Withdrawal
1. Remove the front bumper (see relevant chapter).
2. Set the front cross member to the service position.
3. Unscrew the viscous radiator fan by holding its hub with a second wrench, then remove the diffuser.
4. Remove the ribbed accessory drive belt (see relevant chapter).
5. Unscrew the bolt (see arrow in illustration) and remove the accessory drive belt tensioner pulley.
2.5. unscrew the bolt (see arrow) and remove the tension roller of the accessory drive belt
6. Cars with an afterburning system. Disconnect the hose (see arrow in illustration) from the fresh air pump to the exhaust valves.
2.6. Disconnect the hose (see arrow) from the fresh air pump to the exhaust valves. Vehicles with an afterburning system
7. Unscrew fastening bolts and remove the right and left parts of a back cover of a drive of the gas-distributing mechanism.
8. Set the piston of cylinder No. 1 to TDC by turning the crankshaft in the direction of engine rotation by the central bolt of the drive gear until mark B on the belt pulley aligns with mark A on the timing cover (see illustration).
2.8. Turn the crankshaft in the direction of engine rotation by the central pinion bolt until mark B on the belt pulley aligns with mark A on the timing cover
9. Make sure that the large diameter holes of the camshaft gear setting plates are on the inside opposite each other (see arrows in illustration). Otherwise turn the crankshaft in the direction of engine rotation one more turn.
2.9. Make sure that the large diameter holes of the camshaft gear mounting plates are on the inside opposite each other (see arrows)
10. Vehicles with parking heater. Unscrew the bolts (see arrows in illustration) fixing the heater pipe to the soundproof shield.
2.10. Unscrew the bolts (see arrows) fixing the heater pipe to the soundproof shield. Vehicles with parking heater
11. Unscrew the mounting bolts (see arrows in illustration) and remove the engine mudguard.
2.11. Unscrew the fastening bolts (see arrows) and remove the engine mudguard
12. Unscrew a carving stopper on the block of cylinders approximately at the level of the average cylinder.
13. Replace the plug with a locking pin, catalog number 3242 (see illustration). Make sure that the pin goes into the hole on the cheek of the crankshaft and stops the shaft.
2.13. Replace the plug with a locking pin, catalog number 3242
14. Unscrew the mounting bolts and remove the vibration damper.
15. Remove the bolts (see arrows in illustration) fasteners and remove the lower part of the protective cover of the timing gear drive and the pulley of the radiator blower fan with a viscous coupling.
2.15. Unscrew the bolts (see arrows) fasteners and remove the lower part of the protective cover of the timing gear drive and the pulley of the radiator blower fan with a viscous coupling
16. Unscrew the bolts securing the camshaft gears, keeping the gears from turning with a tool, catalog number 3036 (see illustration).
2.16. Unscrew the bolts securing the camshaft gears, holding the gears from turning with a tool, catalog number 3036
17.. Remove the camshaft gears using a puller, catalog number T40001 (see illustration).
2.17. Remove the camshaft gears using a puller, catalog number T40001
18. Mark with chalk, marker or paint the direction of rotation of the timing belt if the belt is to be reinstalled. Failure to follow the previous course of the toothed belt during its further operation can lead to its damage or rupture.
Attention! The toothed belt tensioner plunger has an oil-filled shock absorber and is therefore compressed slowly and evenly. Excessive force when compressing the tensioner can damage the tensioner.
19. Loosen the tension of the timing belt, for which insert the socket wrench into the hex hole of the tension roller and turn the roller in the direction indicated by the arrow in the illustration until the holes on the plunger and the tensioner body are aligned. Insert into the aligned thrust pin T40011, thereby fixing the plunger in the tensioner body (see illustration).
2.19. Insert a socket wrench into the hex hole of the idler pulley and turn the idler (see arrow), until the holes on the plunger and the tensioner housing are aligned. Insert into the aligned thrust pin T40011, thereby fixing the plunger in the tensioner body:
1 - tension roller
2 - tensioner lever
3 - tensioner housing
20. Carefully remove the timing belt.
Installation
Attention! The toothed belt must not be kinked, twisted or rolled up. A dirty, damaged or worn belt must be replaced.
Attention! Do not turn the crankshaft or camshafts with the toothed belt removed. If it is necessary to change the position of the camshaft after removing the toothed belt, then make sure that the crankshaft is not in the position corresponding to the TDC of the piston of cylinder No. 1 to prevent the valves from hitting the piston crowns. Then mark the position of the timing gear on the crankshaft by marking the gear itself and the cylinder block with paint. Then turn the gear 1/4 turn (90°) forward or backward.
21. Make sure the crankshaft is locked with a lock pin, catalog number 3242 (see illustration 2.13).
22. Install the camshaft gears, secure them with bolts and mounting plates so that the gears can be rotated on the hubs.
Attention! Mounting plates are labeled «front» (front side), «rear» (backside). Follow the markings when installing the plates.
23. Lay the toothed timing belt, observing the same direction of rotation (see illustration). Lay the toothed belt on the tension roller last.
2.23. Laying direction of timing belt
24. Block the camshafts with a retainer, catalog number 3391 (see illustration).
2.24. Block the camshafts with a lock, catalog number 3391
25. Remove the thrust pin T40011, which was used to fix the plunger in the toothed belt tensioner housing. To facilitate the release of the pin from the aligned holes on the plunger and tensioner body, turn the tension roller with a socket wrench in the direction indicated by the arrow in illustration 2.13. The toothed belt tensioner plunger will provide the correct tension.
26. Tighten the tension roller with a force of 15 Nm.
27. Tighten the camshaft gear bolts to 30 Nm.
Further, the installation of the dismantled components is carried out in the reverse order of removal.
Visitor comments