Removal
1. Loosen the water pump pulley mounting bolt.
2. Loosen the alternator mounting strap.
3. Remove the water pump pulley and belt.
4. Remove the crankshaft pulley.
5. Remove the timing belt cover.
6. Move the timing belt tensioner pulley toward the water pump and temporarily secure it.
7. Remove the timing belt from the camshaft sprocket.
8. Remove the camshaft sprocket.
9. Remove the timing belt.
Note: If the timing belt has been running, mark it with an arrow showing the direction of its movement so that it will run in the same direction after installation.
10. Remove the crankshaft sprocket mounting bolts, remove the flange and sprocket.
11. Remove the timing belt tensioner.
Examination
1. Check the camshaft and crankshaft gears and tensioner for wear, cracks and damage. Replace if necessary.
2. Check the ease and smoothness of rotation of the tensioner, as well as the play and noise of operation. Replace if necessary.
3. Check the belt for oil and dust, defects, replace the belt if necessary. Small deposits can be wiped off with a dry cloth or paper. Do not use solvent to clean the belt.
4. When overhauling the engine or adjusting the belt tension, check its condition more carefully. If there are any defects, the belt should be replaced with a new one.
Installation
1. Install the crankshaft flange and sprocket as shown. Pay special attention to their mounting conditions.
Tightening torque: Crankshaft pulley bolt - 140-150 Nm.
2. Install the camshaft sprocket and tighten the bolt to the specified torque.
Tightening torque: Camshaft sprocket bolt - 80-100 Nm
3. Align the marks on the crankshaft sprocket and the camshaft sprocket. The piston of cylinder No.1 should be at the top dead center of the compression stroke.
4. Install the timing belt tensioner; first, attach the tensioner, spring and washer. Temporarily tighten the bolts. Then temporarily tighten the bolts and washer on the side of the elongated hole of the tensioner.
Place the lower end of the spring against the front cover as shown in the figure.
5. Strengthen the tensioner towards the water pump.
6. Install the toothed belt onto the crankshaft sprocket.
7. Install the timing belt onto the camshaft sprocket. When installing the timing belt onto the camshaft sprocket, make sure the tension side is taut. Then turn the camshaft sprocket in the opposite direction with the tension side taut. All timing marks should be aligned.
8. Loosen mounting bolts 1 and 2 in the order shown. This will allow the spring tensioner to move closer to the timing belt. Check the belt to make sure it has not come out of position.
9. Tighten tensioner mounting bolts 2 and 1 in the order shown. If bolt 1 is tightened first, the tensioner may move along with the bolt, which may cause the belt to become overtightened.
10. Turn the crankshaft clockwise once and set the mark on the crankshaft gear at top dead center.
Caution: Do not turn the crankshaft counterclockwise.
11. Loosen tensioner mounting bolts 1 and 2 in the order shown.
12. Retighten tensioner mounting bolts 2 and 1 in the order shown to the specified tightening torque.
Tightening torque: Tensioner mounting bolt - 20-27 Nm (200-270 kg/cm)
13. Recheck the belt tension. Then press the tensioner and the belt from the tensioner side horizontally with medium force (approximately 49 N), approximately to the tips of the belt teeth.
The end of the belt tooth must be removed by half the radius of the tensioner bolt head from the center of the bolt head (see operation above in this chapter "Adjusting the belt tension").
14. Install the timing belt cover.
Tightening torque of the cover bolt is 10-12 Nm
15. Install the crankshaft pulley. Make sure the crankshaft sprocket pin is recessed into the hole in the pulley.
Pulley bolt tightening torque: 140-150 Nm
16. Install the fan belt and adjust the belt tension.
17. Install the water pump pulley.
18. Install the V-belt and adjust its tension.