Removal and installation of a toothed belt when replacing the old belt is relatively simple. In this case, before removing the worn belt, its tension is checked, and a new toothed belt is installed in accordance with the marks made and with the tension that the old belt had.
A special case is a broken toothed belt. The toothed belt must be replaced at 100,000 km. If this parameter is not respected, then a broken belt is not ruled out. The consequences can be dire because the valves will hit the pistons. If this happens, then, in addition to replacing the toothed belt, it is necessary to remove the cylinder head to check the condition of the valves and pistons.
XU7 engine
Toothed belt workshops have suitable stop bolts to secure the camshaft and crankshaft against rotation, as well as a tester to check the toothed belt tension. In addition, they have pliers for removing the plastic clips that secure the fender liner in the wheel arches.
If a toothed belt breaks, we recommend that you immediately tow the vehicle to a workshop. In the case of replacing the belt or when removing it and then reinstalling it, the procedure is as follows.
1. Mount on a trestle in front of the car, on the crankshaft of the engine of which the accessory drive belt pulley is installed.
2. Disconnect the wire terminal «masses» (-) from the battery.
3. Remove the wheel.
4. Remove the fender liner in the wheel arch. To do this, remove both fender liner retainers and unscrew the fastening bolts (see illustration).
13.4 Remove the fender liner in the wheel arch. To do this, remove both retainers 1 of the fender liner and unscrew the bolts 2 of the fastening. The illustration shows only two bolts. Three more are at the bottom of the fender liner
5. Remove the accessory drive belt.
6. Remove the top part of a protective casing of a gear belt.
7. Remove the protective cover under the flywheel (clutch).
8. Install a spanner on the camshaft mounting bolt on the crankshaft and rotate the engine in the direction of rotation until the camshaft is positioned as shown (illustrations 13.8).
13.8 Engine with toothed belt
1 - the installation location of the thrust bolt that prevents the camshaft from turning
2 - the installation location of the thrust bolt that prevents the crankshaft from turning
Install the stop bolt in this position (10 mm) into the hole on the camshaft gear and into the corresponding hole on the cylinder head housing. The crankshaft is fixed in the same way. Both thrust bolts are different. Do not lock the crankshaft or camshaft with smaller bolts.
9. Fix the crankshaft from turning by placing a brake shoe on the ring gear or inserting a screwdriver, and unscrew the fastening bolt located in the middle of the belt pulley.
10. Remove the belt pulley. If the pulley sits tight and does not give in, use the pry bar, alternately squeezing the pulley from different sides. If so, remove the pulley with a puller as shown in the illustration.
13.10 Remove the belt drive pulley from the crankshaft using a puller
11. Remove the bottom part of a protective casing of a gear belt. Now you can start removing the timing belt itself.
Attention! If the toothed belt is removed only for replacement, then in the absence of a belt tensioner, check how the belt being removed is tensioned. To do this, squeeze the belt with your thumb and forefinger and try to move it to one side and then to the other. Remember or designate the amplitude by which the toothed belt is displaced. You can also do otherwise. Press the belt with your thumb and measure the amount of deflection with a ruler, choosing the appropriate starting point. Record the resulting value.
12. Unscrew the nut of the toothed belt tension roller and move the roller to the side to loosen the tension of the toothed belt and remove it from the gear (see illustration).
13.12 Loosen the nut of the toothed belt tensioner and move the roller to the side to loosen the tension of the toothed belt and remove it from the gear.
1 - toothed belt tension roller
2 - toothed belt
3 - water pump gear
4 - crankshaft timing gear
5 - camshaft gear
13. Designate the direction of rotation of a gear belt. It is most convenient to indicate the direction with an arrow facing the direction of rotation of the belt.
14. Set the removed belt aside so that oil or grease does not get on it during repair work, and in addition, to prevent damage to it. It is best to hang the belt on a nail, which will prevent it from bending.
If necessary, you can replace the camshaft gear, crankshaft gear or tension roller. Even if the tension roller will not be removed, then you need to check its travel to make sure that the roller does not «sticks».
Attention! Never rotate the camshaft or crankshaft with the toothed belt removed, regardless of the type of work being done.
15. Place a toothed belt on the gears of the camshaft and crankshaft, as well as on the water pump drive gear and on the tension roller. When laying the belt, follow the following procedure. First, the belt is applied to the camshaft gear. The long side of the belt must be well taut during installation.
Attention! If the toothed belt is laid without fixing the camshaft and crankshaft with stop bolts, then be careful not to rotate the shafts. If the thrust bolts are installed, then remove the thrust bolt that secures the crankshaft.
16. Install the belt pulley on the crankshaft. Before doing this, place a spacer washer on the key and tighten the pulley mounting bolt (see illustration).
13.16 Install the belt pulley on the crankshaft. Before doing this, place a spacer washer on the key and tighten the pulley mounting bolt
1 - thrust bolt for fixing the camshaft gear
2 - spacer
3 - belt pulley of the crankshaft
17. Loosen the tension roller and tighten the toothed belt with it. Tighten the roller bolt again.
18. Rotate the crankshaft at least two turns using the socket, securing it to the belt pulley bolt, so that the toothed belt is well «sat down». Rotate the crankshaft clockwise as viewed from the front end of the engine. After cranking the engine, set the piston of the first cylinder to TDC.
19. Loosen the toothed belt tension roller bolt and wait until the toothed belt «lie down» on the roller and tighten the roller fastening bolt with a torque of 20 Nm.
20. Check the toothed belt tension and make sure it matches the tension with which the old belt was tensioned. The toothed belt tension can be corrected using the tension roller. It has two holes in which you can install a trunnion (hooked) key to rotate the roller.
Attention! The information given above has been tested in practice, however, the accuracy and correctness of settings and adjustments is possible only when using appropriate devices.
21. Remove the belt pulley from the crankshaft, install the toothed belt guard, and then install the belt pulley. When performing these works, hold the crankshaft from turning, and tighten the pulley mounting bolt with a torque of 120 Nm.
22. Install all other parts.
XU10 engine (with 8 valves)
23. Read the instructions given for the XU7 engine. The precautions, as well as the tools and fixtures that were necessary for work on the XU7 engine, fully apply to the XUI0 engine. When replacing the toothed belt on this engine, the procedure is as follows.
24. Install in front of the car on the goats.
25. Disconnect the wire «masses» (-) from the battery.
26. Turn out bolts of fastening of a wheel to provide access to a cranked shaft.
27. Remove the fender liner in the wheel arch (see illustration I3.4).
28. Remove the ribbed belt, as well as the ribbed belt tensioner to gain access to other parts.
29. Remove the upper part of the toothed belt guard (see illustration).
13.29 Remove the upper part 1 of the toothed belt guard
30. Check the crankshaft. by installing the head of the socket wrench into the slot of the belt pulley mounting bolt. Rotate the crankshaft until until the holes for installing the stop bolts on the toothed belt gears on the crankshaft and camshaft are in the appropriate position. The thrust bolt in the crankshaft gear can be installed when the hole in it is approximately at the 11 o'clock position, if the gear is compared with the dial (see illustration).
13.30 Installing thrust bolts in the crankshaft and camshaft gears to prevent them from turning
1 - gear and camshaft thrust bolt
2 - gear and thrust bolt of the crankshaft
Attention! Do not turn the crankshaft in the opposite direction to its rotation.
31. Shift into gear to block the crankshaft and remove the belt pulley bolt on the crankshaft. Never use the thrust bolt inserted into the hole in the toothed belt gear as a counter stop when loosening the belt pulley bolt. You can also keep the crankshaft from turning with the help of a brake «shoe», mounted on the flywheel ring gear. To do this, you need to remove the protective casing of the flywheel.
32. Remove the belt pulley from the crankshaft. The crankshaft must not rotate. You can use a puller if necessary (see illustration).
13.32 Removing the belt pulley from the crankshaft using a three-arm puller 1
33. Remove the lower part of the toothed belt guard. Now you can start removing the timing belt itself.
Attention! If the toothed belt is removed only for replacement, then in the absence of a belt tensioner, check how the belt being removed is tensioned. To do this, squeeze the belt with your thumb and forefinger and try to move it to one side and then to the other. Remember or designate the amplitude by which the toothed belt is displaced. You can also do otherwise. Press the belt with your thumb and measure the amount of deflection with a ruler, choosing the appropriate starting point. Record the resulting value.
34. Loosen the toothed belt tension roller bolt and move the roller to the side, loosening the toothed belt tension (see illustration).
13.34 Loosen the bolt 1 fastening the toothed belt tension roller 4 and move the roller to the side, loosening the tension of the toothed belt. Also remove the spacer washer from the crankshaft
Remove the toothed belt. If the old toothed belt is to be installed again, the direction of rotation of the belt must be marked.
35. Remove the spacer from the crankshaft. Do not remove the thrust bolt from the hole in the camshaft gear.
If necessary, you can also replace the camshaft gear, the toothed belt gear on the crankshaft, as well as the toothed belt tensioner. If the tension roller will not be removed, then you need to check its stroke to make sure that the roller does not «sticks».
Attention! Never rotate the camshaft or crankshaft with the toothed belt removed, regardless of the type of work being done.
36. Place a toothed belt on the gears of the camshaft and crankshaft, as well as on the water pump drive gear and on the tension roller. When laying the belt, follow the following procedure. First, the belt is applied to the camshaft gear. The long side of the belt must be well taut during installation.
Attention! If the toothed belt is laid without fixing the camshaft and crankshaft with stop bolts, then be careful not to rotate the shafts. If the thrust bolts are installed, then remove the thrust bolt that secures the crankshaft.
36. Install the spacer washer on the crankshaft, and then the belt pulley and secure it with a bolt.
37. Turn the toothed belt tension roller in the direction as shown in the illustration,
13.37 Rotate pulley 1 for toothed belt tensioner 2 to tighten the toothed belt slightly
to slightly tighten the timing belt. Tighten the roller mounting bolt in this position.
38. Rotate the crankshaft at least two turns with the socket, fixing it on the belt pulley bolt, so that the toothed belt is well «sat down». Rotate the crankshaft clockwise as viewed from the front end of the engine. After cranking the engine, set the piston of the first cylinder to TDC.
39. Loosen the bolt of the toothed belt tension roller and wait until the toothed belt «lie down» on the roller and tighten the roller fastening bolt with a torque of 20 Nm.
40. Check the toothed belt tension and make sure it matches the tension with which the old belt was tensioned.
Adjustment of the toothed belt tension can be made using the tension roller. It has two holes in which you can install a trunnion (hooked) key to rotate the roller.
Attention! The information given above has been tested in practice, however, the accuracy and correctness of settings and adjustments is possible only when using appropriate devices.
41. Remove the belt pulley from the crankshaft, install the toothed belt guard, and then install the belt pulley. When performing these works, hold the crankshaft from turning, and tighten the pulley mounting bolt with a torque of 110 Nm.
42. Install all other parts.
XU10 engine (with 16 valves)
This engine has two camshafts and two toothed belt tensioners located on the right and left sides. The water pump is also driven by a toothed belt. The toothed belt must be replaced every 100,000 kilometers. As with the removal and installation of the toothed belt on the types of engines already mentioned, special tools are needed to replace the toothed belt on this engine and only for normal routine replacement of the toothed belt can the following procedure be followed.
The sequence of work up to the removal of the protective casing of the toothed belt completely coincides with the sequence of actions indicated for an engine with 8 valves. In addition to them, it is necessary to remove the fastening of the front engine mount in order to gain access to the relevant parts (see illustration 13.0).
13.0 Laying the toothed belt on engines with 16 valves.
1 - toothed belt tension roller
2 - toothed belt tension roller
3 - thrust bolts of gears of camshafts
4 - thrust bolt of the crankshaft gear
Due to the fact that this type of engine has two camshafts, the timing belt is much more difficult to remove and install compared to a single camshaft engine. In this case, the tension of the toothed belt must be carried out using two tension rollers. There are also differences in the fastening of the toothed belt guard. In addition to the three bolts securing the casing in the upper part, it is necessary to unscrew the two nuts in its center. And only after that the upper part of the protective cover can be removed.
43. Engage the gear to block the crankshaft and remove the belt pulley bolts on the crankshaft and remove the belt pulley (see illustration)
13.43 Front side of the engine with 16 valves.
1 - protective cover mounting bolts
2 - protective cover latches
3 - mounting bolts
4 - bolts for fastening the belt tension roller
5 - bolts for fastening the belt pulley to the crankshaft
6 - a bolt of fastening of a distributive gear on a cranked shaft
7 - bolts for fastening the belt pulley to the crankshaft
44. Remove the ribbed belt tensioner so that it does not interfere with further work.
45. Remove the lower part of the toothed belt guard by unscrewing the four bolts.
46. Turn the crankshaft in the direction of engine rotation by inserting a socket wrench into the slot on the head of the timing gear bolt. Once the thrust bolt holes are in position, insert the thrust bolt into the gear hole on the crankshaft.
47. Insert thrust bolts into the holes on the gears of both camshafts. When using prefabricated bolts, refer to the appropriate bolt markings. The camshaft gear thrust bolts are 9041-TZ and the crankshaft gear thrust bolt is 7014 TN. Now you can start removing the timing belt itself.
Attention! If the toothed belt is removed only for replacement, then in the absence of a belt tensioner, check how the belt being removed is tensioned. To do this, squeeze the belt with your thumb and forefinger and try to move it to one side and then to the other. Remember or designate the amplitude by which the toothed belt is displaced. You can also do otherwise. Press the belt with your thumb and measure the amount of deflection with a ruler, choosing the appropriate starting point. Measure both sides of the belt. Write down the obtained values.
48. Loosen the bolt securing the tension roller on the left side of the toothed belt. Take the roller to the side and remove the toothed belt (see left figure in illustration).
13.48 Withdrawal (left figure) and installation (right drawing) toothed belt on engines with two camshafts
1 - thrust bolts of gears of camshafts
2 - toothed belt tension roller
3 - thrust bolt of the crankshaft gear
4 - belt pulley
5 - a bolt of fastening of a distributive gear on a cranked shaft
6 - finger
7 - toothed belt tension roller
8 - toothed belt tension roller
Remove the toothed belt. If the old toothed belt is to be installed again, the direction of rotation of the belt must be marked.
If necessary, the camshaft gears can also be replaced. the toothed belt gear on the crankshaft, as well as the toothed belt tension rollers.
Attention! Never turn the camshafts or crankshafts with the toothed belt removed, regardless of the type of work being done.
49. Check the movement of the toothed belt tension rollers, if they will not be removed or replaced with new ones, and make sure that the rollers have good movement. There should be no traces of grease on the working surface of the rollers.
50. Apply a new toothed belt, as shown in illustration 13.48 (right drawing). At the bottom, put the belt on the crankshaft timing gear. When installing the old toothed belt, do not confuse the direction of its rotation.
51. Install the belt pulley on the crankshaft and temporarily secure it. Insert the stop bolt 3 into the hole on the pulley (see illustration 13.48).
52. Remove bolt 6 (see illustration 13.48).
53. Turn out bolts of fastening of gear wheels of both camshafts. At the same time, do not remove stop bolts from holes of gear wheels, however they cannot be used as stops when unscrewing bolts of fastening of gear wheels. In this case, the thrust bolts will simply break. In this case, a thrust shoe is used to fix the gears (see illustration) or roller, fixing it in the gear and on the cylinder head.
13.53 Camshaft gears.
1 - thrust shoe for holding gears
2 - gear wheel of the left camshaft
3 - bolts for fastening gears of camshafts
4 - gear wheel of the right camshaft
54. Temporarily tighten the bolts 3 for fastening the gears on the camshafts so that there is no gap between the gear and the shoulder of the shaft, and the mono gears themselves can be freely displaced on the shaft.
55. Lay the toothed belt on the water pump drive gear.
56. Put the toothed belt on the right tension roller 8 (see illustration 13.48).
57. Get the toothed belt on the left tension roller 7 (see illustration 13.48).
58. Pull the right side of the toothed belt and put it on the gear of the right camshaft (see illustration). The pinion bolt on the camshaft is tightened with a torque of 75 Nm after the belt has been installed.
13.58 Pull the right side of the toothed belt and put it on the right camshaft gear.
1 - gear mounting bolts on the camshaft
2 - drive gear of the left camshaft
3 - right camshaft drive gear
4 - toothed belt
59. Lay the toothed belt on the second camshaft drive gear (see illustration 13.0)
60. Loosen the fastening of both toothed belt tension rollers and, having brought the left roller 7 (see illustration 13.48) to the toothed belt, tighten it as it was before removal. Tighten the tightening bolt of this tension roller with a torque of 20 Nm.
61. Turn roller 7 clockwise and tighten the roller fastening bolt again with a torque of 20 Nm, if it loosened when turning the roller. The roller is rotated using a trunnion (hook) a key that is inserted into the holes on the roller.
62. Turn the crankshaft two turns in the direction of engine rotation so that the stop bolts can be inserted into the holes of the crankshaft camshaft gear and both camshaft drive gears.
63. Check up once again a tension of a gear belt. It must match the values obtained when the toothed belt was removed. Otherwise installation of a gear belt repeat.
Attention! The information given above has been tested in practice, however, the accuracy and correctness of settings and adjustments is possible only when using the appropriate devices and tools.