Engine Mechanical System Repair Gui Replacement of Front-end Accessory Drive Belt Removal 1 Loosen the screw, rotate the tension pulley clockwise as shown in the figure, and remove the front-end accessory drive belt |Es020035 Installation 1. Installation is the reverse of removal. lEsoz0035 Replacement of Timing Belt Required tools:C00016996, 00016997, ©00017003, 00017015, C00017018, C00017030. Removal 1 Remove the front-end accessory drive belt (refer to Replacement of Front-end Accessory Drive Bett). 2 Remove the screw and the front-end accessory drive belt tension pulley. leso20035 3. Remove 4 M8 screws and the crankshaft shock absorber. ‘Note: Before removing the crankshaft shock absorber (4x10 mm), turn the engine to the timing mounting position with a turning gear to avoid bolts from being loosened when the crankshaft timing pulley bolt Is used for turning engine during engine timing adjustment. Jcs113003En ie Mechanical System 4 Remove 17 MS screws and the front-end timing protective cover, and check gaskets and the protective cover for sealant. Note: The screws are pre-coated with glue. lcst13004 5 Rotate the engine crankshaft clockwise, remove the dustproof bulkhead, and then install the flywheel timing pin. At this time, the crankshaft timing pulley shall be at 90° behind the top dead center of {st cylinder. lcs113006 6 Remove the dustproof bulkhead, and install flywheel timing pin C00017003. Ensure the flywheel is accurately located. cst13222 7 Remove hexagonal screw plugs (2 x M6); insert Intake camshaft timing pin CO0016996 and exhaust camshaft timing pin C00016997. Note: If timing pins cannot be inserted, remove the flywheel timing pin, rotate the crankshaft clockwise for 360°, and insert the flywheel timing pin. Then insert the camshaft timing pin. icst13007Engine Mechanical System 8 Loosen the camshaft timing pulley retaining bolts(2 x M12). Note: Prevent the pulley from rotating with tool 00017015. DO NOT depend on the timing drive belt only. Ics113008 8 Loosen the nut (M10) on the belt tension pulley retaining bot, and rotate the tension pulley anticlockwise to the lowest point with the tool 00017030. 10 Remove and scrap the timing drive belt, Note: Without professional guidance, it is prohibited to rotate the crankshaft after removing the timing drive belt. Otherwise valves, pistons and other components may be damaged. Note: If there is a need to replace the timing drive belt, the idler and tension pulley must be replaced meanwhile. Ics113009 Installation 1 Tighten the camshaft timing pulley with new bolts. Tighten bolts manually, and then loosen them for 1/16 circle (ensure the pulley can rotate freely), Torque forthe timing tension pulley retaining nut 28N.m “Torque forthe timing idler bolt: S7N.m Note: The idler bolt is 2 reverse-thread bolt and shall be tightened anticlockwise. lest13010 2 Rotate the fuel pump timing pulley to align timing marks, as shown in the right figure. 3 Check whether the flywheel and camshaft timing pin stil exists. cs113011Engine Mechanical System 4 Install a new timing drive belt allnstall the crankshaft timing pulley firstly, and {temporarily install a proper support tool to fit the belt with the timing pulley. Keep the bet ight, and then install the bett around the folowing parts in tum: Fuel pump timing pulley (do not damage the fuel Pump timing). cldler. d.intake camshaf timing pulley. ‘@ Exhaust camshaft timing pulley filer ics113012 ‘g.Water pump pulley. ‘h.Timing drive be tension pulley. Note: DO NOT pry the belt onto the pulley with a crowbar; press it by fingers only. cs113005 5 Remove the temporary support tool from the crankshaft timing pulley. lost13012 6 Keep rotating the tension pulley clockwise with tool C00017030 until there is imm overlap ‘between the upper pointer of tension pulley and the spring (as shown in the figure). Tighten the tension pulley retaining nut to the torque 28N.m. lost13013 7 To tighten the camshaft timing pulley bolt, it is required to install toot C00017016 according to the following steps —Rolate the adjustment handle of too! C00017016 anticlockwise to completely buckle the teeth on the timing pulley (the pulley shall be able to rotate flexibly at this time). —Place the tool on the middle of camshaft timing pulley. —Opserve through the hole (eliptical hole). Keep rotating the handle clockwise uni two siding teeth are completely embedded into the timing puley teeth slot (as shown in the figure). yEngine Mechanical System lcst13014 —Tighten two retaining bolts to 108 N.m. Remove tool C00017016. [ost13015 8 Remove timing pins C00016996, C00016997 and C00017003. cst13016 © Check the valve timing and belt tension as below ‘Make a temporary mark on the timing drive belt. —Keep rotating the crankshaft clockwise until the mark (on the timing drive bet retums to its starting position (that is, the bet rotates for a circle). Note: If the upper cover of mounting cylinder has been removed, rotate the crankshaft after 30min. esta017_ —Continue rotating the crankshaft clockwise until flywheel timing pin C00017003 can be installed. lcs113018 — Check whether camshaft timing pins 00016996 and (00016997 can be inserted Notes The crankshaft may be further rotated for 360°. if timing pins cannot be inserted, repeat the steps for bet installation,Engine Mechanical System cs113019 Jos113020 —Check the tensioning positon of timing drive belt tension pulley, and readjust it when necessary. —if the position is comect, remove all the three ting pins and install the sealing bukhead. jost13223 10. Check the sealing condition around the front-end timing protective cover outer lip, and repair it when necessary. During repair, remove the original sealant and clean the surface. Then apply Tonsan 1590 onto it. Leave it stand stil for 2 period of time. Do not instal until silica gel is. salidiied. 41 Install a new gasket and install a protective cover. Apply thread locking glue onto the bolt and tighten it to the torque of 6 N.m. 12. Install the crankshaft shock absorberipulley, and tighten 4 screws (MBX16) to the torque of 33N.m. Note: itis compulsively required to use the bolts (M8x16) with specified length, otherwise the timing system may get damaged easily. Jes113021Engine Mechanical System 13. Install the front-end accessory drive belt tension pulley and screw M10. Tightening torque: 45 Nm. jos113022 14 Install the front-end accessory drive belt (refer to Replacement of Front-end Accessory Drive Belt), and ensure the belt is in the middle of all pulleys. Replacement of Timing Pulley Chamber and ‘Shock Pad Required tools:C00016996, C00016997, C00017003, 00017015, 00017030 and C00017016 (tools ©00016996 and 00017002 are required for the removal of gear chamber casing) Removal 1 Remove the timing drive belt Replacement of Timing Drive Belt). 2 Remove the timing drive belt tension pulley. (eter to os113031 3 Remove two camshaft timing pulleys. Scrap the camshaft timing pulley bolt. os113052Engine Mechanical System 4 Remove the screw M12 and idler. Note: Left-hand thread. os113033 5 Remove screws (5 X M6 and 3X M10) and the timing pulley chamber. Remove the timing pulley chamber shock pad. Note: Check the gaskets, sealing parts, etc. for damage, and replace when necessary. Installation 1. Install the timing pulley chamber shock pad. 2 Apply a small amount of Tonsan 1591 silicone rubber sealant (diameter: 3mm~6mm) onto the positions shown in the figure on the gear chamber casing seal gasket for waterproof sealing. a Idlerhale shock pad b. Sleeve Shock pad 4. Timing pulley chamber shock pad «. Timing pulley chamber 1. Central gasket of timing puley chamberEngine Mechanical System 3 Apply Tonsan 1591 silicone rubber sealant (Giameter: 2mm~5mm) onto the upper cylinder head according to the track shown in the figure. ° OC 4 Install the timing pulley chamber, and tighten the following bolts to the specified torques: 5xMe 0 - lost133t 11.Nm 3xM10. = 45Nm est13224 Note: Apply Loctite adhesive 222 onto the 8 retaining bolts. 5 Install the idler, and tighten the bolts to $7 N.m. cs113238 Note: Left-hand thread 6 Install the timing drive belt tension pulley, and tighten bolts manually. cs113031 7 Install 2 camshaft timing pulleys with new bolts (keep pulley mounting faces consistent with that during removal). Tighten bolts manually, and then loosen them for 1/16 circle,Engine Mechanical System 8 Install a new timing drive belt (refer to Timing Drive Bett). cs113010 ie “ & ie } © = Ty _— Replacement of Gear Chamber Casing Required tools:C00017010 and 00017032 Removal Note: Take care not to deform the gear chamber casing. 11 Remove the timing pulley chamber and its shock pad (refer to Replacement of Timing Pulley Chamber and Its Shock Pad). 2 Remove the crankshaft drive belt and its ‘mounting screws M16. Note: For left-hand thread, do not remove the crankshaft front oil seal until the gear chamber casing is removed. lost13035 3 Remove 12 M6 bolts fixing the gear chamber casing. cs113036Engine Mechanical System 4° Separate the gear chamber casing sealed by silica gel from engine block with the sealant ‘separation tool C00017032 (keep the sealing split position of the tool lubricated). lcs113037 5 Remove the gear chamber casing, cs113038 Note: Position of locating pin D. Installation 1 Remove the otiginal sealant trom the engine block, and clean the mating face. 2 Apply Tonsan 1591 (@-6mm wide and continuous) onto the casing. Note: Install the gear chamber casing within 10min after the sealant is applied. 3° Protect the oil seal mounting cover with tool (00017002, and tighten the bolt to 12 N.m. cs113040 4 Install the crankshaft timing pulley with 2 new bolt (left-hand thread). Tightening requirement: 150 Nm #90" (reference torque: 275 N.m). lcs113041 ‘Note Use the bolt once only. And do not retighten after its rotation angle is tightened.