Warning: Before removing with chalk, marker or paint, mark the direction of rotation of the toothed belt. If a used toothed belt rotates in the opposite direction when a used toothed belt is installed, it will break.
Pic. 3.1–50. Toothed belt: 1 – a casing of a gear belt; 2 - bolt, 10 Nm; 3 - bolt, 43 Nm; 4 - bolt, 22 Nm; 5 - tension roller; 6 - toothed belt; 7 - bolt, 70 Nm; 8 - washer; 9 - fixing plate; 10 – the right pulley of a gear belt; 11 - bolt, 10 Nm; 12 - bolt, 10 Nm; 13 – a back right casing of a gear belt; 14 - water pump; 15 - gasket; 16 – the left pulley of a gear belt; 17 – a back left casing of a gear belt; 18 - fixing plate; 19 - washer; 20 - bolt, 70 Nm; 21 - guide roller; 22 – a pulley of a gear belt of a cranked shaft; 23 - spacer sleeve; 24 - bolt (200 Nm + tighten by 180°)
Removing the toothed belt (pic. 3.1–50.) must be carried out with the following in mind.
1. Check the condition of the toothed belt.
2. When installing, you must use a new bolt 7.
3. Lettering "front vorne" on the fixing plate must face forward.
4. When installing it is necessary to use a new gasket 15 and new bolts 20, 24.
5. The bearing surface between the timing belt pulley and the crankshaft must be free of grease. The pulley can only be installed in one position.
6. During installation, it is not allowed to lubricate the bolt 24 with oil.
Loosen eight screws and remove vibration damper.
Remove poly V-belt.
Remove the V-ribbed belt tensioner.
Remove the left and right toothed belt covers.
Turning the crankshaft of the engine in the direction of its working rotation for the pulley mounting bolt, install
#1 piston to top dead center (TDC).
Pic. 3.1–51. Alignment of the mark on the crankshaft pulley (IN) with pointer (A) on the casing
Make sure the mark on the crankshaft pulley is aligned with the pointer on the casing (pic. 3.1–51).
Pic. 3.1–52. The location of the large holes of the fixing plates on the camshaft pulleys
Check the position of the camshaft timing belt pulleys. When installing the piston of the first cylinder at TDC on the compression stroke, the large holes of the fixing plates on the camshaft pulleys must be directed towards each other (arrow in fig. 3.1–52). Otherwise, turn the engine crankshaft one revolution.
Remove the lower mudguard of the engine compartment.
Pic. 3.1–53. Location of set screw 3242 to fix the crankshaft
Lock the crankshaft in this position. To fix the crankshaft, unscrew the ignition timing sensor from the cylinder block and screw in set screw 3242 instead of the sensor (pic. 3.1–53).
Remove the screws securing the lower part of the toothed belt guard.
Pic. 3.1–54. The location of the bolts of the radiator fan bracket and the lower casing of the toothed belt
Turn out bolts and remove an arm of the fan of a radiator and the bottom casing of a gear belt (pic. 3.1–54).
Pic. 3.1–55. Using Special Tool 3036 (1) for fixing the camshaft pulley from turning
Alternately, using special tool 3036 (pic. 3.1–55), secure the camshaft pulley from turning and loosen three turns, but do not completely unscrew the camshaft pulley bolt.
Pic. 3.1–56. Using the T40001 puller (1) for removing the toothed belt pulley from the camshaft
Using puller T40001 (pic. 3.1–56), remove both camshaft pulleys from their mounting cones. When removing the pulleys, the puller must rest against the bolts of the camshaft pulleys. The camshaft pulleys must rotate freely, but not dangle on the adjusting cones.
Pic. 3.1–57. Tension roller bolt location
Remove the fixing bolt (pic. 3.1–57) tension roller and loosen the tension of the toothed belt.
Remove the toothed belt.
Do not rotate the engine crankshaft with the toothed belt removed, as the pistons may hit the valves.
Warnings: 1. Do not twist or bend the toothed belt. Do not expose the toothed belt to oil, coolant or fuel.
2. If toothed belt teeth are chipped, the ignition distributor, water pump, oil pump, or camshaft may be stuck.
3. A broken toothed belt while the engine is running can be caused by the pistons hitting the valves, causing the valves to deform.
4. Check valve clearances. On deformed valves, they will be much larger than required.
5. If the outer surface of the toothed belt is significantly worn or split, check the condition of the idler pulley tread.
If wear or damage is found on only one side of the belt, check the toothed belt guide and the alignment of the toothed belt pulleys.
If there are any defects on the toothed belt, it must be replaced.
Pic. 3.1–58. The location of the toothed belt on the engine pulleys
6. Install a toothed belt on the engine pulleys, starting with the crankshaft pulley and ending with the idler pulley. The previously removed belt is installed in accordance with the marked marks (pic. 3.1–58).
Pic. 3.1–59. Installing the 3243 Retainer (1), holding the camshaft pulleys
Install special retainer 3243 (pic. 3.1–59), holding the camshaft pulleys.
Pic. 3.1–60. Tensioning the toothed belt with a tension roller and the location of the tension roller fixing bolt
Turn the toothed belt tensioner clockwise with an 8 mm Allen wrench (pic. 3.1–60). Tension the toothed belt and with a second 8 mm Allen key, tighten the tension roller mounting bolt to 22 Nm.
Pic. 3.1–61. Checking the toothed belt tension by turning it 90°
Check the toothed belt tension in the center of the branch between the right toothed belt pulley and the water pump pulley. The toothed belt must rotate 90°with moderate finger force (pic. 3.1–61).
Pre-tighten the camshaft pulley bolts to 30 Nm.
Remove tool 3243 fixing the camshaft pulleys.
Finally tighten the camshaft pulley bolts to 70 Nm.
Remove set screw 3242 holding the engine crankshaft from turning. Screw in the ignition timing sensor with a new sealing ring.
Install poly V-belt.
Install a viscous radiator fan.
Notes
Pic. 3.1–62. Oil pan, engine front and rear covers: 1 - bolt, 30 Nm; 2 - bolt, 10 Nm; 3 – a sealing ring of a cranked shaft; 4 - bolt, 10 Nm; 5 - guide tube for the oil dipstick indicator; 6 - sealing ring; 7 - limiter for the engine torque compensator support; 8 - bolt, 40 Nm; 9 - bolt, 40 Nm; 10 – engine torque compensator support; 11 - bolt, 10 Nm; 12 - oil receiver with a branch pipe; 13 - gasket; 14 - bolt (M8 - 25 Nm, M10 - 45 Nm); 15 - the upper part of the oil pan; 16 - bolt, 10 Nm; 17 – two-mass flywheel; 18 – a bolt of fastening of a flywheel (60 Nm + tighten by 180°); 19 - needle bearing; 20 - gasket; 21 - bolt, 10 Nm; 22 - back cover with sealing ring, 23 - gasket; 24 - cylinder block; 25 - gasket; 26 - oil pump; 27 - sealing ring
1. When installing, it is necessary to use new sealing rings 6, 27 and gaskets 13, 20, 23, 25 (pic. 3.1–62).
2. The use of additional sealing means is not required when installing the upper part 15 of the oil pan.
3. Tightening torque of the friction lining bolts for vehicles with automatic transmission 60 Nm + tighten by 90°.
4. Needle bearing 19 is installed only on vehicles with a manual transmission and is pressed into the end of the crankshaft.
5. Before removing the rear cover, the oil pan must be removed.
Front crankshaft sealing ring
Remove the toothed belt.
Pic. 3.1–63. Fastening elements of the crankshaft pulley: 1 - crankshaft toothed belt pulley; 2 - spacer sleeve; 3 - bolt
Remove bolt 3 (pic. 3.1–63) fastening the crankshaft pulley.
Remove the spacer sleeve 2 and pulley 1 toothed belt.
Pic. 3.1–64. Using Puller 3203 (1) for removing the front crankshaft seal
To remove the front O-ring, use a 3203 extractor (pic. 3.1–64). Unscrew the inner part of the puller six turns from the outer part of the puller and fix both parts firmly.
Install the puller on the crankshaft and, pressing firmly, screw it into the sealing ring. Unlock both parts of the puller and, rotating the inside of the puller, remove the O-ring. Remove the O-ring from the puller.
Clean the seat of the O-ring.
Lubricate the lip and outer surface of the new O-ring with engine oil before installing it.
Pic. 3.1–65. Using Drift 3265 to Install the Front Crankshaft O-Ring
Using mandrel 3265 (pic. 3.1–65), install the sealing ring on the crankshaft and, using the pulley bolt, press the sealing ring into the seat.
Install pulley 1 (see fig. 3.1–63) toothed belt of the crankshaft, spacer sleeve 2 and screw in the mounting bolt 3.
Warnings: The bearing surface between the pulley and the crankshaft must be free of grease. Do not lubricate the crankshaft pulley bolt.
At installation it is necessary to use a new bolt of fastening of a pulley of a cranked shaft.
Install the toothed belt.
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