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 speed control actuator (tempostat) (See Chapter On-board electrical equipment).
10. Bring the piston of the first cylinder to the TDC position at the end of the compression stroke (see Seat adjustment).
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 cylinder head cover (see Equipment and controls in the cabin).
12a. Remove the timing belt center cover.
12b. Remove the lower timing belt cover. (see accompanying illustrations). The top cover is integrated with the head cover.
13. Loosen the belt tensioner bolt by half a turn (see accompanying illustration). After releasing the tensioner, loosen the belt, then retighten the bolt.
14. 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). 15. Remove the pulley from the crankshaft journal.
16. If the old belt is in good condition and will be installed in place, mark with chalk or white paint the original direction of its rotation and position relative to the shaft gears (see accompanying illustration). 17. Loosen the tensioner mounting bolt. Release the tensioner, loosen the belt, then tighten the bolt again. Slip the belt off the toothed wheels and remove it from the engine. If the belt is being removed to replace the crankshaft oil seal, slide the toothed wheel and inner belt guide off the crankshaft journal (see Fig. Security systems).
18. If it is necessary to remove the camshafts or replace their seals, insert a large screwdriver through the hole in the gear wheel of the corresponding shaft to prevent it from turning, then loosen the mounting bolt with an end wrench and remove the wheel. Remove the segment key from the camshaft journal. The wheel of the second shaft is removed in a similar manner.
Examination
Caution! Try not to allow the crankshaft or camshaft gears to turn when the timing belt is removed to avoid damaging the valves by hitting the piston crowns.
1. Manually check the tensioner roller for free rotation, then tug it from side to side to check for play in the bearing (see illustration for paragraph 13). 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 splines and the inner belt guide on the crankshaft). Tighten the camshaft timing gear mounting bolts to the required torque (see Specifications).
2. Before installing the belt, make sure that the camshaft gears are installed with the "UP" mark facing up. The timing marks should be aligned with the pointer on the rear belt cover (see accompanying illustration).
Note: If resistance occurs, stop turning the shaft immediately to avoid damaging the valves by hitting the piston crowns. Carefully adjust the position of the camshaft gears, then try again.
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 securely onto the crankshaft sprocket, then pass it under the tensioner pulley and around the water pump and camshaft sprockets. Loosen the tensioner bolt to provide belt tension, then temporarily tighten the bolt.
5. Carefully rotate the crankshaft six times in a counterclockwise direction, then check that the timing marks on the camshaft gears are positioned correctly (see illustrations above). If the crankshaft turns with jerks or jams, do not apply force, as this may result in damage to the valves when they hit the piston bottoms (if the adjustment is out of adjustment). Remove the belt and repeat the procedure, paying particular attention to aligning the timing marks.
6. 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 (see Fig. Specifications).
7. Reinstall all components removed during disassembly.
8. Adjust the tension of the drive belts (see Chapter Routine maintenance).
9. Start the engine and check its proper functioning.