Contents: Removal ↳ Installation and adjustment ↳
Removal
Remove the ground cable from the battery. Loosen the lower mounting bolts, unscrew the upper tension bolt of the generator. Tilt the generator toward the engine and remove the drive belt. Unscrew the mounting bolts of the toothed belt cover and remove it.
The timing belt cover consists of two parts, each with its own rubber gasket. The lower cover has a mark for setting the first cylinder to TDC. The lower cover can only be removed after removing the auxiliary drive belt pulley from the crankshaft.
Turn the engine crankshaft until the marks on the camshaft pulley and cylinder head, as well as on the crankshaft pulley and oil pump housing, are aligned.
Fix the engine crankshaft. To do this, remove the starter and fix the flywheel ring gear. Unscrew the mounting bolt and remove the crankshaft pulley.
Loosen the two bolts securing the timing belt tension roller and use a screwdriver to move the tension roller away from the belt, compressing the spring, and then tighten the bolts (see Fig. 2B.12).
To reinstall the timing belt, mark its direction of movement.
Remove the toothed belt (see Fig. 2B.13).
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.
Installation and adjustment
Install the belt on the crankshaft pulley, pull it vertically and install it sequentially on the camshaft pulley, tension roller and water pump pulley. Check the alignment of the marks on the pulleys, which should not change (see Fig. 2B.14).
Loosen the timing belt tensioner roller mounting bolts. The spring will tension the timing belt, then tighten the bolts. If the belt tensioner mechanism does not contain a spring, tension it by turning the tensioner roller and tightening the bolts. Install the V-belt pulley on the crankshaft and secure it with a bolt.
Turn the crankshaft two revolutions clockwise and check that the marks on the camshaft pulley and cylinder head match.
Turn the crankshaft 60° counterclockwise, whereby the camshaft toothed pulley shifts by three teeth, and check the belt tension by pressing the long branch of the belt toward the water pump pulley and measuring the distance 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.
When using a special belt tension gauge, install it on the long section of the belt, with the tensioner of the gauge entering the groove between the teeth. The gauge should show a value of 4 to 6 on the used belt and 10-12 on the new belt.
Attention: Adjust the timing belt tension only on a cold engine.
Install the timing belt cover. Install the auxiliary V-belt of the generator drive and adjust its tension. Install the starter.