Remove the alternator and power steering belts.
unscrewing the bolt (1) and turning the bolt (2), loosen the A/C compressor belt tensioner.
Remove tensioner and belt.
Remove the water pump and power steering pulleys.
Remove the crankshaft pulley.
1.6L and 1.8L engine front elements
1 - air conditioning compressor drive belt;
2 - tension device;
3 - bottom cover;
4 - crankshaft pulley;
5 - generator drive belt;
6 - belt drive coolant pump;
7 - pulley of the coolant pump;
8 - top cover.
Remove the upper and lower camshaft belt covers.
Label and disconnect wires and lugs (1) spark plugs.
Remove the cylinder block cover (2) and its gasket (3).
Rotate the crankshaft clockwise until all marks line up. The marks on the camshaft gears must align with the top surface of the cylinder head, and the keys in the center of the camshaft gears must point upwards. In this position, the piston of the first cylinder will be at TDC of the compression stroke.
Remove tensioner.
Remove the toothed belt.
Attention: If this belt is to be re-installed, then it must be marked with an arrow indicating the direction of rotation.
Timing belt alignment marks
A, B, C - installation marks;
1 - gear wheel of the exhaust camshaft;
2 - dowels (dowel pins);
3 - gear wheel of the intake camshaft;
4 - cylinder head;
5 - gear wheel of the crankshaft;
6 - gear wheel of the oil pump.
While holding the camshaft from turning, unscrew the mounting bolts and remove the gears.
Loosen the oil pump gear nut.
Remove the plug from the cylinder block on the left side.
Inserting a screwdriver (1) or a suitable bar into the hole, block the left balance shaft (2) from turning.
Completely unscrew the nut and remove the oil pump gear.
After loosening the bolt securing the gear wheel of the right balancer shaft, remove the tension roller and toothed belt (1).
Remove the crankshaft gear (2).
Examination
See the relevant section in the previous chapter.
Installation
Check gears, idler pulleys for wear and damage.
Check the ease of rotation of the tension and bypass rollers. Replace if necessary.
After checking the tensioner tappet for wear and damage, measure the protruding length of the pushrod. It should be 12 mm. If the length is shorter, the tensioner must be replaced.
Install the balance shaft drive gear (1) on the crankshaft (2) in accordance with the drawing.
After covering the spacer with a thin layer of engine oil, install it on the right balance shaft, then install the gear wheel on this shaft and tighten the flange mounting bolts.
Align match marks (1) And (2) gears with corresponding pointers.
Install the balancer shaft timing belt and tensioner pulley (1).
Bolt (2) must be oriented as shown in the figure.
Tension the toothed belt and tighten the fastening bolt.
Check belt tension (A) (deflection 5-7 mm). Loosen the bolt if necessary (2) and turning the roller (1), adjust the position of the belt.
Install gears correctly (1), (2) and flange (3) on the crankshaft (4).
Insert a screwdriver or suitable bar into the hole in the cylinder block to keep the balance shaft from turning.
Install the oil pump gears and camshafts. Tighten the mounting bolts.
Press the pusher of the tensioner and, aligning the holes of the pusher and the body, insert the wire pin (1).
If necessary, remove the tensioner and press the plunger in a vise.
Adjust the position of the tension roller, while the holes for the pins (1) must be to the left of the bolt (2), and the roller bracket must rest against the tensioner (3).
Turn the intake gears (I) and graduation (II) valves so that their keys (1) And (2) were facing up. Then align the marks (A).
Attention. Do not confuse the gears, as the marks (1) And (2) offset from the key.
Install the crankshaft and oil pump gears so that the alignment marks (B) And (IN) positioned as shown in the figure.
The toothed belt is put on in the following sequence:
- crankshaft gear;
- stretching device;
- oil pump gear;
- bypass roller;
- intake camshaft gear;
- exhaust camshaft gear (before putting on, it is necessary to turn this gear one tooth clockwise until the alignment mark of the cylinder head is aligned).
The sequence of putting on the toothed belt
Turning the tensioner (2) in the direction of the arrow, tighten the belt slightly and tighten the center bolt (A).
Turn the crankshaft first 1/4 turn counterclockwise, and then in the opposite direction until all alignment marks are aligned (TDC).
After removing the plug from the back cover of the toothed belt, screw the special tool into the hole until it stops in the tensioner bracket.
Having unscrewed the central bolt of the tensioner, tension the toothed belt.
While holding the tensioner pulley with a tool and a torque wrench, tighten the center bolt to the correct torque.
Screw in the tool until it contacts the tensioner bracket.
After that, turn the fixture another 2.5-3 turns. In this case, the pusher of the tensioning device must be drowned to the required value (4±0.5mm).
Insert stopper (1) into the hole in the back cover of the toothed belt.
Install the toothed belt covers and tighten the mounting bolts. Do not confuse the cover bolts - they have different lengths (the length of the bolts is shown in the figure).