Camshaft gear
Removing
SOHC engines
1. Remove the timing belt (see Removing and installing timing belt).
2. Remove the timing cover (see Removal and installation of a cover of the gas-distributing mechanism).
3. Secure the camshaft from turning by holding it with an open end wrench on the hex section. Turn out a fixing bolt and remove a gear wheel of a camshaft.
DOHC engines
1. Remove the timing belt, (see Removing and installing timing belt). Before releasing the gear bolt, rotate the crankshaft 60°back from TDC to prevent the valves from coming into contact with the pistons.
2. In order to prevent the camshaft from turning, fully screw in the gear fixing bolt.
3. Turn out a fixing bolt and remove a cogwheel from a pin of a camshaft, - try to remember an adjusting position of components. If the gear locking rod has a loose fit, remove it from the camshaft and store it in a safe place.
Installation
SOHC engines
You will need a new camshaft gear bolt!
1. Install the gear wheel, install the NEW mounting bolt and tighten it finger tight for now.
2. Install the timing belt (see Removing and installing timing belt).
DOHC engines
1. Make sure that the locking rod is in its regular place, then install the gear on the camshaft - follow the hit of the locking rod in the mating hole.
2. Screw in the gear wheel mounting bolt, then match the mounting holes in the wheel and head, and screw in the M6 bolt. Tighten the gear wheel mounting bolt to the required torque. Rotate the crankshaft 60°clockwise until the notches on the crankshaft sprocket are in position «at 12 o'clock» and align it with the molded mark on the oil pump cover.
3. Install the timing belt (see Removing and installing timing belt).
Injection pump gear
Removing
SOHC engines
1. Remove the timing belt (see Removing and installing timing belt).
2. Insert the KM-6011 tool into the hole for fixing the flange in order to prevent the injection pump gear from turning. If you do not have a special tool at hand, use a rod with a diameter of 9.5 mm and a length of 75 mm.
3. Turn out three fixing bolts and remove a cogwheel.
DOHC engines
1. Remove the timing belt (see Removing and installing timing belt).
2. In order to prevent the high-pressure fuel pump shaft from turning, screw in the M8 bolt fixing the gear wheel until it stops.
If necessary, the gear wheel can be blocked in another way: using a device in the form of a fork with bolts screwed in at the ends and equipped with locking nuts.
3. Loosen and remove the gear nut.
4. Remove the gear wheel from the injection pump shaft - try to remember the installation position of the components. If the key has a loose fit in the injection pump shaft trunnion, remove it and put it in a safe place.
The gear wheel has a tapered fit on the shaft journal and in some cases a puller may be required to remove it.
Installation
SOHC engines
1. Place the gear wheel on the pump shaft, make sure that the cutout on the sprocket is aligned with the cutout on the flange and the hole for entering the KM-6011 blocking rod.
2. Screw in the gear wheel mounting bolts and tighten them until hand-tight.
3. Install the timing belt (see Removing and installing timing belt).
DOHC engines
1. Make sure that the key is properly seated in the shaft trunnion, then install the gear wheel - make sure the key fits into the keyway.
2. Screw the fixing nut and tighten it with the required force, blocking the gear wheel from turning by screwing in the M8 fixing bolt.
3. If a fork was used to fix the sprocket, match the mounting holes and screw in the M8 bolt.
4. Install the timing belt (see Removing and installing timing belt).
Crankshaft gear
Removing
SOHC and DOHC engines
1. Remove the crankshaft pulley (see Removal and installation of the crankshaft pulley).
2. On models with manual transmission ask an assistant to block the crankshaft from turning, turn on the highest gear and depress the foot brake pedal all the way. On models with AT unscrew one of the torque converter mounting bolts and tighten the latter to the transmission case using a steel bar and suitable bolts with washers (see chapter automatic transmission). If the engine is removed from the vehicle, the flywheel/drive plate must be blocked (see Removal, condition check and installation of a flywheel / drive disk). Loosen the gear wheel bolt.
3. Remove the timing belt (see Removing and installing timing belt).
4. Turn out a fixing bolt with a washer and remove a gear wheel — if the wheel does not give in, use a suitable puller. If the key is loose in the shaft journal, remove it and put it in a safe place.
5. On DOHC engines remove the flange spacer from the crankshaft trunnion - try to remember the installation position of the components.
Installation
SOHC and DOHC engines
1. Installation is carried out in the reverse order of dismantling the components - make sure that the key fits into the shaft trunnion and that the keyway of the gear wheel hub is correctly aligned with it.
On DOHC engines, the flange spacer is installed with the protruding side facing out.
Oil pump gear (DOHC engines)
Removing
1. Remove the timing belt (see Removing and installing timing belt).
2. Having blocked the gear wheel of the oil pump from turning with the help of a replaceable end head with an extension, put on one of the bolts of the oil pump cover, unscrew the central bolt of the gear wheel.
3. Remove the gear wheel from the oil pump shaft, try to remember the installation position of the components.
Installation
1. Install the gear, - make sure that the keyway is aligned with the key. Tighten the nut to the required torque, blocking the gear wheel from turning the sprocket in the manner used for removal.
2. Install the timing belt (see Removing and installing timing belt).
Tensioner assembly
Removing
SOHC engines
1. Remove the timing belt (see Removing and installing timing belt).
2. Turn out a fixing bolt and remove assembly a tensioner from the engine.
DOHC engines
1. Remove the timing belt (see Removing and installing timing belt).
2. Carefully release the tension spring, then remove the mounting bolts and remove the tensioner assembly.
Installation
SOHC and DOHC engines
1. Installation is in the reverse order to the removal of the components. On SOHC engines, check alignment of the control arm (1) with reciprocal cutouts in the oil pump cover (2).
On SOHC engines, the final tightening of the tensioner mounting bolt is done after the timing belt is installed.
Intermediate roller
Removing
SOHC and DOHC engines
1. Remove the timing belt (see Removing and installing timing belt).
2. Turn out a bolt of fastening and remove a roller from the engine.
On SOHC engines, the intermediate roller is removed along with the spacer.
Installation
SOHC and DOHC engines
Installation is carried out in the reverse order to the dismantling of the components. Make sure the fasteners are tightened to the correct torque.
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