Withdrawal
Pic. 2.14. Timing Belt Components
Remove the crankshaft and coolant pump pulleys and the pump drive belt (pic. 2.14).
Attention! Turn the crankshaft clockwise until the alignment marks on the crankshaft sprocket and the block correspond to the TMP of the piston of the 1st cylinder.
Attention! The alignment marks of the camshaft sprockets must be aligned with the benchmarks on the cylinder head (sprocket guide pins pointing up).
Remove the timing belt cover.
Remove the automatic timing belt tensioner.
Pic. 2.15. Timing belt outline
Note. If the timing belt is reused, it must be chalked on the back (non-working) belt surface an arrow indicating the direction of rotation (or crankshaft pulley location), so as not to confuse the direction of rotation when installing the belt.
Pic. 2.16. Removing the timing belt
Remove the timing belt (pic. 2.16).
Pic. 2.17. Removing camshaft sprockets
Remove the camshaft sprockets (pic. 2.17).
Note. Be careful not to damage the cylinder head with the wrench when removing the camshaft sprocket.
Pic. 2.18. Balance shaft lock
Before removing the oil pump sprocket, unscrew the plug on the left side of the block and insert an 8 mm screwdriver into the plug hole to fix the balance shaft. The screwdriver must go into the hole to a depth of more than 60 mm (pic. 2.18).
Loosen the oil pump sprocket nut, remove the sprocket.
Loosen the right balance shaft sprocket bolt until it can be turned by hand.
Remove the tensioner and balance shaft drive belt.
Attention! After removing the balance shaft belt, do not attempt to loosen the balance shaft sprocket bolt by holding the balance shaft sprocket with pliers or a similar tool.
Pic. 2.19. Removing the sprocket «IN» balance shaft drives
Remove the sprocket from the crankshaft «IN» balance shaft drives (pic. 2.19).
Check sprockets, timing belt tensioner pulley and guide pulley
Check the camshaft sprocket, crankshaft sprocket, timing belt tensioner pulley and idler pulley for excessive wear, cracks or damage. Replace if necessary.
Pic. 2.20. Checking the timing belt tensioner pulley
Check the ease and smoothness of rotation of the timing belt tensioner pulley and idler pulley, and make sure that there is no excessive play and extraneous noise during rotation. Replace parts if necessary (pic. 2.20).
Replace the roller if traces of lubricant leakage from its bearing are found.
Checking the automatic tensioner
Check for fluid leaks from the tensioner. Replace tensioner if necessary.
Pic. 2.21. Check of a condition of a tip of a pusher of a tensioner
Check up a condition of a tip of a pusher of a tensioner. Replace tensioner if damaged or worn (pic. 2.21).
Pic. 2.22. Checking the protrusion of the pusher from the tensioner housing
Measure the protrusion of the pushrod from the tensioner housing (pic. 2.22).
If the protrusion is not equal to the nominal value, replace the tensioner.
Nominal value: 14.5 mm.
Pic. 2.23. Checking the effort of moving the pusher in the tensioner housing
Place the tensioner in a soft metal vise. Slowly push the pusher into the housing. If the movement force is low, replace the tensioner. Check several times (pic. 2.23).
Note. The tensioner in the vise must be installed evenly, without distortion. Be sure to use the soft jaws of the vise.
Checking the timing belt
Check the belt for dirt or oil deposits. Replace if necessary.
Remove light soiling of the belt with a dry rag or tissue paper.
Do not use solvents for these purposes.
Pic. 2.24. Examples of damage and defects in the timing belt
When overhauling the engine or adjusting the belt tension, carefully inspect the belt. If any of the defects listed below are found, replace the belt with a new one (pic. 2.24).
Installation
Pic. 2.25. Installing the sprocket «IN» balance shaft drive to crankshaft
Install the sprocket on the crankshaft «IN» balance shaft drives (pic. 2.25).
Attention! Pay attention to the orientation of the sprocket flange. If the sprocket is installed incorrectly, the belt will break.
Pic. 2.26. Scheme of installing a spacer on the right balance shaft
Lubricate the spacer with engine oil and install it on the right balance shaft (pic. 2.26).
Observe the installation orientation of the spacer.
Pic. 2.27. Aligning the mark on the balancing shaft sprockets with the benchmarks
Install the drive sprocket onto the right balance shaft and hand-tighten the sprocket mounting bolt. Align the marks on the balance shaft sprockets with the benchmarks (pic. 2.27).
Fit the balance shaft drive belt with no slack in the drive branch.
Pic. 2.28. Installing the balance shaft tensioner
Install the balance shaft tensioner so that its center is located to the left of the mounting bolt, and the roller flange is directed towards the crankshaft pulley (pic. 2.28).
Align the alignment mark of the right balance shaft with the bench mark.
Pic. 2.29. Belt tension
Tighten the belt by turning the tensioner until there is no slack. When tightening the tensioner mounting bolt, make sure that the shafts do not rotate. If the shafts turn, the belt will receive excess tension (pic. 2.29).
Check the alignment of the alignment marks with the benchmarks.
Pic. 2.30. Belt tension check
Check belt tension (pic. 2.30).
Method 1: press the middle of the belt with your finger, check that the deflection boom is within the nominal value.
Nominal deflection: 5–7 mm.
Method 2: Check belt tension with a tension gauge.
Pic. 2.31. Installing the belt guide and sprocket «A» crankshaft
Install the belt guide and sprocket «A» crankshaft. The orientation of the parts is shown in Figure 2.31.
Attention! If the guide is installed incorrectly, the belt will break.
Install the special washer and crankshaft sprocket mounting bolt. Tighten the bolt to the specified torque.
Tightening torque of the crankshaft sprocket bolt: 110–130 Nm.
Pic. 2.32. Installing a screwdriver to fix the balance shaft
Insert a screwdriver into the plug hole on the left side of the block to fix the balance shaft (pic. 2.32).
Pic. 2.33. Installing the oil pump sprocket
Install the oil pump sprocket (pic. 2.33).
Tighten the fastening nut to the specified torque. Tightening torque for oil pump sprocket: 50–60 Nm.
Pic. 2.34. Installing camshaft sprockets
Install the camshaft sprockets, tighten the fastening bolts to the nominal torque (pic. 2.34).
The moment of an inhaling of a bolt of fastening of an asterisk of a camshaft: 80–100 Н·м.
Install the auto tensioner.
Pic. 2.35. Fixing the pusher of the automatic tensioner in the housing with a suitable pin
Attention! Before installation, fix the auto-tensioner push rod in the body with a suitable pin (pic. 2.35).
Note. The fixation of the pusher is carried out in three stages.
Note. 1. Install the auto-tensioner in a vise without distortion. Install a spacer under the tensioner housing.
Note. 2. Slowly push the pusher into the housing until the holes in the housing and the pusher are aligned.
Note. 3. Fix the pusher with a suitable pin.
Attention! Do not remove the pushrod locking pin before installing the timing belt.
Pic. 2.36. Tensioner pulley installation
Install the tensioner pulley on its lever (pic. 2.36).
Tighten the fastening bolt to the nominal torque.
Tensioner pulley tightening torque: 43–55 Nm.
Pic. 2.37. Alignment of camshaft sprocket marks with benchmarks
Align the camshaft sprocket marks with the benchmarks when installing the piston of cylinder No. 1 at TDC of the compression stroke (pic. 2.37).
Note. If the timing marks of the camshafts do not match the benchmarks, turn the shaft in the right direction, but no more than two teeth of the sprocket, since then the valve and piston come into contact.
Note. If more than two teeth turn is required, carefully turn the crankshaft counterclockwise about 45 degrees. Return the crankshaft to its original position.
Pic. 2.38. Star identification label
Note. Check that the camshaft sprocket identification marks match the engine displacement (pic. 2.38).
Check the alignment of the crankshaft alignment mark with the benchmark.
Pic. 2.39. Mounting marks
Check the alignment of the oil pump alignment mark with the benchmark (pic. 2.39).
Slide the belt onto the tensioner pulley, working counterclockwise from the crankshaft sprocket. Hold the belt on the tensioner roller.
Pulling the belt, put it on the oil pump sprocket.
Put the belt on the guide roller.
Slide the belt onto the intake camshaft sprocket.
Turn the exhaust camshaft clockwise by one tooth until the alignment mark on the sprocket is aligned with the upper plane of the cylinder head. Tensioning the belt with both hands, put it on the exhaust camshaft sprocket.
Rotate the auto-tensioner roller until all slack in the belt is taken out. Temporarily tighten the roller bolt.
Pic. 2.40. Alignment marks with benchmarks
Check the alignment of all installation marks with benchmarks (pic. 2.40).
Remove the auto tensioner push rod retainer.
Pic. 2.41. Protrusion measurement «A» pushrod tensioner
Rotate the crankshaft two turns clockwise. Take a break for 15 minutes. Measure protrusion «A» pushrod tensioner (distance between arm and tensioner housing) (pic. 2.41).
Make sure the performance is within specifications.
Nominal value: 6–9 mm.
Pic. 2.42. Installing timing belt covers
Install timing belt covers (pic. 2.42).