the camshaft timing belt pulley
- set the piston of the first cylinder to TDC (to the compression stroke). Check that the TDC mark on the cylinder head cover is visible through the small hole in the camshaft timing belt pulley (pic. 3.12);
- with chalk, marker or paint, mark the direction of rotation of the timing belt, and also apply alignment marks to the camshaft pulley and timing belt. If, during installation, the toothed belt rotates in the opposite direction, this will lead to its destruction;
Pic. 3.13. The location of the tension roller mounting bolt and the removal of the spring
- loosen the tension roller bolt and remove the spring (pic. 3.13). Remove the toothed belt from the pulleys. If it is necessary to remove the cylinder head, camshaft or replace the camshaft O-ring, it is not necessary to remove the toothed belt from the crankshaft pulley;
Pic. 3.14. Using wrenches to hold the camshaft from turning and loosen the timing belt pulley bolt
- If the camshaft timing belt pulley is worn or damaged, remove the cylinder head cover. Holding the camshaft from turning with a wrench (pic. 3.14) behind the hexagon, unscrew the mounting bolt and remove the toothed belt pulley from the camshaft;
Pic. 3.15. Fixing the blade of the flywheel screwdriver from turning and unscrewing the bolt securing the crankshaft pulley
- remove the cover covering the opening for inspecting the flywheel, and with the blade of a large flat-bladed screwdriver behind the ring gear of the flywheel, fix it from turning (pic. 3.15). Turn out a bolt of fastening of a pulley of a cranked shaft. Since the bolt is too tight, use a wrench with a large shoulder. Using a pry bar or vibration damper remover, remove the pulley from the crankshaft (pic. 3.16). Before removing the pulley, make sure that the piston of the first cylinder is set to TDC;
Pic. 3.16. Using a pry bar to remove the pulley from the crankshaft
Pic. 3.17. Arrangement of bolts of fastening of the bottom casing of a gear belt
- remove the bolts (pic. 3.17) and remove the lower toothed belt cover and its gasket. Remove the toothed belt guide from the crankshaft;
- if the toothed belt is to be reinstalled, put alignment marks on the crankshaft pulley and toothed belt;
- slide the toothed belt off the pulley and remove it from the engine;
Pic. 3.18. Using a puller to remove the pulley from the crankshaft
- If the pulley is worn or damaged, or the crankshaft front O-ring needs to be replaced, remove the timing belt pulley from the crankshaft. The pulley should be easy to remove from the crankshaft. If the pulley is too tight, remove it with a puller (pic. 3.18). To attach the puller arms, drill 2 holes in the pulley and cut the threads into them.
Examination
Attention! Do not twist or bend the toothed belt. Do not expose the toothed belt to oil, coolant or fuel.
Attention! Do not rotate the engine crankshaft with the toothed belt removed, as the pistons may hit the valves.
Check up a condition and smoothness of rotation of idle and tension rollers. Check the condition and measure the length of the spring, which should be 46.0 mm for engines from 1996 to 1997 and 42.0 mm for engines from 1998 to 2000.
A broken toothed belt while the engine is running can cause the pistons to hit the valves, causing the valves to become deformed. Check valve clearances. On deformed valves, they will be much larger than required.
If toothed belt teeth are chipped, the water pump, oil pump, or camshaft may be stuck.
If the outer surface of the toothed belt is significantly worn or split, check the condition of the idler and idler roller raceways.
If wear or damage is found on only one side of the belt, check the toothed belt guide and the alignment of the toothed belt pulleys.
Attention! If there are any defects on the toothed belt, be sure to replace it.
Note. Professionals recommend replacing the timing belt whenever it is removed, as a broken belt while the engine is running can cause severe engine damage and costly repairs.
Installation
Install in the following order:
- wipe off all dirt and grease from the front of the engine, in the area of the toothed belt;
- if removed, then reinstall the idle and tension rollers and the tension roller spring. Take the tension roller to the maximum tension of the spring and temporarily fix it in this position with a bolt;
- Install the toothed belt pulleys on the camshaft and crankshaft. Install the crankshaft pulley so that the teeth of the crankshaft sensor are located on the side of the front cover of the engine;
- check that the TDC mark on the cylinder head cover is visible through the small hole in the camshaft timing belt pulley (see fig. 3.12), and the crankshaft pulley key points to the TDC mark on the front cover. In this case, the piston of the first cylinder is at TDC on the compression stroke;
- install the toothed belt on the crankshaft, oil pump, water pump and idler and idler pulleys. When reinstalling the toothed belt, align the previously applied marks;
Pic. 3.19. The side of the toothed belt guide that must be on the belt side
- install the toothed belt guide on the crankshaft, with the side with the tooth pattern towards the toothed belt (pic. 3.19);
Pic. 3.21. Places for applying a layer of sealant to the upper and lower casing of the toothed belt
- apply a layer of sealant to the mating surface (see fig. 3.21), install the lower casing of the toothed belt and fix it with bolts;
- install the crankshaft pulley and check the alignment of the mark on the pulley with the TDC mark on the front cover. Screw in and tighten the pulley mounting bolt to 108 Nm;
Pic. 3.20. Branch tensioned when installing a toothed belt on the camshaft pulley
- install the toothed belt on the camshaft pulley, while pulling the belt branch located on the front side of the engine (pic. 3.20);
- loosen the tension roller mounting bolt in the retracted position, while the spring will turn the roller, as a result of which the belt will be tensioned;
- for the crankshaft pulley mounting bolt, slowly turn the crankshaft clockwise 1 7/8 turns until the mark on the crankshaft pulley aligns with the 45°sign to TDC located on the lower toothed belt casing, then tighten the tension roller mounting bolt to 42 N·m;
Pic. 3.1. Alignment of the mark on the vibration damper with the TDC sign on the front cover
- for the crankshaft pulley bolt, turn the crankshaft clockwise 2 1/8 turns until the mark on the vibration damper aligns with the TDC mark on the front cover (see fig. 3.1). Check that the TDC mark on the cylinder head cover is visible through the small hole in the camshaft timing belt pulley, otherwise repeat the timing belt installation steps (see fig. 3.12).
Attention! Do not start the engine until you are absolutely sure that the toothed belt is installed correctly. If the belt is installed incorrectly, severe and costly engine damage can result.
Further installation is carried out in the reverse order of removal, taking into account the following.
Apply a layer of sealant to the mating surface, install the upper toothed belt cover and fasten it with screws (pic. 3.21).