Proceed with the procedures only after the engine has completely cooled down.
Removing
1. Disconnect the negative cable from the battery.
2. On engine 1.6 l disconnect the airflow mass sensor connector (MAF).
3. Remove the air filter with suction hose and air intake sleeve (see chapter Power supply systems, release and reduction of toxicity of exhaust gases).
4. Turn out bolts of fastening and remove the top cover of a gear belt.
5. Remove the accessory drive belt.
On cars with К/В a belt only remove from a pulley, but do not take it out.
6. Remove spark plugs (see chapter Vehicle settings and routine maintenance).
7. Turn out two bolts of fastening of the sensor of position of a camshaft (CMP) (1) and take it aside with the attached wiring.
The layout of the TDC setting marks
8. Remove the right forward wheel. If necessary, remove the wheel arch locker. If there is an oil bath in the engine design, remove the flywheel cover (see chapter Manual 5-speed gearbox).
9. Set the piston of the 1st cylinder to the TDC position (see Section In-Vehicle DOHC Gasoline Engine Repair Procedures).
10. Remove the crankshaft pulley. When doing this, make sure that the previously set shaft position does not change. To keep the shaft from turning, block it.
11. Remove the bottom cover of a gear belt.
12. If you intend to use the toothed belt repeatedly, mark the direction of its movement with an arrow (clockwise).
13. Loosen the tension of the toothed belt, for which loosen the fixing bolt of the tension roller. If necessary, turn the tensioner roller with a hex wrench by the eccentric in a clockwise direction.
Timing belt loosening
14. Remove a gear belt and check up its condition.
Do not change the position of the engine with the toothed belt removed.
Installation and tension
Before installing, check if the TDC marks match (see Section In-Vehicle DOHC Gasoline Engine Repair Procedures) on the camshaft pulleys, as well as on the crankshaft gear. Installing a toothed belt with the wrong position of the gears can damage the valves and pistons of the engine.
1. Check the installation position of the water pump. Label (2) on the pump must match the mark (1) on the cylinder block.
Water pump alignment marks
2. Put the toothed belt on the gears without turning them. In this case, be sure to follow the correct laying of the belt.
Scheme of laying a toothed belt
1 — a gear wheel of a cranked shaft
2 - Tension roller
3 - Water pump
4 - Intermediate roller, outlet side
5 — a gear wheel of an inlet camshaft
6 — a gear wheel of a final camshaft
7 - Intermediate roller, intake side
When laying the toothed belt on the intake camshaft sprocket, make sure that no teeth are missed and that the mark when the belt is applied is aligned with the top edge of the cylinder head.
3. Tension the toothed belt. To do this, turn the tension roller counterclockwise with a hex key through the adjusting eccentric so as to achieve maximum tension. At the same time, the tension roller pointer is on the right, near the mark. Secure the toothed belt tensioner in this position.
Timing belt initial tension
When adjusting the tension of the toothed belt, the part between the intermediate roller on the exhaust side and the crankshaft gear must be tensioned, otherwise fine adjustment is not possible.
4. Screw in the old crankshaft pulley bolt. Smoothly, without jerks, turn the crankshaft by hand 2 turns clockwise. Then check if the marks on the camshaft gears and on the crankshaft gear match. If there is a mismatch, remove the belt and repeat the adjustment.
5. Adjust the toothed belt tension. To do this, slightly loosen the adjusting bolt of the toothed belt tensioning roller and turn the adjusting eccentric clockwise so that the position of the pointer corresponds to accompanying illustrations.
Adjusting the new toothed belt
A - Pointer (1) toothed belt tension roller must match the mark (2)
IN — Pointer (1) toothed belt tension roller must match the mark (2) «NEW»
Adjusting an already used toothed belt
A - Pointer (1) toothed belt tensioner must align with the left edge of the mark (2)
IN - Pointer (1) toothed belt tension roller must match the mark (2) «USED»
Adjustment marks may differ depending on the year of manufacture of the car. The specified values also apply to adjusting the toothed belt tension as part of maintenance work.
6. Tighten the idler roller adjusting bolt to 20 Nm.
7. Establish the bottom cover of a gear belt.
8. Install the crankshaft gear. In this case, always use a new bolt. Tighten the bolt first 95 Nm, and then tighten it with a hard wrench at an angle 30 deg. and another corner 15 deg.
9. Fix the camshaft position sensor to the rear toothed belt cover with two bolts, tightening them with force 8 Nm. Pre-lubricate the threads of the bolts with sealant.
10. Further installation is carried out in the reverse order to the removal of components.
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