Removing, checking the condition and installing the timing belt and its tensioner

Removing

The components of the gas distribution mechanism drive and the fastener details of its covers are shown in the accompanying illustration.

1. Turn the crankshaft, bringing the engine to the TDC position of the end of the compression stroke of the first cylinder. In this position, the mark on the crankshaft pulley will be aligned with the pointer on the timing belt cover, and the distributor runner will turn its nose towards the location of the BB terminal of the spark plug wire of the first cylinder.

2. Disconnect the negative cable from the battery.

3. Empty the cooling system and remove the heatsink and fan assembly.

4. Remove drive belts from steering pump, alternator and air conditioning compressor pulleys (if the latter is included in the vehicle).

5. Give a bolt of fastening of a pulley of a cranked shaft. To block the pulley from turning, you can use the old drive belt and lever.


6. Using a puller, remove the crankshaft pulley from the engine.

7. Release the BB wires from the clips on the top cover of the timing belt.

8. Disconnect the charcoal canister and distributor hoses from the tubes at the front of the timing belt cover and move them out of the working area.

9. Give the fixing bolts of the upper cover of the timing belt, move the wires towards the BB and remove the cover from the engine.

10. Give fixing bolts and remove from the engine a forward lower cover of a gas-distributing belt.

11. Remove the timing belt guide plate from the crankshaft gear and make sure that the timing mark on the gear wheel is aligned with the mating mark on the oil pump housing.

12. If further use of a gas-distributing belt is supposed, mark the direction of its rotation with an arrow. Also mark the location of the timing marks of the crankshaft and camshaft gears relative to the timing belt.

13. Loosen the lock nut of the timing belt tensioner, then turn the tensioner with a suitable bar wrench and re-secure it with the lock nut.

14. Remove the timing belt from the crankshaft and camshaft gears.

Attention! After removing the timing belt, do not allow the crankshaft and camshaft to rotate to avoid damage to the pistons and valves when they hit each other.

15. Loosen the timing belt tensioner locknut and remove the tensioner with the spring from the engine. Try to remember the installation order of the wavy and flat tensioner washers.

16. Remove the cylinder head cover and loosen the rocker axle mounting bolts. This procedure is necessary for the correct tension of the timing belt when installing it.

Status check

1. Wipe the timing belt and tensioner components with a clean, dry cloth.

2. Inspect the belt for characteristic defects (see accompanying illustration).



3. Check the tensioner spring for signs of wear, deformation or other damage.

4. Manually check the freedom of rotation of the tension roller, thereby evaluating the condition of its bearing.

5. Check up a condition of a contact surface of a tension roller.

6. Check if the fixing bolts are damaged.

7. Replace any worn or defective components.

Installation

1. Make sure that the engine is still at the TDC position of the end of the compression stroke of the first cylinder. If necessary, correct the position of the crankshaft.

2. Make sure that the guide pin on the camshaft is at the top of its motion diagram.

3. Install the tensioner with spring on the front of the cylinder block. Make sure that the end of the spring engages with the stud so that the belt is tensioned.

4. Install the flat washer first, then the wave washer (concave side to tensioner). Using a bar wrench, move the idler away from the belt and temporarily tighten the locknut.




5. If a new belt is installed, it must be equipped with landing marks. Otherwise, mark one of the notches between the belt teeth and count back from this position 53 notches. Mark also this 53rd notch (see accompanying illustration).

Note. When installing the old belt, the same direction of rotation should be observed.

6. Put the timing belt on the gears of the camshaft and crankshaft, making sure that the marks on the belt are aligned with the marks on the wheels and that the belt rotates correctly (if the old one is installed).

7. Loosen the tensioner locknut and allow the latter to tension the belt.

Note. The fixing bolts of the rocker arm assembly must be loosened as mentioned above, otherwise the belt tension will not be correct.

8. Using a bar wrench, swing the tensioner two or three times in both directions, making sure that the belt tension is adequate.

9. After locking the tensioner in this position with a bar wrench, tighten its locknut to the required torque.

Note. To avoid noise and / or accelerated belt wear, do not set the belt tension force greater than the force developed by the tensioner spring.

10. With the camshaft guide pin located at the top of its stroke diagram, tighten the bolts of the rocker arm axles of the fourth, fifth and sixth cylinders with the required force.

11. Using a wrench on the crankshaft pulley bolt, turn the engine clockwise so that the guide pin drops to its lowest position. Now tighten the bolts of the rocker axles of the first, second and third cylinders with the required force.

12. For the final check, rotate the engine further clockwise by returning the camshaft guide pin to the top position and make sure that the mounting bolts of all rocker arm axles are tightened to the required torque.

13. Install the timing belt guide plate on the crankshaft pulley, concave side out. Install the upper and lower timing belt covers. Check that the seals are installed correctly. Tighten the mounting bolts to the required torque.

14. Install the cylinder head cover.

15. Install the remaining components in the reverse order of their dismantling, paying attention to the following points:

• Install the water pump pulley, fan and radiator in accordance with the instructions;
• Adjust the tension of the drive belts.