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3.5. Replacement of a gear belt

Prevention
Before removal by chalk, a marker or paint note the direction of rotation of a gear belt. If at installation of the gear belt which was in the use it rotates in other party, it will lead to its destruction.
Fig. 3.1-50. Gear belt: 1 – casing of a gear belt; 2 – bolt, 10 N · m; 3 – bolt, 43 N · m; 4 – bolt, 22 N · m; 5 – tension roller; 6 – gear belt; 7 – bolt, 70 N · m; 8 – washer; 9 – the fixing plate; 10 – right pulley of a gear belt; 11 – bolt, 10 N · m; 12 – bolt, 10 N · m; 13 – back right casing of a gear belt; 14 – water pump; 15 – laying; 16 – left pulley of a gear belt; 17 – back left casing of a gear belt; 18 – the fixing plate; 19 – washer; 20 – bolt, 70 N · m; 21 – the directing roller; 22 – pulley of a gear belt of a bent shaft; 23 – expansion plug; 24 – a bolt (200 N · + to tighten m on 180 °)

Removal of a gear belt (fig. 3.1-50.) it is necessary to carry out taking into account the following.
1. Check a condition of a gear belt.
2. At installation it is necessary to use a new bolt 7.
3. The inscription "front vorne" on the fixing plate has to be directed forward.
4. At installation it is necessary to use new laying 15 and new bolts 20, 24.
5. On a basic surface between a pulley of a gear belt and a bent shaft there should not be a lubricant. Installation of a pulley is possible only in one situation.
6. At installation bolt lubricant is not allowed by the 24th oil.
Turn out eight bolts and remove a quencher of fluctuations.
Take off poliklinovy a belt.
Remove the mechanism of a tension of a poliklinovy belt.
Remove the left and right casings of a gear belt.
Turning a bent shaft of the engine in the direction of its working rotation for a bolt of fastening of a pulley, establish
the piston of the first cylinder in the top dead point (TDP).
Fig. 3.1-51. Combination of a tag on a pulley of a bent shaft (V) with the index (A) on a casing

Make sure that the tag on a pulley of a bent shaft was combined with the index on a casing (fig. 3.1-51).
Fig. 3.1-52. An arrangement of big openings of the fixing plates on pulleys of camshafts



Check the provision of pulleys of a gear belt of camshafts. At installation of the piston of the first cylinder in VMT in a compression step big openings of the fixing plates on pulleys of camshafts have to be directed to each other (an arrow to fig. 3.1-52). Otherwise turn a bent shaft of the engine on one turn.
Remove the lower mudguard of a motor compartment.
Fig. 3.1-53. An arrangement of the adjusting screw 3242 for fixing of a bent shaft

Record a bent shaft in this situation. For fixing of a bent shaft turn out the ignition moment sensor from the block of cylinders and instead of the sensor screw the adjusting screw 3242 (fig. 3.1-53).
Turn out the screws fixing the lower part of a casing of a gear belt.
Fig. 3.1-54. Arrangement of bolts of fastening of an arm of the fan of a radiator and lower casing of a gear belt

Turn out bolts and remove an arm of the fan of a radiator and the lower casing of a gear belt (fig. 3.1-54).
Fig. 3.1-55. Use of special device 3036 (1) for fixing of a pulley of the camshaft from a provorachivaniye

Serially, using special adaptation 3036 (fig. 3.1-55), record a camshaft pulley from a provorachivaniye and turn off on three turns, but do not turn out completely a bolt of fastening of a pulley of the camshaft.
Fig. 3.1-56. Use of a stripper of T40001 (1) for removal of a pulley of a gear belt from the camshaft

Using a stripper of T40001 (fig. 3.1-56), remove both pulleys of camshafts from their landing cones. At removal of pulleys the stripper has to rest against bolts of fastening of pulleys of camshafts. Pulleys of camshafts have to rotate freely, but not dangle on adjusting cones.
Fig. 3.1-57. Arrangement of a bolt of fastening of a tension roller

Turn out a bolt of fastening (fig. 3.1-57) of a tension roller and weaken a tension of a gear belt.
Take off a gear belt.
Do not turn a bent shaft of the engine at the taken-off gear belt as pistons can hit against valves.

Preventions
1. Do not overwind and do not bend a gear belt. Exclude hit on a gear belt of oil, cooling liquid or fuel.
2. If there was a vykrashivaniye of teeths of a gear belt, perhaps, jammed the ignition distributor, the water pump, the oil pump or the camshaft.
3. The rupture of a gear belt on the working engine can be caused by blow of pistons about valves therefore valves can be deformed.
4. Check gaps of valves. On the deformed valves they will be much more demanded.
5. If the external surface of a gear belt is considerably worn-out or stratified, check a condition of a racetrack of single pulleys.
If wear or damage are found only on one party of a belt, check a guide of a gear belt and alignment of pulleys of a gear belt.
With any defects on a gear belt it needs to be replaced.
Fig. 3.1-58. An arrangement of a gear belt on engine pulleys

6. Establish a gear belt on engine pulleys, since a pulley of a bent shaft and finishing with a tension roller. Earlier taken off belt is established according to the put tags (fig. 3.1-58).
Fig. 3.1-59. Installation of the clamp 3243 (1) holding pulleys of camshafts

Establish the special clamp of 3243 (fig. 3.1-59) holding pulleys of camshafts.
Fig. 3.1-60. Tension of a gear belt tension roller and arrangement of a bolt of fixing of a tension roller

Turn a tension roller of a gear belt a face six-sided key on 8 mm clockwise (fig. 3.1-60). Pull a gear belt and the second face six-sided key on 8 mm tighten a bolt of fastening of a tension roller the moment of 22 N · m.
Fig. 3.1-61. Check of a tension of a gear belt its turn on 90 °

Check a tension of a gear belt in the center of a branch between the right pulley of a gear belt and a pulley of the water pump. The gear belt has to turn on 90 ° from moderate effort of fingers of a hand (fig. 3.1-61).
Previously tighten bolts of fastening of pulleys of camshafts the moment of 30 N · m.
Remove adaptation 3243 fixing pulleys of camshafts.
Finally tighten bolts of fastening of pulleys of camshafts the moment of 70 N · m.
Turn out the adjusting screw 3242 holding a bent shaft of the engine from a provorachivaniye. Screw the ignition moment sensor with a new sealing ring.
Establish poliklinovy a belt.
Install the radiator fan with the viscous coupling.

Notes
Fig. 3.1-62. Oil pallet, forward and back covers of the engine: 1 – bolt, 30 N · m; 2 – bolt, 10 N · m; 3 – sealing ring of a bent shaft; 4 – bolt, 10 N · m; 5 – the directing tube for the index of the oil probe; 6 – sealing ring; 7 – the limiter for a support of the compensator of torque of the engine; 8 – bolt, 40 N · m; 9 – bolt, 40 N · m; 10 – support of the compensator of torque of the engine; 11 – bolt, 10 N · m; 12 – an oil receiver with a branch pipe; 13 – laying; 14 – a bolt (M8 – 25 N · m, M10 – 45 N · l); 15 – the top part of the oil pallet; 16 – bolt, 10 N · m; 17 – two-mass flywheel; 18 – a bolt of fastening of a flywheel (60 N · + to tighten m on a corner 180 °); 19 – needle bearing; 20 – laying; 21 – bolt, 10 N · m; 22 – a back cover with a sealing ring, 23 – laying; 24 – block of cylinders; 25 – laying; 26 – oil pump; 27 – sealing ring

1. At installation it is necessary to use new sealing rings 6, 27 and laying of 13, 20, 23, 25 (fig. 3.1-62).
2. Application of the additional condensing resources at installation of the top part 15 of the oil pallet is not required.
3. · m + to tighten the moment of tightening of bolts of fastening of a frictional overlay for cars with the automatic transmission of 60 N on a corner 90 °.
4. The needle bearing 19 is installed only on cars with the mechanical transmission and is pressed in an end face of a bent shaft.
5. Before removal of a back cover it is necessary to remove the oil pallet.

Forward sealing ring of a bent shaft
Take off a gear belt.
Fig. 3.1-63. Elements of fastening of a pulley of a bent shaft: 1 – pulley of a gear belt of a bent shaft; 2 – expansion plug; 3 – bolt

Turn out a bolt of 3 (fig. 3.1-63) of fastening of a pulley of a bent shaft.
Remove the expansion plug 2 and a pulley of 1 gear belt.
Fig. 3.1-64. Use of a stripper 3203 (1) for removal of a forward sealing ring of a bent shaft

For removal of a forward sealing ring use a stripper of 3203 (fig. 3.1-64). Turn out an internal part of a stripper on six turns from an external part of a stripper and rigidly record both parts.
Establish a stripper on a bent shaft and, strongly pressing, screw in it in a sealing ring. Rasfiksiruyte both parts of a stripper and, rotating an internal part of a stripper, remove a sealing ring. Remove a sealing ring from a stripper.

Clear an installation site of a sealing ring.
Oil engine a working edge and an external surface of a new sealing ring before its installation into place.
Fig. 3.1-65. Use of a mandrel 3265 for installation of a forward sealing ring of a bent shaft

Using a mandrel of 3265 (fig. 3.1-65), establish a sealing ring on a bent shaft and by means of a bolt of fastening of a pulley press a sealing ring in a nest.
Establish a pulley 1 (see fig. 3.1-63) a gear belt of a bent shaft, the expansion plug 2 and screw a bolt of fastening 3.

Preventions
On a basic surface between a pulley and a bent shaft there should not be a lubricant. It is impossible to grease a bolt of fastening of a pulley of a bent shaft.
At installation it is necessary to use a new bolt of fastening of a pulley of a bent shaft.

Establish a gear belt.