Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Using a 13 mm spanner, turn the power steering pump belt tensioner and insert a 4 mm pin through the center of the hexagon into the rear plate of the tensioner. Remove the power steering pump drive belt.
2. Loosen the generator pivot bolts and tension adjustment bar mounting bolts. Use the adjusting bolt to loosen the belt tension and remove the belt.
3. Models with air conditioning: Using a 13 mm wrench, turn the accessory drive belt tensioner by the hexagon clockwise until it stops to loosen the belt tension.
4. Models with air conditioning: While holding the tensioner in this position, insert a pin, up to 3 mm in diameter, through the center of the hexagon into the rear plate of the tensioner. Remove the accessory drive belt.
5. Disconnect the connector from the starter solenoid relay.
6. Unscrew the 2 bolts securing the starter to the gearbox and remove the starter.
7. Remove the upper part of the timing belt cover.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Upper timing drive cover.
8. Rotate the crankshaft until the marks on the camshaft gears align.
CAUTION: Do not rotate the crankshaft by the camshaft gears, camshaft mounting bolts or timing belt.
9. Install the LRT-12-134 device to align the camshaft marks.
10. Models with air conditioning: While holding the accessory drive belt tensioner, remove the pin and release the tensioner so that it rotates fully counterclockwise.
11. Remove the lower part of the timing belt cover.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Lower part of the front timing belt cover: vehicles with air conditioning system.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Lower part of the front timing belt cover: vehicles without air conditioning.
12. Remove and discard the timing belt tensioner mounting bolt.
13. Remove the spring indicator together with the timing belt tensioner.
14. If you intend to continue using the timing belt, mark the direction of its movement.
15. Remove the timing belt.
ATTENTION: Remove the belt from the gear wheels only by hand, without using tools that can damage both the belt and the gear wheels. Do not rotate the crankshaft with the timing belt removed and the cylinder head installed. The timing belt should be replaced if the cylinder head is to be removed, new gear wheels, a new tensioner or a coolant pump are to be installed. Timing belts must be handled with care. Timing belts should be stored on their edge and with a bending radius not exceeding 50 mm. Do not use a belt that has been twisted or folded in half, since the cord threads may be damaged. Do not use the timing belt if other wear particles (crumbs, threads) are found in the belt cover in addition to dust. Do not use the timing belt if partial engine seizure has occurred. Belts that have covered 72,000 km must be replaced. Do not use timing belts whose surface is contaminated with oil or coolant. The cause of pollution must be eliminated.
Installation
1. Wipe the crankshaft pinion gear, camshaft gears, coolant pump wheel and tensioner roller.
ATTENTION: If the gears manufactured by sintering (powder metallurgy technology) have been in contact with oil for a long time, they must be soaked in a solvent and then washed in a clean solvent before installation. The porous structure of the sintered material absorbs oil, which, when released, will contaminate the timing belt.
2. Check that the timing marks on the camshaft gears are aligned and that the LRT-12-134 tool holds the gears together.
3. Check the position of the marks on the crankshaft drive gear relative to the mark on the oil pump housing (90° before TDC).
4. Position the spring indicator so that it is above the bolt on the right and so that the tensioner lever is at the 9 o'clock position.
5. Screw in the new special one and tighten it just enough so that the tensioner lever can just barely be moved.
6. Put on the timing belt without using tools (only by hand). During installation of the belt, its branch between the toothed wheels of the intake and exhaust camshafts must remain taut.
CAUTION: If the old timing belt is used, the rotation mark must point in the correct direction.
7. Check that the belt is completely on all gears and rollers.
8. Install the lower part of the timing belt cover.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Lower part of the front timing belt cover: vehicles with air conditioning system.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Lower part of the front timing belt cover: vehicles without air conditioning.
9. Remove the LRT-12-134 camshaft alignment tool.
10. Using a 6mm Allen key, turn the tensioner counterclockwise until the notch on the tensioner pointer aligns with the spring indicator.
NOTE: If installing an old belt, the spring indicator must be aligned with the bottom edge of the pointer.
CAUTION: The tensioner pointer must approach the spring indicator from above. If the tensioner pointer passes the spring indicator, the tensioner must be completely pulled back and the operation repeated.
11. After checking the correct position of the pointer relative to the indicator, tighten the tensioner bolt to a torque of 22 Nm.
12. Turn the crankshaft 2 revolutions until the marks on the camshaft gears align.
CAUTION: Do not rotate the crankshaft by the camshaft gears, camshaft mounting bolts or timing belt.
13. Check that the tensioner pointer is positioned correctly relative to the indicator.
14. If the position needs to be corrected, loosen the tensioner mounting bolt enough so that the lever can be moved with greater force. Turn the lever clockwise until the tension on the belt is completely released, then turn the lever clockwise until the pointer is correctly aligned with the indicator.
15. After checking the correct position of the pointer relative to the indicator, tighten the tensioner bolt to a torque of 22 Nm.
16. Turn the crankshaft 2 revolutions until the marks on the camshaft gears align.
17. Check the position of the pointer relative to the indicator; if necessary, repeat the operation described above.
18. Clean the starter and gearbox mating surfaces.
19. Install the starter, screw in the mounting bolts and tighten them to a torque of 45 Nm.
20. Connect the connector to the starter solenoid relay.
21. Install the upper part of the timing belt cover.
ENGINE - MODIFICATION K, volume 1.8, Front exhaust camshaft oil seal, Upper timing drive cover.
22. Install the alternator drive belt.
23. Tighten the belt, tighten the adjuster bar bolts and pivot bolts.
24. Models with air conditioning: Turn the accessory belt tensioner fully clockwise. Insert the pin into the rear plate, holding the tensioner in this position.
25. Models with air conditioning: Install the accessory drive belt, loosen the tension, remove the pin from the tensioner and release the tensioner.
26. Wipe the power steering pump pulley.
27. Place the belt on the power steering pulley, move the tensioner away, remove the pin and release the tensioner.
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