Replacing the timing belt (4G93 engine)

Removing

Before you start removing parts, do the following:

• A) Remove the engine crankcase guard.
• b) Remove the support bracket and engine support assembly.

Removal of parts is carried out in the order of the numbers indicated in the figures "Removing the crankshaft pulley" And "Timing Belt Replacement".

When removing parts, pay attention to the following operations:

1. Removing the drive belt for the power steering pump and air conditioning compressor.

A) Loosen the lock nut of the belt tensioner pulley for the power steering pump and air conditioning compressor.



b) Loosen the adjusting bolt to release the belt tension, then remove the belt.

Attention: in case of reuse of the drive belt of the power steering pump and air conditioning compressor, it is necessary to chalk on the back (non-working) belt surface an arrow indicating the direction of rotation (clockwise).

1. Removing the alternator drive belt,

A) Loosen the set bolt on the alternator adjusting bar and the swivel bolt.








b) Loosen the alternator drive belt by turning the adjusting bolt, then remove the belt.

Attention: in case of reusing the alternator drive belt, it is necessary to chalk on the back (non-working) belt surface an arrow indicating the direction of rotation (clockwise).

3. Removing the crankshaft pulley.

Using the special tool, fix the crankshaft pulley from turning and unscrew the crankshaft pulley mounting bolt.

Caution: secure the special tool securely so that it does not move.

4. Removing the timing belt.


A) Rotate the crankshaft clockwise until the timing marks on the camshaft pulley and crankshaft sprocket align with the matching timing marks to set the No. 1 cylinder piston to TDC on the compression stroke.

Caution: Always turn the crankshaft in a clockwise direction only.

b) Loosen the timing belt tensioner adjusting bolt.

V) Insert a screwdriver into the hole in the tensioner bracket and fully move the timing belt tensioner in the direction shown in the figure



G) Temporarily tighten the tensioner adjusting bolt.

d) Remove the timing belt.

Attention: in case of reusing the timing belt, it must be chalked on the back (non-working) belt surface an arrow indicating the direction of rotation (clockwise).

Examination

Note: See the verification procedure in section "Timing Belt Replacement (4G15 engine) ".

Installation

Attention:

• Since water or oil can seriously reduce the life of the timing belt, when removing parts, ensure that the timing belt, pulleys and tensioner bracket are clean and dry, never wash them. Contaminated parts must be replaced.
• If any of the parts are oily, then check for oil leakage through the seals (including front camshaft oil seal).
• Check up a condition and smoothness of rotation of a roller of a tensioner.
• If a used timing belt is installed, check its condition.

Installation is made in an order, the return to removal.

When installing parts, pay attention to the following operations:

1. Installing the timing belt tensioner.

A) Insert a screwdriver into the hole in the tensioner bracket and fully move the timing belt tensioner in the direction shown in the figure.



b) Temporarily tighten the tensioner adjusting bolt.


2. Installing the timing belt.

Attention:

• Install the timing belt so that the belt tension does not loosen between the pulleys and rollers.
• Install a used belt so that the arrow on the back of it matches the direction of rotation of the belt (clockwise).

A) Check that the marks on the camshaft pulley and the crankshaft sprocket are aligned with the corresponding alignment marks (while the piston of cylinder No. 1 will be at TDC of the compression stroke).

b) Install the timing belt in the following order, making sure that the working branch (side) belt was tensioned: crankshaft toothed pulley, coolant pump pulley, camshaft pulley, tensioner pulley.

Attention: after installing the timing belt, apply force to the camshaft pulley to turn it counterclockwise and check that the belt is fully tensioned and all the timing marks are aligned.

3. Adjusting the tension of the timing belt.

A) Loosen the adjusting bolt 1/4-1/2 turn so that the timing belt is tensioned by the tensioner spring force.



b) Turn the crankshaft in the direction of rotation (clockwise) 2 turns and make sure that all the marks on the pulleys are aligned with the corresponding alignment marks.

Attention: since the purpose of this operation is to apply the appropriate tension to the working branch of the timing belt using torque on the camshaft, turn the crankshaft only two turns. It is forbidden to turn the crankshaft in the opposite direction (counterclock-wise).

V) Check that there is no protrusion of the teeth of the timing belt relative to the camshaft pulley in the sector "A", shown in the figure, and the normal engagement of the timing belt with the pulleys is ensured. After that, tighten the tensioner roller mount.



3. Installing the front lower timing belt cover.

A) Install the bolt shown in the figure first.



b) Install the remaining bolts, tighten them to the nominal torque.

Tightening torque - 10±2 N.m

4. Installation of the guide plate and crankshaft pulley.

A) Clean then degrease the surface of the crankshaft pulley in contact with the guide plate.

Note: degreasing is necessary to improve the mating of parts.

b) Clean the threaded hole in the end of the crankshaft, the end of the shaft, the pulley bolt washer and the surfaces in contact with it.



V) Install the guide plate on the crankshaft, positioning it as shown in the figure.



G) Lubricate the mating surface with a minimum amount of engine oil (cone) crankshaft nose and crankshaft bolt threads.

d) Before installing the crankshaft pulley bolt, it is necessary to install the bolt washer with the chamfered side to the bolt.

e) Using the special tool, stop the crankshaft pulley from turning or stop the flywheel from turning, and install the crankshaft pulley mounting bolt.

Attention: securely fasten the special tool so that it does not rotate.

After completing the installation of the parts, perform the following operations:

• A) Install the support bracket and engine mount assembly.
• 6) Install the engine crankcase guard.
• V) Adjust the tension of the accessory drive belts (see chapter "Maintenance and general inspection and adjustment procedures").
• G) Install the decorative engine cover.