Note: The illustration shows the relative positions of the timing marks on the drive chains and corresponding sprockets with the components installed.
1. Gas distribution mechanism drive chain.
2. Exhaust camshaft sprocket.
3. Timing chain tensioner guide.
4. Timing chain tensioner.
5. Balance block sprocket.
6. Balance block drive chain.
7. Balance block drive chain tensioner.
8. Crankshaft sprocket.
9. Gas distribution mechanism drive chain calming device.
10. Intake camshaft sprocket.
A. Installation mark (dark blue link).
B. Installation mark (stamp).
C. Position of the crankshaft key (vertically upwards).
D. Installation mark (stamp).
E. Installation mark (orange link).
F. Installation mark (outer groove - there are two outer grooves on the intake camshaft sprocket, the wider one is the timing mark).
1. Make sure the crankshaft key is installed vertically upward.
2. If the drive chain guide has been removed from the front cover, install it on the front cover.
3. Install the crankshaft sprocket (2), balancer block sprocket (3) and balancer block drive chain (1):
A. Installation mark
B. Installation mark (orange link).
C. Installation mark (dark blue link).
Install the chain and sprockets, aligning the timing marks properly.
If the timing marks do not match, turn the balance shaft slightly to adjust the position.
Caution: After installing the balancer block drive chain, it is necessary to check again that all installation marks match.
4. Holding the cylindrical part (A) of the balance shaft (width of cylindrical part: 19.0 mm), tighten the balance shaft sprocket bolt.
1. Upper oil pan. Arrow points towards the front of the engine.
Caution: Hold the balance shaft only by the cylindrical part. Do not tighten the balance shaft sprocket mounting bolt by tensioning the drive chain.
5. Install the balancer block drive chain tensioner (1):
Lock the plunger in the maximum compression position using the locking pin (A) and install the tensioner, (www.monolith.in.ua)
After installing the tensioner in place, carefully remove the locking pin (in the direction of the arrow in the figure).
Check the position of the timing marks on the balancer block drive chain and sprockets again.
6. Align the timing marks on each sprocket with the marks on the drive chain.
1. Exhaust camshaft sprocket.
2. Intake camshaft sprocket. 3.
Gas distribution mechanism drive chain.
A. Installation mark (dark blue link).
B. Installation mark (stamp).
C. Installation mark (outer groove - there are two outer grooves on the intake camshaft sprocket, the wider one is the timing mark).
D. Installation mark (orange link).
E. Installation mark (stamp).
Note: If the timing marks do not match, slightly turn the camshaft by the hexagonal part to adjust the position.
Caution: After installing the drive chain, recheck the position of the timing marks on each sprocket and on the chain.
7. Install the chain guide (3) and tensioner guide (2).
1. Gas distribution mechanism drive chain.
2. Chain tensioner guide.
3. Chain tensioner.
8. Install the timing chain tensioner (1):
Lock the plunger in the maximum compression position using the locking pin (A) and install the tensioner.
After installing the tensioner in place, carefully remove the locking pin.
9. Check the position of the timing marks on the sprockets and drive chain again.
10. Install the front oil seal.
11. Install the front cover:
Install a new sealing ring into the cylinder block.
Caution: Make sure that the sealing ring is installed without distortion.
Using a gun, apply a continuous bead of sealant (B) to the front cover as shown in the figure.
A. Places of sealant application.
B. Sealant roller.
The arrow points to the outside of the engine.
Note: Use original sealant or equivalent.
Make sure the timing marks on each sprocket and drive chains still match. Install the front cover.
Attention.
- Make sure the sealing ring in the cylinder block is installed correctly.
- Be careful not to damage the front oil seal with the front of the crankshaft.
Install the front cover and tighten the mounting bolts in the order shown in the figure.
Note: The following bolt sizes are used to secure the front cover:
- M6: No.1
- M10: No.6, 7, 10, 11, 14
- M12: No.2, 4, 8, 12
- M8: all others.
Attention: Installation must be completed within five minutes after applying the sealant.
Tighten all bolts in the order shown in the figure to the specified tightening torque.
Caution: Remove all excess sealant that spills out.
12. Install the crankshaft pulley.
Install the crankshaft pulley by tapping on its center part (not in a circle) with a plastic hammer.
Caution: Be careful not to damage the outer edges of the seal.
Secure the crankshaft pulley (1) with the holder (A).
Apply fresh engine oil to the threads and seating surfaces of the crankshaft pulley bolt.
Tighten the crankshaft pulley bolt to 68.6 Nm.
Loosen the pulley bolt completely.
Tighten the crankshaft pulley bolt to 29.4 Nm.
Apply a color mark (B) to the crankshaft pulley (2) using paint, aligning it with any of the six angle marks (A) on the flange (1) of the crankshaft pulley bolt.
Tighten the bolt another 60 clockwise (corner tightening).
Use the applied color mark to make sure that the bolt is tightened to the required angle.
Make sure the crankshaft rotates freely clockwise.
13. Install all remaining parts in the reverse order of removal.