Pic. 5.16. Engine components removed when replacing the timing belt: 1 - crankshaft pulley; 2 - the lower cover of the gas distribution mechanism drive; 3 - timing belt drive; 4 – a forward cover of a drive of the gas-distributing mechanism; 5 – arm of the right suspension support of the power unit; 6 - water pump pulley.
Checking the timing belt is performed as follows.
1. Remove the front timing cover.
2. Inspect the condition of the timing belt. Replace the belt if during the inspection you find: – traces of oil on any surface of the belt; - signs of wear of the toothed surface, cracks, undercuts, folds and delamination of the fabric from the rubber; – cracks, folds, depressions or bulges on the outer surface of the belt; - Loosening or delamination on the end surfaces of the belt.
WARNING: A belt with traces of engine oil on any surface must be changed without fail, as the oil quickly destroys the rubber. Cause of oil on the belt (usually due to a leak in the seals of the crankshaft and camshafts) must be eliminated immediately.
3. Check belt tension. A properly tensioned belt should rotate 90°with finger force 15–20 N (1.5–2 kgf), applied in the middle between the pulleys of the crankshaft and camshafts.
4. Install the parts in the reverse order of removal.
Replacing the timing belt is as follows.
NOTE: Work on a manhole, overpass or, if possible, on a lift.
You will need: special tools for blocking the camshafts and crankshafts, as well as the timing belt tensioner pulley, a 10 socket wrench, ring wrenches or socket heads for 8, 13, a 18 key.
1. Remove the A/C compressor drive belt and accessory drive belt (refer to Inspection and Replacement of the Accessory Drive Belt).
2. Remove generator (see Generator Removal and Installation).
3. Securely support the engine.
4. Remove the right suspension bracket of the power unit (refer to Right Powertrain Mount Replacement).
5. Remove pulley 6 (pic. 5.16) water pump by unscrewing the four bolts of its fastening.
6. Remove bracket 5 (pic. 5.17) the right suspension support of the power unit by unscrewing the three bolts of its fastening.
7. Remove front cover 4 (see fig. 5.16) timing gear drive by unscrewing the eight bolts of its fastening.
Pic. 5.17. Fastening the bracket of the right suspension support of the power unit.
8. Set the transmission lever to neutral position.
9. Turn the engine crankshaft by the bolt of its pulley so that the marks on the VCT mechanisms (valve timing changes) camshafts were installed in the same way as shown in fig. 5.18 ("at 11 o'clock").
Pic. 5.18. Mounting marks on VCT mechanisms.
10. Turn out the plug located in a forward part of the block of cylinders on the right (pic. 5.19), and install the fixing rod in the opened hole until it stops against the crankshaft (see Setting the No. 1 Cylinder Piston to TDC on the Compression Stroke).
Carefully turn the crankshaft by the bolt securing its pulley until the shaft stops with the fixing rod.
Pic. 5.19. Hole plug for installing the crankshaft fixing rod.
NOTE: The fixing rod is a cylindrical piece about 65 mm long, stepped in diameter. Part of small diameter rod (4 mm), 10 mm long is a shank included in the groove of the crankshaft. The rest of the cylindrical part of a larger diameter (8 mm) serves as a guide in the bore of the cylinder block.
11. Fix the camshafts from turning by installing a locking device in the special grooves in the housings of the VCT mechanisms (pic. 5.20).
Set the fixture so that the marks on the branches of the fixture are at the top, and the mark in the form of a line should be on the side of the exhaust camshaft, and the mark in the form of a dot should be on the intake side.
Pic. 5.20. Fixing the camshafts from turning with a special tool.
12. Engage IV gear in a manual transmission (or set the automatic transmission selector to position "P" - parking) and brake the vehicle with the parking brake to prevent the engine crankshaft from turning.
13. Turn out a bolt of fastening of a pulley (pic. 5.21) to the toe of the crankshaft and remove the pulley.
WARNING: Do not reuse the crankshaft pulley bolt.
Pic. 5.21. Crankshaft pulley and its fastening
14. Turn out three bolts of fastening of the lower cover of a drive of the gas-distributing mechanism and remove a cover.
Pic. 5.22. Loosening the timing belt tension.
15. Loosen the tension of the timing belt, for which move the leading branch of the belt as far as possible in the direction shown by the arrow in fig. 5.22. In this case, the tension roller will move to its original position. Fix the tension roller in this position by inserting a metal rod of suitable diameter into the holes of the roller and its bracket.
16. Remove the belt from the gear pulleys of the VCT mechanisms, the crankshaft and the tension roller.
WARNING: Do not rotate the crankshaft with the timing belt removed, as the pistons will damage the valves.
17. Put a new belt on the gear pulley of the exhaust camshaft VCT mechanism. Tension the drive belt and slide it over the intake camshaft VCT sprocket. Next, tighten the drive branch of the belt and put it on the crankshaft toothed pulley. Get the driven branch of the belt behind the tension roller.
18. Check the correct installation of the belt on the toothed pulleys and remove the fixing rod from the holes of the tension roller and its bracket. In this case, the tension roller spring will set the required belt tension.
19. Install the lower timing cover and crankshaft pulley. Tighten the crankshaft pulley bolt in two stages: 1st - with a torque of 40 N·m (4 kgf·m); 2nd - tighten by 90°.
20. Remove the fixing device from the housings of the mechanisms for changing the valve timing of the camshafts.
21. Remove the crankshaft fixing rod from the hole in the cylinder block (see point 11).
22. Engage the gearbox in neutral, rotate the crankshaft two turns and stop it in a position where the marks on the VCT mechanism housings are in the position shown in fig. 5.18.
23. Install the fixing rod in the hole of the cylinder block (see point 11) and carefully tighten the crankshaft until it locks with the rod.
24. Install the locking tool on the VCT mechanism bodies (see fig. 5.20). If the tool can be installed without difficulty, the timing belt is installed correctly. If the device cannot be installed (shifted valve timing), remove the belt, install the retainer and repeat the installation of the belt as described above.
25. If the timing belt is installed correctly, remove the fixing device from the VCT mechanism housings, remove the fixing rod from the hole in the cylinder block, reinstall the plug of this hole, tightening it with a torque of 20 N·m (2 kgf·m), and install all removed parts in the reverse order of removal.
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