Remove the alternator and power steering belts.
By loosening bolt (1) and rotating bolt (2), loosen the tension of the air conditioner compressor belt tensioner.
Remove the tensioner and belt.
Remove the water pump and power steering pulleys.
Remove the crankshaft pulley.
Front elements of the 1.6L and 1.8L engines
1 - air conditioning compressor drive belt;
2 - tensioner;
3 - bottom cover;
4 - crankshaft pulley;
5 - generator drive belt;
6 - coolant pump drive belt;
7 - coolant pump pulley;
8 - top cover.
Remove the upper and lower camshaft drive belt covers.
Mark and disconnect the spark plug wires and caps (1).
Remove the cylinder block cover (2) and its gasket (3).
Turn the crankshaft clockwise until all marks are aligned. The marks on the camshaft gears must be aligned with the top surface of the cylinder head, and the keys in the center of the camshaft gears must be facing upward. In this position, the piston of the first cylinder will be at TDC of the compression stroke.
Remove the tensioner.
Remove the timing belt.
Caution: If this belt is to be reinstalled, it must be marked with an arrow indicating the direction of rotation.
Timing Belt Alignment Marks
A, B, C - installation marks;
1 - exhaust camshaft gear;
2 - keys (locating pins);
3 - intake camshaft gear;
4 - cylinder head;
5 - crankshaft gear;
6 - oil pump gear.
While holding the camshaft from turning, unscrew the mounting bolts and remove the gears.
Loosen the oil pump sprocket nut.
Remove the plug from the cylinder block on the left side.
By inserting a screwdriver (1) or a suitable rod into the hole, block the left balance shaft (2) from turning.
Completely loosen the nut and remove the oil pump gear.
After loosening the bolt securing the right balance shaft toothed wheel, remove the tension roller and toothed belt (1).
Remove the crankshaft gear (2).
Examination
See the relevant section in the next chapter.
Installation
Check the gears, tension rollers and idlers for wear and damage.
Check the ease of rotation of the tension and idler rollers. Replace if necessary.
After checking the tensioner plunger for wear and damage, measure the plunger protrusion length. It should be 12 mm. If the length is less, the tensioner must be replaced.
Install the balance shaft drive gear (1) onto the crankshaft (2) as shown in the figure.
After applying a thin layer of engine oil to the spacer sleeve, install it onto the right balance shaft, then install the gear onto this shaft and tighten the flange mounting bolts.
Align the timing marks (1) and (2) of the gear wheels with the corresponding pointers.
Install the balance shaft drive toothed belt and tension roller (1).
The bolt (2) must be oriented as shown in the figure.
Tension the timing belt and tighten the mounting bolt.
Check the belt tension (A) (deflection 5-7 mm). If necessary, unscrew the bolt (2) and, by turning the roller (1), adjust the position of the belt.
Correctly install the gears (1), (2) and flange (3) on the crankshaft (4).
Insert a screwdriver or suitable rod into the hole in the cylinder block to hold the balance shaft from turning.
Install the oil pump and camshaft gears. Tighten the mounting bolts.
Press in the tensioner plunger and, aligning the plunger and housing holes, insert the wire pin (1).
If necessary, remove the tensioner and press the push rod in a vice.
Adjust the position of the tension roller, while the holes for the pins (1) should be to the left of the bolt (2), and the roller bracket should rest against the tensioner (3).
Turn the inlet (I) and outlet (II) valve gears so that their keys (1) and (2) face upward. Then align the alignment marks (A).
Caution: Do not mix up the gears, as marks (1) and (2) are offset from the key.
Install the crankshaft and oil pump gears so that the timing marks (B) and (C) are positioned as shown in the figure.
The toothed belt is put on in the following sequence:
- crankshaft gear;
- tensioner;
- oil pump gear;
- idler pulley;
- intake valve camshaft gear;
- exhaust valve camshaft gear (before installing, it is necessary to turn this gear wheel one tooth clockwise until the installation mark on the cylinder head is aligned).
Timing Belt Installation Sequence
Turn the tensioner (2) in the direction of the arrow to slightly tighten the belt and tighten the central bolt (A).
Turn the crankshaft first 1/4 turn counterclockwise, then in the opposite direction until all timing marks are aligned (TDC).
After removing the plug from the rear cover of the timing belt, screw the special device into the hole until it stops against the tensioner bracket.
After loosening the central bolt of the tensioner, tighten the toothed belt.
While holding the tensioner pulley with a fixture and torque wrench, tighten the center bolt to the specified torque.
Screw the tool in until it contacts the tensioner bracket.
After this, turn the device another 2.5-3 turns. In this case, the tensioning device pusher should sink to the required value (4±0.5 mm).
Insert the plug (1) into the hole in the rear timing belt cover.
Install the timing belt covers and tighten the mounting bolts. Do not mix up the cover mounting bolts - they are of different lengths (the length of the bolts is shown in the figure).
