1. KM-800-20
2. KM-800-1
3. KM-800-30
4. KM-800-10
5. KM-800-2
To adjust the timing belt, you will need the following special tools: camshaft sprocket locking tools (KM-800-1 and KM-800-2), crankshaft sprocket locking tool (KM 800-10), timing belt wedge (KM-800-30) and camshaft sprocket timing tool (KM-800-20).
Removing
1. Disconnect the negative battery cable and set the N1 piston to TDC.
2. Remove the crankshaft pulley.
3. Check if the timing marks are aligned correctly.
4. Install the KM-800-10 tool on the crankshaft sprocket and lock the shaft.
5. Lock camshafts, tool KM-800-1 (marking 1 and 2, red handle) is designed for shafts of the right cylinder head, and the KM-800-2 tool (marking 3 and 4, green handle) for shafts of the left head. Clamp the tool lever on the water pump flange.
6. Install the camshaft sprocket locking tool (drawing on the left). TOP marks should be directed upwards (drawing on the right).
7. Loosen the timing belt tensioner pulley nut.
8. Turn the tensioner pulley clockwise until it stops and tighten the nut.
9. Loosen the top bolts (drawing on the left) and lower (drawing on the right) timing belt guide pulleys.
10. Remove the timing belt. If you did not use special tools, turn the crankshaft about 60°back before removing the belt. Thus, the likelihood of contact between valves and pistons is reduced.
11. Carefully inspect the belt for wear and damage and replace if necessary.
Installation
Tensioner pulley adjustment
A. Tensioner pulley mark
B. Stop mark
Warning! There are two types of belts and two types of tensioners that are installed on the described engines. The type of belt depends on the type of tensioner. Modified tensioners are installed on 1997 and later engine models and are marked E on the pulley. Conventional tensioners are installed on pre-1997 engines and are marked D. If you have difficulty determining the type of tensioner, contact a specialist.
1. Thoroughly clean the shaft sprockets and pulleys.
2. Align the timing marks of the camshaft sprockets on the right cylinder head (1 and 2) (drawing on the left) and left (drawing on the right) slots in the timing belt rear cover and align them again if you turned the crankshaft 60°.
3. Align the mark on the crankshaft sprocket with the slot in the oil pump housing (indicated by arrows).
4. Put the belt on the sprockets. The arrows on the belt must point in the direction of rotation of the belt, and the double line on the belt must match the timing mark on the crankshaft sprocket.
5. Lock the timing belt with a wedge.
6. In engines equipped with a conventional tensioner, the belt must first be put on the lower guide pulley and on the camshaft sprockets of the left cylinder head. Label (arrow) on the tensioner pulley bracket will help determine the type of tensioner.
7. In engines equipped with a modified tensioner, the belt must first be put on the tensioner pulley.
8. Then the belt must be put on the camshaft sprockets of the right cylinder head.
9. Pass the belt over the lower idler pulley.
10. Loosen the lower idler pulley bolt. Turn the pulley counterclockwise to tension the left side of the belt. Check that the timing marks are still aligned.
11. Tighten the pulley bolt.
12. Loosen the upper idler pulley bolt. Turn the pulley counterclockwise to tension the top of the belt. Check that the timing marks are still aligned. Tighten the pulley bolt.
13. Loosen the tensioner pulley nut and turn the pulley arm counterclockwise so that the distance between the plate and the stop is 0.5–1.5 mm (indicated by an arrow). Tighten the nut.
14. Remove all blocking tools and turn the crankshaft two full turns.
15. Check that the timing marks are still aligned.
16. Loosen tensioner nut and install tensioner arm as shown (see fig. Tensioner pulley adjustment). Label (A) should be 3-4 mm above the stop mark (IN). Tighten the nut.
17. Rotate the crankshaft two full turns. Check that the timing marks are still aligned. Make adjustments if necessary.
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