Warning! In order to check the installation of the timing mechanism and the fuel pump, it is necessary to use special tools:
- camshaft blocking tool KM932;
- pin blocking the protrusion of the fuel pump KM927;
- crankshaft blocking pin KM929;
- camshaft sprocket wrench KM933.
Tools for adjusting the timing mechanism
A. Crankshaft lock pin
B. Fuel pump protrusion blocking pin
C. Camshaft locking tool
Crankshaft lock pin dimensions
Dimensions of the fuel pump protrusion blocking pin
Check and adjustment
1. Remove the auxiliary drive belt. Unscrew the idler pulley auxiliary post, bottom bolt and pulley support plate pivot bolt and remove the idler.
2. Remove the brake vacuum pump.
3. To improve access to the fuel pump sprocket housing and pump, do the following:
- remove the air filter cover and exhaust pipe;
- unscrew the nut from the top of the right power unit mount and raise the right side of the engine as far as it will go.
4. Remove the cylinder head cover and set the piston of the first cylinder to top dead center on the compression stroke.
5. Remove the crankshaft sensor.
6. Remove the screws and remove the fuel pump sprocket cover from the chain cover.
7. Check that the crankshaft pulley mark is aligned with the pointer and insert the crankshaft locking pulley into the crankshaft sensor hole and fix the crankshaft from turning.
8. Insert the fuel pump protrusion blocking pulley into the hole in the protrusion and, moving the pulley, insert it into the hole in the pump housing.
9. Insert the camshaft locking tool into the hole on the left end of the camshaft (indicated by an arrow).
10. If all the locking pins are installed normally, then the timing mechanism does not need to be adjusted. If at least one of the blocking pins is not installed, it is necessary to adjust the gas distribution mechanism.
11. Remove the pump blocking pin and remove the bolt on the right side of the suspension from the cylinder head.
12. Unscrew the upper head of the chain tensioner and remove the plunger, noting the position in which it is installed.
13. Lock the camshaft by turning and unscrew the camshaft sprocket mounting bolt. Install the new bolt finger-tight.
14. Loosen the bolts securing the fuel pump sprocket to the pump lug.
15. Check the position of the setting mark (arrow) on the fuel pump. In this case, the upper sprocket of the timing chain must be aligned with the protrusion of the pump. Insert the fuel pump protrusion blocking pin and tighten the sprocket mounting bolts to the required torque.
16. Install the camshaft lock pin.
17. After installing all the locking pins, put the camshaft sprocket in place by screwing the sprocket mounting bolt. While doing this, support the sprocket so that the slack in the chain is on the side of the chain tensioner.
18. Secure the camshaft against turning with a wrench and tighten the camshaft sprocket bolt to the required torque in several stages.
19. Remove all blocking pins, install a new O-ring to the upper head of the timing chain tensioner. Insert plunger into cylinder head and tighten to specified torque.
20. Turn the engine crankshaft two full revolutions and check that all locking pins can be installed.
21. Check that the mating surfaces of the fuel pump sprocket housing and chain housing are clean and dry.
22. Install the fuel pump sprocket housing on the gasket or sealant layer and secure with bolts, tightening them to the required torque.
23. Install the tension mechanism.
24. Install the power unit support. Install the cylinder head cover.
25. Install the exhaust pipe and air cleaner cover.
26. Install the brake vacuum pump.
27. Install the crankshaft sensor in the cylinder block and connect the battery.
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