4-cylinder petrol engines
1. The toothed drive belt must be changed every 100,000 km, even if it is still in good condition. When replacing the belt, follow the instructions exactly. If the camshaft is not installed correctly relative to the crankshaft, the valves may knock on the pistons.
2. Disconnect the battery and the shield under the engine.
3. Remove the water pump and power steering drive belt.
4. Remove the cylinder head cover and unscrew the spark plugs.
5. Place a ring spanner on the crankshaft timing belt pulley bolt and set the piston of the first cylinder to TDC.
6. Now the crankshaft should be held precisely in this position. First, check from the flywheel side whether the mark for setting the ignition timing on the flywheel is opposite the "0" mark on the clutch housing, and the installation mark on the camshaft sprocket opposite the tongue in the camshaft drive cover or look in the lower window of the camshaft drive cover (see illustration). Secondly, check if both rocker arms of the first cylinder have a gap when moved. Now the crankshaft cannot be turned until the toothed drive belt is installed.
20.6 Inspection windows in the camshaft drive cover of some engines. At the top - for the camshaft sprocket, at the bottom - for the crankshaft sprocket
7. Partially drain the coolant and close the drain hose on the manifold.
8. Remove the timing belt cover.
9. Loosen the timing belt tension roller. To do this, loosen both nuts, press the roller back and tighten both nuts again.
10. Carefully remove the toothed drive belt. Make sure that no oil or grease gets on the belt and do not bend it. The direction of the belt should be marked with chalk or paint on the back of the belt.
11. If necessary, remove the camshaft pulley. When doing so, mark the keyway as this is necessary for installation.
12. Please note the following instructions:
13. The camshaft sprocket has two grooves for keys. When installing the pulley, the marked groove must coincide with the key. Tighten the bolt with a tightening torque of 50 Nm.
14. The camshaft sprocket has two marks (see illustration). On one side is a mark (7), opposite is a small projection (6). They are used together with the keyway (5) on J6R and J7R engines. On the opposite side is a timing mark (1) and two projections (2) in relation to the rectangular hole (4). These timing marks together with the keyway (3) are used on J7T engines. Which sprocket design uses a toothed drive belt with square teeth?.
20.14 Camshaft sprocket
15. Newer models have a toothed drive belt with rounded teeth, i.e. parts for the old toothed drive belt will not fit the new one. In addition, both belts have a different number of teeth. The following description assumes that the engine has been completely disassembled. If the belt is removed as described above, you can proceed to additional work.
16. Assemble the engine as described in chapter 3, before installing the cylinder head. Just install the cylinder head for now. Align the three pulleys as shown (see illustration).
20.16 Alignment of pulleys. Position before installing toothed drive belt
17. Turn the crankshaft until the ignition timing mark on the flywheel aligns with the "0" mark on the clutch housing. Also, after installing the camshaft drive cover, you can check through the inspection window whether the timing mark on the crankshaft sprocket is visible (see illustration 20.6).
18. Turn the intermediate shaft until the timing mark on the pulley is in line with the rib in the cylinder block.
19. Temporarily place the sprocket on the camshaft (with marked groove for key) and turn the camshaft so that the timing mark on the pulley is in line with the vertical line passing through the rocker arm axis.
20. After all pulleys and sprockets have been adjusted, inspect everything again (see illustration 20.16).
21. Now install the cylinder head as described when assembling the engine. Tighten the toothed drive belt as follows:
22. Referring to Illustration 20.16, check again that the timing marks of the three sprockets are aligned and fit the toothed drive belt. Sections "A" and "B" should not be loose after installation (see illustration).
20.22 Parts "A" and "B" must not sag before tensioning the toothed drive belt
23. Loosen both tension roller bolts by a quarter of a turn. The tension roller is then set to a new position and tensions the toothed drive belt. Tighten both screws after adjusting the tension roller.
24. Rotate the crankshaft two full engine revolutions in its normal direction.
25. Check the tension of the toothed drive belt using a special tool (see illustration). A toothed drive belt must have a certain amount of deflection, which depends on the shape of the belt teeth:
- a) The deviation value of the square tooth drive belt is 5.5-7.0 mm.
- b) For a belt with rounded teeth, this value is 6.0-8.0 mm.
20.25 Special tool for tensioning a toothed drive belt, installed on a long section
26. If you do not have a special tool, the above deviation can be checked by pressing on the toothed drive belt. Adjust by loosening and tightening both tensioner screws.
27. Reinstall all removed parts and let the engine run for 10-15 minutes.
Turbocharged diesel engine
28. The toothed drive belt must be changed every 90,000-100,000 km, even if it can still work. To fix the crankshaft exactly at TDC, a special locking pin (No. 861) is needed. The diameter of the locking pin is 8 mm, i.e. a punch of the same diameter will fit it.
29. Remove the shield under the engine and disconnect the battery.
30. Remove all obstructing parts from the front of the engine.
31. Remove the glow plugs. This will make it easier to turn the engine when setting it to TDC.
32. Place the wrench on the crankshaft bolt and turn the engine until the piston of the first cylinder is at TDC. To accurately set the dead center, examine the timing marks of the camshaft sprocket and the fuel pump drive gear through the inspection windows (see illustration). If the camshaft drive cover has been removed, temporarily reinstall it.
20.32 If the piston of the first cylinder is at TDC, both timing marks should be visible through the "windows"
33. In this position of the engine, install the locking pin at a certain point (see illustration). The pin fits into the hole in the crankshaft, but be careful not to let it get into one of the mounting holes of the rotating parts. Once the pin is installed, the crankshaft can no longer move. The mounting holes are 12 mm in diameter, and since the diameter of the pin hole is 8 mm, it is easy to determine that the pin has fallen into the wrong hole. Remove the camshaft drive cover again. The cylinder head cover can also be removed.
20.33 The crankshaft locking pin is installed in the cylinder block at the indicated location. The mounting holes are also visible
34. Loosen both belt tensioner nuts (see illustration). Pull back the timing belt tensioner plunger and tighten it again.
20.34 Timing Belt Tensioner Fastening Bolts
35. If the removed drive belt is to be reinstalled, mark the direction of travel on the back of the belt. If the belt is contaminated with oil or grease, it must be replaced.
36. When installing the timing belt, follow the following instructions carefully.
37. Assemble the engine as described in Chapter 3, before installing the cylinder head. Only install the cylinder head for now. Align the three sprockets as shown (see illustration).
20.37 Correct installation of camshaft sprocket, fuel pump drive gear (top) and crankshaft sprocket
38. Turn the crankshaft until the piston of the first cylinder is set to TDC and (see illustration 20.33) insert the locking pins into the cylinder block and crankshaft (it is naturally pushed in if only the belt is changed). Move the crankshaft back and forth. If it does not move, the pin has been installed correctly. The timing mark of the crankshaft sprocket is in the position shown in Illustration 20.37 (bottom arrow).
39. Turn the camshaft sprocket until the mark on the camshaft sprocket is aligned with the protrusion in the camshaft drive cover.
40. Turn the fuel pump drive gear until the mark is aligned with the fuel pump rib.
41. After all the gear sprockets have turned, check everything again (see illustration 20.37).
42. Install the cylinder head as described when assembling the engine. Now fit the drive belt as follows:
43. Referring to Illustration 20.37, make sure once again that the timing marks of the three sprockets are aligned and install the drive belt. Temporarily install the camshaft drive cover and make sure that both timing marks are visible (see illustration 20.32). Put on the belt as described below.
44. If the engine has been completely disassembled, measure the gap between the intermediate shaft housing and the belt tensioner. Insert a 0.10 mm thick feeler gauge (see illustration).
20.44 Measure the clearance between the intermediate shaft housing and the belt tensioner. To adjust the tension, turn the bolt (A)
45. Loosen the lock nut and bolt. Then tighten the lock nut again and remove the feeler gauge. Carefully install the drive belt. Make sure that all the teeth are in the slots of the crankshaft sprocket, camshaft and fuel pump.
46. As a further check, count the number of tooth bases between the two upper timing marks. If there are 20, you can be sure that the belt is installed correctly.
47. Loosen both nuts no more than a quarter turn (see illustration 20.34). Set the tensioner to the new position and tighten the drive belt. Tighten both nuts in the new tensioner position.
Drive belt tension
48. Perform the following work with special care. Tension is set using special tools (see illustration 20.25), installed in the places shown by arrows (see illustration):
20.48 The tension of the drive belt is measured at the point indicated by the arrow
49. Turn the crankshaft two full turns in the normal direction of engine rotation.
50. The tension of the drive belt is determined using a special tool (see illustration 20.25), with the only difference being that it is installed between both sprockets (see illustration 20.48). Press the device against the belt. The belt should bend by 3-5 mm. If necessary, loosen the tensioner screws again and adjust the tension. If you do not have a special tool, press the drive belt with your finger.
51. Reinstall all removed parts and let the engine run for 10-15 minutes.
V6 Engine
52. The removal of the parts belonging to the valve timing mechanism was described during engine disassembly. When installing the chain drive sprockets, camshaft drive chains, etc., see the chapter that describes engine assembly.