Timing belt.
1 - accessory drive belts, 2 - coolant pump pulley, 3 - alternator adjustment bar, 4 • timing belt upper cover, 5 - TPM drive belt, 6 - coolant pump, 7 - crankshaft pulley, 8 - rear left cover timing belt (upper), 9 - rear left timing belt cover (lower), 10 - right balance shaft sprocket, 11 - camshaft sprocket, 12 - automatic tensioner lever, 13 - timing belt tensioner pulley, 14 - automatic tensioner, 15 - special washer, 16 - crankshaft sprocket, 17 - oil pump sprocket, 18 - guide roller, 19 - guide plate, 20 - balancer drive belt tensioner pulley, 21 - balancer drive belt, 22 - sprocket "IN" crankshaft, 23 - plug.
Withdrawal
Attention: Turn the crankshaft clockwise until the alignment marks on the crankshaft sprocket and cylinder block are aligned to set the piston of cylinder No. 1 to TDC on the compression stroke. In this case, the marks of the camshaft sprockets must be aligned with the corresponding alignment marks on the cylinder head cover, and the locating pins of the camshaft sprockets should be directed upwards.
1. Remove accessory drive belts. Remove the crankshaft pulley and coolant pump pulley.
Timing belt - general view.
1 - crankshaft sprocket, 2 - exhaust camshaft sprocket, 3 - dowel pin, 4 - intake camshaft sprocket, 5 - alignment marks, 6 - oil pump sprocket.
2. Remove the front timing belt covers.
3. Align the camshaft and crankshaft sprocket marks with the alignment marks.
4. Remove the automatic timing belt tensioner and slide the tensioner pulley away from the timing belt.
5. Remove the timing belt.
Note: In case of reusing the timing belt, 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.
6. If necessary, remove the camshaft sprockets.
Note: Be careful not to damage the cylinder head with the wrench when removing the camshaft sprocket.
7. If necessary, remove the oil pump sprocket.
- A) Before removing the oil pump sprocket nut, unscrew the plug on the left side of the cylinder block and insert an 8 mm screwdriver into the hole of the plug to fix the balance shaft in the appropriate position. The screwdriver must go to a depth of more than 60 mm.
- b) Loosen the oil pump sprocket nut and remove the sprocket.
8. Loosen the right balance shaft sprocket bolt until it can be further removed by hand.
9. Remove the tensioner pulley and balancer drive belt.
Caution: After removing the balancer drive belt, do not attempt to loosen the balancer shaft sprocket bolt by holding the balancer shaft sprocket with pliers or a similar tool.
Note: in case of reuse of the balancer drive belt, it is necessary to chalk 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.
10. Remove the sprocket "IN" crankshaft (balance shaft drive sprocket).
Examination
Sprockets, timing belt tensioner pulley and idler pulley
1. Check the camshaft sprocket, crankshaft sprocket, timing belt tensioner pulley and idler pulley for excessive wear, cracks or damage. Replace if necessary.
2. Check the ease and smoothness of rotation of the timing belt tensioner roller and guide roller, and check that there is no excessive play and extraneous noise during rotation. Replace if necessary.
3. Replace the roller if traces of lubricant leakage from its bearing are found.
Automatic tensioner
1. Check for fluid leaks from the tensioner. Replace tensioner if necessary.
2. Check tensioner rod for wear or damage. Replace tensioner if necessary.
3. Measure the protrusion of the rod from the tensioner housing. If protrusion is not within specification, replace tensioner.
- Rated value: 14.0 mm
4. Place the tensioner in a vice with soft metal jaws. Slowly slide the tensioner rod into the tensioner body. If the rod movement force is low, then replace the auto-tensioner. Significant resistance to stem movement should be felt. Check in several steps.
Note: The auto-tensioner must be installed at right angles to the face of the vise jaws. To prevent damage to the tensioner, use soft jaw pads.
5. Preparing the tensioner for installation if the tensioner rod is in the fully extended position.
- A) Install the auto-tensioner in the vise at a right angle to the surface of the vise jaws (without distortion). Install a flat washer under the tensioner housing.
- b) Gradually squeezing the vise, slowly sink the stem into the tensioner body until the holes in the body and stem are aligned.
- V) Insert a dowel pin into the holes in the body and stem to secure the stem.
Caution: Do not remove the dowel pin from the hole in the auto tensioner housing.
Installation
Attention:
- Since water or oil can seriously reduce the life of the timing belt, when removing parts, ensure that the timing belt, sprockets and rollers are clean and dry, never wash them. Contaminated parts must be replaced.
- If any of the parts are oily, then check for oil leakage through the seals (including front camshaft oil seal).
- Check up a condition and smoothness of rotation of a roller of a tensioner.
- If a used timing belt is installed, check its condition (see the relevant section in chapter "Maintenance and general inspection and adjustment procedures").
1. Install the sprocket on the crankshaft "IN" crankshaft (balance shaft drive sprocket).
Attention: pay attention to the installation direction of the sprocket flange. If the sprocket or flange is installed incorrectly, the balancer drive belt may be damaged.
2. Installing the right balance shaft sprocket.
- A) Apply engine oil to the outer surface of the spacer and install it on the right balance shaft. Make sure the installation direction of the spacer is as shown in the figure.
- b) Install the sprocket on the right balance shaft and pre-tighten the sprocket mounting bolt by hand.
3. Installation of the balancer drive belt.
- A) Align the marks on the balance shaft sprockets with the alignment marks on the oil pump housing.
- b) Install the balancer drive belt without slack in the working branch.
- V) Install the balancer drive belt tensioner roller so that its center is located to the left of the mounting bolt, and the roller flange is directed towards the crankshaft pulley.
- G) Align the right balance shaft sprocket mark with the alignment mark on the oil pump housing.
- d) By turning the tensioner up, tension the balancer drive belt so that the working branch of the belt does not sag. In this position, tighten the tensioner mounting bolt. Be careful when tightening the tensioner mounting bolt, do not allow the shaft to rotate. If the shaft turns, the belt will be over-tensioned.
4. Check that the sprocket marks are aligned with the alignment marks.
5. Check the tension of the balancer drive belt.
Make sure that when you press your finger in the middle of the span of the belt in the direction indicated by the arrow, the deflection of the belt corresponds to the nominal value.
- Belt deflection: 5 -7 mm
6. Installing the crankshaft sprocket (for timing drive).
- A) Install the guide plate and crankshaft sprocket. Make sure that the installation direction of the parts is in accordance with the figure.
Attention: pay attention to the installation direction of the guide plate. If the guide plate is not installed correctly, the drive belt will break.
- b) Install the special washer and crankshaft sprocket bolt. Tighten the bolt to the specified torque.
- Tightening torque: 110-130 Nm
7. Installing the oil pump sprocket.
- A) Insert a screwdriver into the service hole on the left side of the cylinder block to secure the left balance shaft.
- b) Install the oil pump sprocket and tighten its fastening nut to the specified torque.
- Tightening torque 50-60 Nm
8. Establish an asterisk of a camshaft and tighten a bolt of its fastening the nominal moment.
- Tightening torque: 80-100 Nm
9. Install the auto tensioner.
Caution: Do not remove the dowel pin from the hole in the auto tensioner housing.
10. Install the roller on the tensioner arm. Tighten the fastening bolt to the nominal torque.
- Tightening torque: 43-55 Nm
11. Rotate the camshaft sprockets so that the sprocket dowel pins are at the top. Align the camshaft sprocket marks with the alignment marks.
Note:
- If the timing marks on the camshafts do not match the timing marks on the cylinder head before installing the timing belt, do not turn the camshaft sprocket more than 2 teeth in each direction. When turning the camshaft sprocket more than 2 teeth, the valves and pistons may touch.
- If it is necessary to turn the camshaft sprocket more than 2 teeth, carefully turn the crankshaft counterclockwise a certain amount before turning the camshaft sprocket. After aligning the camshaft sprocket mark, return the crankshaft to its original position (TDC).
Note: if the camshaft sprockets have been replaced, check that the identification marks on the camshaft sprockets match the engine.
12. Align the crankshaft mark with the alignment mark and align the oil pump sprocket mark with the alignment mark.
13. Installing the timing belt.
- A) Install the timing belt counterclockwise onto the tensioner pulley and crankshaft sprocket. Hold the belt on the tensioner roller with your left hand.
- b) Pulling the belt with your right hand, put it on the oil pump sprocket.
- V) Put the belt on the guide roller.
- G) Put the belt on the intake camshaft sprocket.
- d) Turn the exhaust camshaft sprocket clockwise one tooth until the sprocket mark is aligned with the alignment mark.
- e) Pulling the belt with both hands, put it on the exhaust camshaft sprocket.
14. Slightly raise the auto-tensioner roller so that there is no slack in the belt, then pre-tighten the roller bolt.
15. Check the alignment of all sprocket marks with alignment marks.
16. Remove the dowel pin from the auto tensioner housing.
17. Turn the crankshaft two turns clockwise and leave it stationary for about 15 minutes.
18. Measure protrusion "A" tensioner rod (distance between arm and tensioner housing) and check that it is within the nominal value range.
- Rated value: 6-8mm
19. Tighten the tensioner pulley bolt to rated torque.
- Tightening torque: 43-55 Nm
20. Install the upper and lower timing belt covers and tighten the cover bolts to the specified torque.
Torque:
- bolts "A" And "IN": 8-10 Nm
- Bolt "WITH": 10-12 Nm
21. Install the crankshaft pulley, coolant pump pulley and install the accessory drive belts.
22. Adjust the tension of the accessory drive belts.