Dismantling
1. Disconnect "negative" battery terminal.
2. Remove the lower engine protection.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
3. Remove the left rear timing belt cover.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, Left rear timing belt cover.
4. Remove the right forward wheel.
5. Turn away 3 bolts of fastening of the right dirt-protective panel and remove the panel.
6. Turn the crankshaft clockwise using the socket head for the pulley mounting bolt. Align risk "SAFE" on the crankshaft pulley with a mark "ARROW" on the engine front plate, with the marks on the rear camshaft gears aligned as shown.
ATTENTION: It is forbidden to turn the engine by the camshaft gear bolts or by the timing belt. Do not use the arrow on the oil pump housing as a match mark.
7. Insert the LRT-12-232 pin through the bottom pan hole so that the pin fits into the hole in the drive plate.
CAUTION: The pin is inserted through the bottom tray hole closest to the edge of the tray, as shown.
8. Remove and discard the exhaust camshaft oil seal from the cylinder head.
9. Install the LRT-12-175 tool on the rear gears, unscrew and discard the bolts securing the gears to the camshafts.
10. Remove the gear wheels, timing belt and tool assembly.
CAUTION: Do not rotate the crankshaft or camshafts with the timing belt removed.
11. If further use of the timing belt is expected, then mark the direction of its movement.
12. Remove the tool LRT-12-175 from the gears and remove the timing belt from the wheels.
WARNING: Do not rotate the crankshaft with the timing belt removed and the cylinder heads installed.
WARNING: Timing belts require careful handling and storage. Timing belts should be stored on edge and not allowed to have a bend radius of less than 50 mm. Do not use a timing belt that has been twisted or folded in half as the cords may be damaged. Do not use the timing belt if other than dusty wear particles are found on the belt cover (crumbs, thread). Do not use the timing belt if there has been a partial wedging of the engine Belts that have passed 72,000 km must be replaced. Do not use timing belts whose surface is contaminated with oil or coolant. The cause of the contamination must be eliminated.
Installation
NOTE: It is possible that after replacing the front or rear timing belt and setting the crankshaft pulley to the 'SAFE' position, the position marks on the rear cogwheels will no longer align. Such a mismatch is acceptable provided that the belt replacement procedure was carried out without errors.
1. Clean the camshaft gears and their seats on the camshafts.
WARNING: If sintered gears (powder metallurgy technology), have been in contact with oil for a long time, then, before installation, they must be soaked in a solvent and then washed in a pure solvent. The porous structure of the sintered material absorbs oil, which, if released, will contaminate the timing belt.
2. Lay the reversed gears on a flat surface with the marks turned as shown.
3. Put the timing belt on the gears, keeping the alignment marks aligned.
4. Install the LRT-12-195 tool between the gear wheels, turn the tool nut until the belt is sufficiently tensioned.
5. Turn over the gears with the belt and fit LRT-12-175 to the gears.
6. After checking the alignment of the alignment marks, remove the LRT-12-195 tool that was between the wheels.
7. Install guide pins LRT-12-198 into the end of each camshaft.
8. Using the LRT-12-198 guide pins, slide the gears onto the camshafts.
9. Screw special bolt LRT-12-197 into the front end of the left exhaust shaft.
10. With the help of a partner, by installing a 30 mm socket on the LRT-12-197 special bolt, rotate the left camshaft until the projections on the gears align with the grooves of each of the camshafts.
11. Unscrew the guide pins LRT-12-198 and screw in new bolts for fastening the gear wheels.
12. Tighten the gear wheel bolts:
- Stage 1: 27 Nm
- Step 2: Turn 90°
13. Remove tool LRT-12-175 from gears.
14. Remove special bolt LRT-12-197 from the front of the exhaust camshaft.
15. Wipe the left exhaust camshaft seal housing and install a new seal.
16. Remove pin LRT-12-232 from bottom pan.
17. Install the mudguard and secure it with bolts.
18. Reinstall the right wheel and tighten the nuts to 115 Nm.
19. Install the left rear timing belt cover.
KV6 ENGINE - MODIFICATION K, Left cylinder head camshafts, Left rear timing belt cover.
20. Reinstall the lower engine guard.
EXTERIOR PARTS, REPAIR WORKS, Engine lower shield.
21. Attach "negative" battery terminal.
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