You will need: a hex wrench “6”, heads “12”, “13”, “14”, a small chisel, a hammer
Drain the cooling system.
Remove the radiator of the cooling system.
Remove the power steering pump drive belt and fan pulley.
Remove the alternator and water pump drive belt.
Loosen the inlet hose clamp and remove the hose.
Remove the cylinder head cover.
Remove the four bolts and remove the front cylinder head cover assembly with fan drive clutch and fan (viscous clutch with fan removed for clarity).
Remove the water pump.
Remove the crankshaft speed sensor (timing sensor).
Remove the two bolts and remove the upper chain tensioner cover with gasket.
Remove the cover carefully, as the hydraulic tensioner spring acts on it.
Then remove the hydraulic tensioner.
Remove the lower chain tensioner in the same way.
Remove the two bolts and remove the plastic chain guide.
Remove the gears from the camshafts by removing the bolts securing the gears to the camshaft flanges.
Remove the crankshaft pulley.
The chain cover can be removed without removing the block head. But at the same time, damage to the head gasket is possible, since adhesive sealant was applied to the upper end of the cover when it was installed.
At the same time, when installing the cover in place, it is difficult to achieve accurate centering of the cuff on the crankshaft bushing, which will lead to its rapid wear.
Therefore, when disassembling the timing drive, remove the block head (see Replacing the head gasket ZMZ-406 GAZ-3110 ).
With a 14 head, we unscrew the four bolts securing the clutch crankcase amplifier to the block.
With keys 14 and 17, we unscrew the two bolts securing the amplifier to the clutch housing and remove the amplifier.
We unscrew four nuts with a head of 13 and a key of 12 eleven bolts securing the oil pan to the cylinder block.
Carefully, trying not to damage the gasket, remove the pallet from the studs and put it on the beam.
Using a 6 hexagon wrench, unscrew the 7 screws securing the cover.
Prying off with a screwdriver, remove the chain cover.
Remove the upper chain from the intermediate shaft sprocket.
Using a 6 hexagon wrench, we unscrew the axle of the upper chain tensioner shoe and remove the shoe.
If necessary, use a 14 key to unscrew the shoe axis extension.
Using a 6 hexagon wrench, we unscrew the axle of the lower hydraulic tensioner shoe and remove the shoe.
Bend the edges of the locking plate with a chisel.
Using a screwdriver, holding the intermediate shaft sprocket, unscrew the two bolts with a 12 wrench.
Remove the sprocket along with the lower chain from the axis of the intermediate shaft.
Using a 6 hexagon wrench, unscrew the two screws and remove the lower chain damper.
We assemble in the reverse order.
Before assembling the timing gear drive, we clean the mating surfaces of the cylinder block and the chain cover from the remnants of the gasket and sealant.
After removing, wash the chains and gears in gasoline, wipe and dry them.
Inspect the chains. If cracks, chips, or significant signs of wear are found on the chain bushings, replace the chains.
Replace gears that have chipped or chipped teeth.
Replace damaged chain guides.
The tensioner sprockets must rotate freely on the axles. If the sprocket teeth are chipped or chipped, replace the tensioners.
If you removed the gear from the crankshaft, press it onto the crankshaft, install the O-ring and bushing.
Turn the crankshaft so that mark 1 on the crankshaft gear matches mark 2 on the cylinder block. In this case, the piston of the 1st cylinder will take the TDC position.
Install the chain damper 4 without tightening the bolts 3 fastening the damper.
Put chain 5 on the crankshaft gear after lubricating it with engine oil.
Put the chain on the driven gear 1 and install the gear on the countershaft 2 so that the pinion of the gear fits into the hole of the countershaft.
In this case, mark 4 on the gear must coincide with mark 5 on the cylinder block, and the chain branch passing through the damper 3 must be tensioned.
Install the countershaft drive gear so that its locating pin fits into the hole in the driven gear.
Install the two countershaft gear bolts with the lock plate underneath them.
Tighten the bolts to 22–25 Nm (2.2–2.5 kgf m) and secure them by bending the edges of the lock plate on the edges of the bolt heads.
While pressing the tensioner lever, tighten the chain and check the alignment of the marks on the gears and the cylinder block.
Tighten the chain guide bolts.
Lubricate the top chain with engine oil and then slide it over the countershaft drive gear through the hole in the cylinder head
Place the chain on gear 2 and turn the exhaust camshaft slightly clockwise to install gear 2 with the chain on it.
Camshaft pin 8 must fit into the gear hole.
Insert bolt 1.
Turn the camshaft with the wrench on the square on the camshaft.
Then, turning the camshaft slightly counterclockwise, tension the chain.
The intermediate and crankshafts must not rotate while doing this.
Mark "A" must align with the top surface of the cylinder head.
Remove bolt 6 and remove gear 4 from the intake camshaft.
Put a chain on gear 4 and install gear 4 with chain on the camshaft by slightly turning the camshaft clockwise.
Camshaft pin 5 must fit into the gear hole.
Slightly turn the camshaft counterclockwise to tension the chain.
The "A" mark on gear 4 must align with the top surface of the cylinder head.
The rest of the shafts must not rotate.
Install bolt 6. Tighten bolts 1 and 6 to a torque of 46–74 Nm (4.6–7.4 kgf m), holding the camshafts from turning with a wrench by the squares.
Install damper 3 by pushing it into the hole in the block head.
Install damper 7.
Install the chain cover and water pump. Apply a thin layer of sealant to the surfaces of the covers adjacent to the cylinder block and block head.
When installing the chain cover, be careful not to damage the crankshaft oil seal.
Install the upper and lower chain tensioners. Install the crankshaft pulley.
Install the crankshaft pulley bolt, then, engaging fifth gear and braking the car with the parking brake, tighten the bolt to 104–128 Nm (10.4–12.8 kgf m), while holding the crankshaft from turning.
When the ratchet is tightened, the pulley is pressed onto the crankshaft.
Turn the crankshaft two turns by the ratchet and set the piston of the 1st cylinder to the TDC position (see operation 3).
Check if the labels match.
Install the front cover of the cylinder head, first apply a layer of sealant to the surface of the cover adjacent to the block head.
Tighten the cover bolts to 12–18 Nm (1.2–1.8 kgf m).
Install the cylinder head cover. Tighten the cover bolts to 6.0–12 N m (0.6–1.2 kgf m).
Connect the crankcase ventilation hose and tube to the fittings on the valve cover, and the wires to the ignition coils.
Put the ends of the high-voltage wires on the spark plugs.
Install the previously removed attachments.