Removing
Remove the lower protective covers.
Raise the power unit to release the engine mount from the load on the power unit and remove the engine mount.
Insert special tool (wrench or ratchet with 12.7 mm insert) into a special hole in the automatic tensioner of the accessory drive belt assembly.
Turn the auto tensioner counterclockwise to align the hole «A» with hole «IN».
Attention! If the accessory drive belt is reused, chalk on the reverse (non-working) side of the belt with an arrow indicating the direction of rotation.
Insert a special key into the hole for fixing the automatic tensioner and remove the accessory drive belt.
Note. Instead of a special key, it is allowed to use a wire that must be bent at a right angle.
Disconnecting the crankshaft position sensor connector
To avoid possible damage to the engine management wiring harness on the power steering pump pulley, do not remove the wiring tape located on the connector when disconnecting the crankshaft position sensor connector.
Turn the crankshaft clockwise until the timing marks on the camshaft sprocket and crankshaft sprocket are aligned with the corresponding timing marks, and set the No. 1 cylinder piston to TDC on the compression stroke.
Attention! Turn the crankshaft only clockwise.
If the automatic timing belt tensioner cannot be removed or is removed with the rod fixed, remove the plug and screw the special rod into the hole of the attachment mounting bracket so that it rests against the groove on the tensioner arm.
Slowly screw in the special rod, aligning the hole «IN» on the body of the automatic tensioner with a hole «A» on the tensioner rod.
Attention! Screw in the special rod in increments of no more than 30°per second. If the rod is turned at full speed immediately, it may be deformed due to the difficult movement of the tensioner rod.
Insert a wire with a diameter of 2 mm into the hole in the auto-tensioner housing.
Loosen the tensioner roller adjusting bolt and remove the timing belt.
Attention! If the timing belt is reused, it must be chalked on the back (non-working) belt surface with an arrow indicating the direction of rotation.
Removing the crankshaft sprocket
Using a special tool, fix the crankshaft from turning and unscrew the sprocket mounting bolt.
Attention! Make sure that the special tool is securely fastened and does not move.
Checking the automatic tensioner
Check the auto tensioner for oil leaks, if any, replace it.
Also check the tensioner rod for wear and damage, if necessary, replace the automatic tensioner.
Measure the stem protrusion. If this value is not within the standard value, replace the auto tensioner.
Standard value «A»: 11 mm.
Press the tensioner rod against the cylinder block and apply the appropriate force (98–196 N), then measure the stroke «IN», as it shown on the picture. If the stroke is outside the Specified value, replace the auto tensioner.
Standard value «IN»: 1 mm or less.
If the stem retracts without much resistance, replace the tensioner.
Check for smooth rotation of the tensioner pulley.
Attention! Before removal, if the balancer drive belt is being reused, chalk on the back (non-working) side of the belt with an arrow indicating the direction of rotation.
Installing the balancer drive belt
Check that the marks on the crankshaft sprocket and on the balance shaft sprocket are aligned with their respective alignment marks.
Install the balancer drive belt onto the crankshaft sprocket and balancer shaft sprocket. Ensure there is no slack in the belt.
Attention! Install the old belt so that the reverse arrow (non-working) its sides coincided with the direction of rotation of the belt.
Adjustment of a tension of a belt of a drive of the balancing mechanism
Install the balancer drive belt tensioner pulley with its flange toward the front of the engine. Temporarily fix the tensioner roller with a bolt so that the center of the tensioner roller axle is shifted to the left and up from the center of the roller mounting bolt.
Tension the working branch of the belt by applying a force of 3±0.5 Nm to it. To do this, hold the balancer drive belt tensioner with your hand in the direction indicated by the arrow in the figure. Then fix the balancer drive belt tensioner in this position by tightening the fastening bolt.
Attention! When tightening the bolt, make sure that the tensioner roller does not rotate with the mounting bolt. If the tensioner pulley rotates, it will put too much tension on the balancer drive belt.
Bolt tightening torque: 19±3Nm.
Rotate the crankshaft 2 turns clockwise and set the #1 cylinder piston to TDC on the compression stroke. Check alignment of alignment marks.
Make sure that the deflection of the working branch of the balancer drive belt corresponds to the standard value. To do this, press with a force of 100 N in the center of the belt between the sprockets (while keeping the roller from turning), as it shown on the picture.
Standard deflection: 5–7 mm.
Adjust the deflection of the belt to match the standard value.
Installing the crankshaft position sensor rotor and crankshaft sprocket
Clean and degrease the mating surface of the crankshaft and sprocket in contact with the crankshaft position sensor rotor.
Clean the crankshaft tapped hole, shaft end, sprocket bolt washer and surfaces in contact with it.
Install the crankshaft position sensor rotor and crankshaft sprocket, positioning them as shown.
Lubricate the mating surface with a small amount of engine oil (cone) crankshaft nose and crankshaft bolt threads.
Before installing the crankshaft sprocket mounting bolt, install the washer with the chamfered side to the bolt.
Use the special tool to prevent the crankshaft sprocket or flywheel from turning. Install and tighten the crankshaft pulley bolt.
Tightening torque: 167 Nm.
Installing the automatic timing belt tensioner (auto tensioner rod is in fully extended position)
Place the auto tensioner in a soft jaw vise.
While slowly squeezing the vise, push down the auto-tensioner rod until the hole is aligned «A» in stem with hole «IN» in the tensioner housing.
Attention! The auto-tensioner must be installed at a right angle to the vise jaw surface, without distortion.
Attention! Pushing the stem in too fast may damage it. Do this step by step.
Install a wire or pin of the required diameter in the hole for fixing the rod in the tensioner body.
Install the automatic tensioner on the engine and tighten the mounting bolts to the specified torque.
Tightening torque: 23±3 Nm.
Note. Do not remove the wire from the automatic tensioner
Installing the timing belt tensioner pulley
Install and temporarily secure the tensioner pulley so that the straight line passing through the centers of the pulley holes is positioned as shown in the figure.
Timing belt installation
Check that the tensioner pulley and auto tensioner are in the correct position. Make sure the marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket are aligned with their respective alignment marks (while the piston of cylinder No. 1 must be at TDC of the compression stroke).
Attention! If the timing marks are not aligned, the valves may jam with the piston when the camshaft sprocket is turned.
Remove the service hole plug on the cylinder block and insert a Phillips screwdriver into it (rod diameter 8 mm).
If the screwdriver is inserted to a depth of 60 mm or more, then the alignment marks are aligned correctly. If the screwdriver is inserted only to a depth of 20-25 mm, then turn the oil pump sprocket one turn and align the alignment marks again. Then check that the screwdriver is inserted to a depth of 60 mm or more. Leave the screwdriver inserted into the hole until the timing belt installation operation is complete.
Note. A bolt can be used to fix the balance shaft (M6 with thread length 10 mm and total length 45 mm).
Install the timing belt on the sprockets (do not let the belt slack between sprockets or rollers).
Installation order
1. Crankshaft sprocket and timing belt tensioner pulley.
2. Oil pump sprocket and on the timing belt guide roller.
3. Camshaft sprocket.
Attention! When installing the old belt, make sure that the arrow on the back of it coincides with the direction of rotation of the belt (clockwise).
Note. Before installing the timing belt on the camshaft sprocket, make sure that all sprocket marks match the corresponding alignment marks.
Move the tensioner pulley so that its holes are horizontal. After that, lightly press the tensioner roller against the timing belt and temporarily tighten the bolt before adjusting the belt tension.
Engine 4G69
Make sure the sprocket marks line up with the corresponding alignment marks.
Remove the screwdriver from the service hole on the cylinder block, then install and tighten the plug to the specified torque.
Tightening torque: 36 + 3 Nm.
Timing Belt Tension Adjustment
Screw the special rod into the hole of the attachment mounting bracket.
Attention! Screw in the special rod by hand, as using a special tool may damage the wire inserted into the automatic timing belt tensioner.
Slowly screw in the special rod until the wire inserted into the automatic tensioner can be easily moved.
Turn the crankshaft 1/4 turn counterclockwise, then turn the crankshaft clockwise to align the timing marks.
Loosen the tensioner roller mounting bolt and use the special tool and a torque wrench to apply torque to the tensioner roller (tighten the belt).
Standard value: 3.5 Nm.
After that, while holding the tensioner roller from turning, tighten the fastening bolt with the nominal tightening torque.
Tightening torque: 48±5Nm.
Attention! When tightening the mounting bolt, make sure that the tensioner roller (or its shaft) does not turn with the bolt.
Remove the wire or pin from the auto tensioner.
Remove the special rod from the attachment bracket hole and install the plug.
Turn the crankshaft clockwise two turns and align the timing marks.
Wait about 15 minutes and check that the wire can be easily inserted into the automatic tensioner and just as easily removed from it. If not, check that the protrusion of the auto-tensioner rod is within the nominal values.
Standard value A: 3.8-4.5 mm.
If the stem protrusion is out of the nominal value range, then repeat the operations again, and then check that the marks of all sprockets are aligned with the corresponding alignment marks.
Final operations
Install the engine mount.
Install the bottom guards.
Adjust the tension of the accessory drive belt.