2. Check the ease and smoothness of rotation of the tension and guide rollers, as well as the presence of play and noise. Replace rollers if necessary.
Self tensioner
1. Check self-tensioner for leakage and replace if necessary.
2. Check the end of the rod for wear and damage. Replace if necessary.
3. Measure the length of the protruding part of the rod. If it differs from the nominal value, replace the self-tensioner.
- The nominal value is 12 mm.
4. Using a vise with small jaws, press the self-tensioner rod into the housing. If the rod comes back easily, replace the self-tensioner. When the rod is pressed in, resistance should be felt.
Warning.
- 1. When clamping the self-tensioner in a vise, make sure that it is in a horizontal position? nie. To prevent damage to the self-tensioner, use soft pads on the jaws.
- 2. If the plug is at the bottom of the tensioner body, install a flat washer to prevent the plug from coming into direct contact with the vise jaws.
Installation
1. Install the gear «IN» on the crankshaft.
Warning. Pay special attention to the location of the flange. Improper installation may result in a broken belt.
2. Apply a light coat of engine oil to the outer surface of the spacer bushing, then install the spacer bushing onto the right balance shaft. Make sure to install in the direction shown in the illustration.
3. Install the balance shaft gear on the right balance shaft and tighten the flange mounting bolts securely.
4. Align the match marks on each gear with the match marks on the front of the housing.
5. After installing the timing belt «IN» ensure that the tension is such that there is no slack in the belt. Install the tensioner «IN» so that the pulley is aligned with the left mounting bolt, and its flange is directed towards the front of the engine. Align the alignment mark on the gear of the right balance shaft with the alignment mark on the front of the case.
Warning. Pay attention to the location. As a result of its incorrect installation, a belt breakage is possible.
6. Raise tensioner «IN» for tensioning the toothed belt «IN» so that its working branch is taut. In this position, tighten the tensioner mounting bolt «IN». When tightening the bolt, take care to prevent the shaft from rotating with it. If the shaft turns, the belt will be over tightened.
7. Make sure that the alignment marks are aligned.
8. Make sure that when pressing with your index finger on the center of the working section of the belt in the direction of the arrow, its deviation does not exceed the value given below.
- Belt deflection - 5-7 mm.
9. Install the flange and crankshaft gear onto the crankshaft. Make sure the installation is done as shown in the picture.
10. Install the special washer and gear bolt on the crankshaft, then tighten the gear bolt.
- The tightening torque of the crankshaft gear bolt is 110-130 Nm.
11. Insert a screwdriver into the plug hole on the left side of the cylinder block to hold the shaft in position.
12. Install the oil pump gear and tighten the nut to the correct torque.
13. Install the camshaft gear and tighten the bolt to the appropriate torque.
- The tightening torque of the camshaft gear bolt is 80-100 Nm.
14. Install self-tensioner.
Warning. Leave the wire pin installed in the tensioner.
Note.
- If the self-tensioner rod is in the fully extended position, push it in as follows:
- 1. Clamp the tensioner in a soft-jawed vise while holding it in a horizontal position. If the plug is in the bottom of the tensioner, install a flat washer.
- 2. Slowly push the rod in with a vise until the mounting hole A of the rod aligns with the mounting hole B of the cylinder.
15. Install the idler pulley on the idler arm. Locate the holes in the tensioner pulley shaft end to the left of the center bolt and finger-tighten the center bolt.
Warning. Leave the wire pin installed in the tensioner.
16. Rotate the two gears so that their dowel pins are facing up. Then align the alignment marks.
17. Align the alignment marks of the gear and crankshaft.
18. Align the oil pump gear alignment marks.
19. Install the toothed belt on the tensioner pulley and crankshaft gear. Hold the toothed belt on the tensioner pulley with your left hand.
20. Pulling the belt with your right hand, install it on the gear wheel of the oil pump.
21. Install the belt on the guide roller.
22. Install the belt on the gear wheel of the intake camshaft.
23. Turn the exhaust camshaft sprocket one tooth clockwise until its alignment mark is aligned with the top sequence of the cylinder head. Then, pulling the belt with both hands, install it on the gear wheel of the exhaust camshaft.
24. Gently raise the tensioner pulley in the direction of the arrow so that the belt does not sag, and temporarily tighten the center bolt.
25. After turning the crankshaft 1/4 turn counterclockwise, turn it in the opposite direction to set the piston of the first cylinder to top dead center.
26. Loosen the central bolt and then use the special tool and torque wrench to tighten it to 2.6-2.8 Nm as shown.
Note. Use a torque wrench with a torque of 0-3 Nm.
27. While holding the tensioner pulley with a special tool and a torque wrench, tighten the central bolt to the required torque. Screw the special tool into the left engine support bracket until its end contacts the tensioner arm. After that, screw in the special tool a little more and remove the wire pin installed in the self-tensioner.
28. Remove special tool.
29. Turn the crankshaft two full turns clockwise and leave it in this position for about 15 minutes. Then measure the output «A» tensioner rod (distance between tensioner arm and its housing), to make sure it matches the nominal value.
- Rated value: 3.8-4.5mm
If the value obtained differs from the nominal value, repeat steps 25 to 29 until the required value is reached.
Note. If you cannot measure the distance «A» between the tensioner arm and its housing (for example, if the engine is installed on a car) use the following alternative method.
- 1. Screw in the special tool until its end contacts the tensioner arm.
- 2. From now on, screw in the special tool to retract the tensioner rod, counting the number of turns of the tool made until the tensioner arm touches the body. Make sure that the number of revolutions made of the special tool corresponds to the nominal value.
- Rated value: 2.5-3 turns.
30. Install the rubber plug in the back cover of the toothed belt.
31. Establish the bottom and top covers of a gear belt.