Replacing the toothed belt on CVH engines (60,000 km / 36 months)

1. Remove ground wire from battery.

2. Loosen the lower mounting bolts, unscrew the upper alternator tension bolt, tilt the alternator towards the engine and remove the drive belt.

3. Unscrew the 4 bolts securing the toothed belt cover and remove it.

4. On engine models made from 2/82, the timing belt cover consists of two parts, each with its own rubber gasket. On the bottom cover there is a mark for setting the first cylinder to TDC.

5. The bottom cover can only be removed after removing the pulley from the crankshaft.



6. Rotate engine crankshaft until aligned (indicated by an arrow) marks on the camshaft pulley and cylinder head.



7. Align the marks on the crankshaft pulley and oil pump housing.


8. Fix the engine crankshaft by removing the starter and fixing the flywheel ring gear.

9. Unscrew the mounting bolt and remove the crankshaft pulley.



10. Loosen the bolts securing the toothed belt tension roller and use a screwdriver to remove the tension roller from the belt, compressing the spring, and tighten the bolts.

11. To reinstall the toothed belt, note the direction of its movement.

12. Remove toothed belt.

Attention! After removing the belt, it is strictly forbidden to turn the crankshaft and camshaft pulleys, as pistons may collide with open valves, which will lead to serious engine damage.

13. Install the belt on the crankshaft pulley, pull it vertically and install the tension roller and the water pump pulley in series on the camshaft pulley. Check the alignment of the marks on the pulleys, which should not change.



14. Key (2) on the crankshaft and mark (1) on the oil pump housing must match.


15. Loosen the toothed belt tensioner bolts. Under the action of the spring, the toothed belt will be tensioned, and then tighten the bolts. If the belt tensioner does not contain a spring, tension by turning the idler roller and tightening the bolts.

16. Install the V-belt pulley on the crankshaft and secure it with the bolt.

17. Turn the crankshaft two turns clockwise and check that the marks on the camshaft pulley and the cylinder head match.



18. Rotate the crankshaft 60°counterclockwise (in this case, the camshaft pulley is displaced by three teeth) and check the belt tension, for which purpose press at point A on the long branch of the belt towards the water pump pulley and measure the distance X between the outer diameter of this pulley and the top of the belt tooth on the long branch. The value of this distance should be within 4–6 mm. If this condition is not met, re-adjust the toothed belt tension.

19. If this condition is not met, re-adjust the toothed belt tension.



20. When using a special belt tension gauge, install it on a long branch of the belt, and the gauge tensioner should enter the recess between the teeth.




21. The meter should show a value of 4 to 6 on a used belt and 10 to 11 on a new belt.

Attention! To adjust the toothed belt tension only on a cold engine.

22. Install the toothed belt cover. Long bolts (М6х55) cover fasteners are installed from above.

23. Install the alternator drive V-belt and adjust its tension.

24. Install starter.