Removal
1. Disconnect the negative cable from the battery.
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
2. Support the rear wheels with wheel chocks and firmly apply the parking brake.
3. Loosen the front wheel nuts, then jack up the front of the car and place it on supports (see Chapter Routine maintenance).
4. Remove the front wheels and engine crankcase guard.
5. Support the power unit with a jack (to distribute the load, place a wooden block between the jack head and the engine oil pan).
6. Remove the upper engine mount bracket (see Checking the condition and replacing the powertrain suspension supports).
7. Remove the spark plugs and drive belts (see Routine maintenance).
8. Unbolt the steering pump and move it to the side without disconnecting the hydraulic lines (see Chapter Suspension and steering).
9. Remove the engine oil dipstick.
10. Bring the piston of the first cylinder to the TDC position at the end of the compression stroke (see Bringing the piston of the first cylinder to the top dead center (TDC) position).
Caution! The crankshaft should only be turned in the normal direction (counterclockwise) – failure to comply with this requirement will result in timing belt adjustments being disrupted.
11. Remove the upper timing belt cover (see accompanying illustration).
12. Remove the idler roller with bracket from the front of the engine.
13. Using a chain or strap wrench, block the crankshaft pulley from turning, then loosen the pulley mounting bolt with a socket wrench (see accompanying illustration).
14. Remove the pulley from the crankshaft journal.
15. Remove the dipstick guide tube from the front of the engine.
16. Remove the lower timing belt cover.
17. If the old belt is in good condition and will be installed in place, mark with chalk or white paint the direction of its rotation and its position relative to the shaft gears (see accompanying illustration).
18. Loosen the timing belt tensioner mounting bolt (see accompanying illustration). After releasing the tensioner, loosen the belt, then tighten the bolt again. Remove the crankshaft fluctuation sensor (see ibid), then remove the belt from the toothed wheels. If the belt is removed in order to replace the crankshaft oil seal, remove the toothed wheel and the inner belt guide from the crankshaft journal (see Replacing the front crankshaft oil seal).
19. If it is necessary to remove the camshaft or replace its seal, insert a large screwdriver through the hole in the shaft gear to prevent it from turning, then use an end wrench to loosen the mounting bolt and remove the wheel. Remove the woodruff key from the camshaft journal.
Examination
1. Manually check the tensioner roller for free rotation, then tug it from side to side to check for play in the bearing (see accompanying illustration). The defective roller must be replaced.
2. Carefully inspect the timing belt on both sides, checking for signs of wear (especially the persistent walls of the teeth), cracks, cuts, abrasions and traces of oiling (see accompanying illustration). A defective belt must be replaced.
Note: Unless the engine mileage is very low, it is recommended to replace the belt regardless of its condition. Never install an old belt on the engine unless you are 100% sure that it is in good condition.
Installation
1. If removed, reinstall the shaft gears (don't forget about the camshaft spline key and the inner belt guide on the crankshaft). Tighten the camshaft timing gear mounting bolt to the required torque (see Specifications).
2. Before installing the belt, make sure that the camshaft gear is installed with the mark in the form of a dot or the letter "UP" facing up. The two installation marks should be in the plane of the cylinder head surface (see accompanying illustration).
3. Temporarily install and secure the crankshaft pulley with the bolt, then turn the shaft (if it was shot down) so that the timing mark on its gear is aligned with the corresponding indicator on the oil pump housing (see accompanying illustration).
4. Fit the belt snugly onto the crankshaft timing gear, then pass it under the tensioner pulley and around the water pump and camshaft timing gears (see accompanying illustration).
5. Loosen the tensioner bolt to ensure belt tension, then temporarily tighten the bolt.
6. Carefully rotate the crankshaft six times counterclockwise, then check that the timing marks on the camshaft gear are correctly positioned. If the crankshaft rotates jerkily or is jammed, do not apply force, as this may damage the valves when they hit the piston crowns (if the adjustment is out of adjustment). Remove the belt and repeat the procedure, paying particular attention to aligning the timing marks.
7. To adjust the belt tension, loosen the tensioner bolt by half a turn (180°) and turn the crankshaft counterclockwise three teeth past TDC. Now tighten the bolt to the required force.
8. Reinstall all components removed during disassembly.
9. Adjust the tension of the drive belts (see Chapter Routine maintenance).
10. Start the engine and check its proper functioning.