Table of contents: Removal ↓ Installation ↓
Timing Chain Installation Components
1 - Front cylinder head cover; 2/3 - Inlet/outlet camshaft sprocket; 4 - Timing chain tensioner; 5 - Timing chain tensioner lever; 6 - Front cylinder block cover; 7 - Front crankshaft oil seal; 8 - Crankshaft pulley; 9 - Timing chain; 10 - Timing chain guide; 11 - Pin; 12 - Oil pump drive sleeve; 13 - Crankshaft sprocket; 14 - Sealing ring
On models with Manual transmission remove the power unit and separate the engine from the manual transmission (see section Removal and installation of the power unit). Then remove the components indicated in paragraph 3 and go to the item 5.
Removal
1. Remove the right front wheel and the right front wheel arch liner.
2. Drain the engine oil (see Chapter Vehicle settings and routine maintenance).
3. Remove the following components:
- Accessory drive belts and intermediate pulleys of these belts (see section Replacement of auxiliary drive belts and intermediate belt rollers);
- Cylinder head cover (see section Removal and installation the cylinder head cover);
- The front section of the exhaust pipe (see Chapter Fuel and exhaust systems);
- Starter (see Chapter Engine electrical systems);
- Both sections of the oil pan and the oil pickup (see section Removal and installation the oil pan and oil intake);
- Right headlight (see Chapter On-board electrical equipment).
4. Support the engine by installing lifting eyes on it and lifting it with a winch. Alternatively, support the engine with a jack. Remove the right engine mount strut and both right engine mount brackets (see section Removal and installation of the power unit).
5. Remove the generator (see Chapter Engine electrical systems) and the front cylinder head cover (see section Removal, inspection and installation of camshafts).
6. Remove the auxiliary cylinder head bolts.
7. Set the piston of the first cylinder to the TDC position as described in Section Removal, inspection and installation of camshafts.
8. Using the starter mounting hole, install a stopper on the flywheel ring gear to prevent the crankshaft from turning. Alternatively, the crankshaft counterweight can be blocked with a hammer handle after removing the upper section of the oil pan.
9. Remove the crankshaft bolt.
Note: Do not remove the mounting bolts as they will be used as supports for the pulley puller.
10. Install the puller jaws (1) into the groove of the crankshaft pulley (2) and remove the pulley.
11. Remove the auxiliary drive belt idler pulley bracket assemblies from the front cylinder block cover (see section Replacement of auxiliary drive belts and intermediate belt rollers).
12. Carefully, being careful not to damage the front seal or bushing, remove the oil pump drive bushing using long pliers or two screwdrivers.
13. Remove the AC bolts shown in the illustration and remove the front cylinder block cover.
Note: Do not damage the front of the cylinder head gasket. If this occurs, replace the gasket (see section Removal and installation, disassembly and assembly of the cylinder head).
14. Remove the sealing ring from the cylinder block.
15. Heat the pins (1) of the front cylinder block cover using a hair dryer (2) and remove the pins with pliers (3).
16. Remove the front oil seal by pushing it out from the inside of the front cover with a screwdriver.
17. As described in Section Removal, inspection and installation of camshafts, set the intake valve phase adjuster to the maximum advance position, remove the timing chain tensioner and camshaft sprockets.
Note: There is no need to make marks on the chain.
18. Remove the chain, its guide and tensioner lever. Check the chain for cracks and wear of the rivets.
19. Remove the crankshaft sprocket.
Installation
Installing sprockets, chain, its guide and tensioner lever
1 - Purple or orange link; 2 - Outer circle; 3 - Risk; 4 - Camshaft pin; 5 - Stamped mark; 6 - Exhaust shaft sprocket; 7 - Intake shaft sprocket; 8 - Timing chain tensioner; 9 - Crankshaft key; 10 - Blue Link; 11 - Timing chain; 12 - Crankshaft sprocket; 13 - Chain tensioner lever; 14 - Chain guide
1. Completely clean the mating surfaces of all removed parts from the remains of the old gasket.
2. Install the sprockets, timing chain, chain guides and tensioner so that the various marks on them are positioned as shown in the illustration above and facing outward.
Note: Install the following components in the following order: crankshaft sprocket and chain, tensioner arm, chain guide, camshaft sprockets, chain tensioner.
3. Temporarily install the oil pump drive sleeve, crankshaft pulley and pulley mounting bolt so that the crankshaft can be turned.
4. Turn the crankshaft clockwise and set the intake valve timing adjuster to the maximum retard position (see section Removal, inspection and installation of camshafts).
5. Turn the crankshaft again a few turns clockwise and make sure that the timing marks match.
6. Remove the crankshaft pulley and oil pump drive sleeve.
7. Using a suitable punch or a piece of pipe of suitable diameter, press the front oil seal into the front cylinder block cover with the embossed part facing outwards.
8. Install on the cylinder block new sealing ring (1) and using a screwdriver, apply sealant to the joint between the cylinder head gasket and the cylinder block in two places (2).
9. Apply sealant to the rear of the front cylinder block cover and to the top surface of the front cover.
10. As shown in the illustration, install the front cover (1) as tightly as possible to the cylinder block (2), moving it parallel to the crankshaft and be sure to leave a small gap between the cover and the cylinder head gasket (3). Then slide the cover diagonally to the joint between the block and the cylinder head so that the cover is mated with the cylinder head gasket.
11. Temporarily secure the front cover with several bolts and press the pins through it into the cylinder block.
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12. Temporarily tighten the front cover mounting bolts and the auxiliary cylinder head bolts. Then tighten the specified bolts to the specified torque.
13. Align the flat surfaces of the oil pump drive sleeve with its internal gear and install the sleeve, being careful not to damage the front oil seal.
Note: If necessary, turn the internal pump gear with a screwdriver.
14. Install the accessory drive belt idler roller bracket assemblies (see section Replacement of auxiliary drive belts and intermediate belt rollers).
15. Install the crankshaft pulley and tighten its mounting bolt.
Note: The crankshaft must be locked in the same way as when removing the pulley.
16. Install the front cylinder head cover (see section Removal, inspection and installation of camshafts).
17. Install the right engine mount bracket and stand.
18. Further installation is carried out in the reverse order of dismantling the components.
19. After at least 30 minutes of installation, warm up the engine and check for engine oil leaks.