Timing belt and accessory drive

Replace the timing belt and accessory drive carried out as follows:

1) Remove the cover of the engine;

2) remove the belt (Fig. 2.56), as follows:

- Release the accessory drive belt, pulley unscrewing the screw clockwise;

- Remove the accessory drive belt;

- Release the belt tensioner (counterclockwise);

- Remove the accessory drive belt;

3) Unscrew the top cover of the timing belt and remove it;

4) Install a lifting beam 999 over the 5006 engine in the middle and insert the lifting hook 999 in 5460 lifting eye, if necessary, install additional bracket 999 5383;

5) Lift the motor a few millimeters;

6) Remove the motor support on the part of the camshaft (Fig. 2.57), as follows:

- Remove the screw from the support on the body;

- Unscrew the two screws and remove the screw from the engine mounts;

- Remove the support together with a rubber component;

7) on cars with air conditioning, disconnect the hose from the bracket, unscrew the two screws and remove the bracket;

8) Remove the lower timing belt cover (Fig. 2.58), as follows:

- Remove the screw (arrow);

- Remove the driven pulley;

- Remove the bottom cover of the timing belt;

9) Remove the right front wheel, which should:

- Put a support under the vehicle;

- Remove the wheel;

- Slightly loose cover;

10) Remove the crankshaft pulley (Fig. 2.59), as follows:

- Turn out four bolts of fastening of a pulley;

- Set the tool 999 5433 and fix it with four bolts;

- Unscrew the central nut;

- Slightly lower the engine (if necessary);

- Remove the tool;

11) set the gas distribution mechanism and the crankshaft on labels, which is necessary to turn the crankshaft clockwise until combined labels timing, on the inside cover of the timing belt, the crankshaft pinion and the housing of the oil pump (Fig. 2.60);

12) Remove the timing belt (Fig. 2.61), as follows:

- Set the mark (see. Prev. Para) facing each other;

- Turn out the top bolt (arrow) of the tensioner;

- Loosen the bottom bolt (arrow);

- Turn the tensioner so that the pulley rotates freely;

- Turn out the bottom bolt;

- Remove the tensioner;

- Remove the timing belt;

- Clean and check all the toothed pulleys;

13) Check the tensioner and tension rollers (Fig. 2.62), as follows:

- Rotating rollers, listen to the presence of background noise in the bearings;

- Make sure that the contact surfaces of the rollers are clean and smooth;

- Also check whether the lever is not stuck in a roller bearing it; Check the tension wheel;

- Loosen the lever and apply grease 1161246-2 bearing and contact surfaces;

- Torque arm tensioner 40 Nm;

- Torque tension roller 25 Nm;

14) Assemble the tensioner, as follows:

- Make sure there are no signs of leaks;

- Remove the plastic retaining ring with the piston rod;

- Tighten the belt tensioner with special tool 999 5456 (Fig. 2.63);

- Set in the tensioner device and tighten the central nut accessories; wait a few minutes to complete the compression, and then insert the locking pin (2 mm diameter) into the piston (see. Fig. 2.63);

15) put on a new timing belt, for which:

- Set the tensioner;

- Set the tension screws and tighten to 25 N ?� m;

- Head of the belt around the crankshaft pulley and the right tension roller;

- Head of the belt around both sprocket timing;

- Head of the belt around the water pump pulley and pull it over the tensioner pulley;

16) Pull the belt, as follows:

- Remove the locking pin from the tensioner;

- With a push force in points 1 and 2 (Fig. 2.64);

17) put a new plastic ring on the piston rod tensioner (Fig. 2.65).

Make sure that the plastic ring is correctly positioned in the center;

18) Check the belt tension, for which:

- Wait about 5 minutes after adjusting the tension of the timing belt;

- 998 8500, set the indicator on the toothed belt between the toothed pulley exhaust camshaft pulley and the coolant pump (Fig. 2.66);

- Consider the value of using a mirror, thus it is impossible to remove the indicator until the completion of the measurement. Average belt tension should be between 2.5-4.0 units.

If the normal value is not received, the tensioner must be replaced;

19) Turn the crankshaft two turns and check the match marks on the crankshaft pulley on the camshaft sprockets and timing belt cover;

20) Install the crankshaft pulley (Fig. 2.67), as follows:

- Adjust the position of a pulley with a special tool 999 5433;

- Put the central nut and tighten to 180 Nm;

- Remove the tool;

- Tighten the pulley bolt to 25 Nm and then tighten it to an angle of 30 degrees;

21) Install the timing belt cover (Fig. 2.68), as follows:

- Put the bottom cover;

- Put the driven pulley, tightening torque 25 Nm.

- Put the top cover (1 screw) with a torque of 10 Nm;

22) wear accessory drive belt (Fig. 2.69), as follows:

- Clean the pulley groove;

- Turn the tensioner;

- Wear accessory drive belt,

- Free the tensioner (counterclockwise);

23) set the motor support on the part of the camshaft (Fig. 2.70), as follows:

- Establish a support to the engine and tighten the nuts and bolts to 67 Nm;

- Insert the screw into the support on the body and gently tighten it;

- Remove the lifting beam 999 5006 from the engine;

- Then tighten the bolt of a support point on the body 98 Nm;

- For vehicles with air conditioning need to mount the bracket on the body and the hose to the bracket;

- Tighten the bolts to 10 Nm;

- Start the engine and check the operation;

24) set the wheel (Fig. 2.71), as follows:

- Secure the cover;

- Put the wheel nuts and tighten its mounting crosswise torque of 110 Nm;

- Tightening pneumatic wrench, use only a torque nozzle 951 2661;

- Tighten wheel nuts by hand.