2. Loosen the lower mounting bolts, unscrew the upper generator tension bolt, tilt the generator toward the engine and remove the drive belt.
3. Unscrew the 4 timing belt cover mounting bolts and remove it.
4. On engine models built with 2/82, the timing belt cover is in two pieces, each with its own rubber gasket. The lower cover has a mark for setting the first cylinder to TDC.
5. The lower cover can only be removed after the pulley has been removed from the crankshaft.
6. Turn the engine crankshaft until the marks on the camshaft pulley and cylinder head are aligned (indicated by the arrow).
7. Align the marks on the crankshaft pulley and the oil pump housing.
8. Fix the engine crankshaft by removing the starter and fixing the flywheel ring gear.
9. Unscrew the mounting bolt and remove the crankshaft pulley.
10. Loosen the timing belt tension roller mounting bolts and use a screwdriver to move the tension roller away from the belt, compressing the spring, and tighten the bolts.
11. To reinstall the timing belt, mark its direction of movement.
12. Remove the timing belt.
Caution! After removing the belt, it is strictly forbidden to turn the crankshaft and camshaft pulleys, as this may cause the pistons to hit the open valves, which will lead to serious damage to the engine.
13. Install the belt on the crankshaft pulley, tighten it vertically and install the tension roller and water pump pulley on the camshaft pulley in sequence. Check the alignment of the marks on the pulleys, which should not change.
14. The key (2) on the crankshaft and the mark (1) on the oil pump housing must match.
15. Loosen the timing belt tension roller mounting bolts. The spring will tension the timing belt, then tighten the bolts. If the belt tensioning mechanism does not contain a spring, tension it by turning the tension roller and tightening the bolts.
16. Install the V-belt pulley onto the crankshaft and secure it with a bolt.
17. Turn the crankshaft two turns clockwise and check that the marks on the camshaft pulley and cylinder head match.
18. Turn the crankshaft 60° counterclockwise (the camshaft toothed pulley shifts by three teeth) and check the belt tension by pressing at point A on the long branch of the belt toward the water pump pulley and measuring the distance X between the outer diameter of this pulley and the top of the belt tooth on the long branch. The value of this distance should be within 4–6 mm. If this condition is not met, re-adjust the toothed belt tension.
19. If this condition is not met, re-adjust the timing belt tension.
20. When using a special belt tension gauge, install it on the long section of the belt, and the tensioner of the gauge should enter the recess between the teeth.
21. The gauge should show a value of 4 to 6 on a used belt and 10 to 11 on a new belt.
Attention! Adjust the timing belt tension only on a cold engine.
22. Install the timing belt cover. The long bolts (M6x55) for securing the cover are installed from above.
23. Install the generator drive V-belt and adjust its tension.
24. Install the starter.