A) While holding the power steering pump drive belt with your hand, unscrew the pulley mounting nut, as shown in the figure.
b) Loosen the belt tension adjusting bolt and remove the power steering pump drive belt.
V) Remove the power steering pump key and pulley.
G) Loosen the three screws securing the pump and remove it.
2. Remove the alternator drive belt.
A) Loosen the alternator mounting bolt, adjusting bolt (or nut) and lock bolt.
b) Slide the alternator towards the engine and remove the drive belt.
3. Remove the three clips, unscrew the five bolts and remove the timing belt cover No. 2 along with the gasket.
4. Remove the four glow plugs (see section "Removing the cylinder head").
Note: The glow plugs must be turned out as this will allow the crankshaft to turn smoothly, allowing the correct belt tension to be adjusted.
5. Set the piston of cylinder No. 1 to TDC of the compression stroke.
Parts for removing and installing the timing belt
1 - a bolt of fastening of a pulley of a cranked shaft (М3=196 Nm),
2 - crankshaft pulley,
3 - cover No. 1 of the timing belt,
4 - timing belt cover and generator bracket,
5 - cover No. 2 of the timing belt,
6 - toothed pulley of the injection pump drive,
7 - tension roller,
8 - a gear pulley of a drive of a camshaft,
9 - tension spring,
10 - timing belt,
11 - crankshaft toothed pulley,
12 - timing belt guide,
13 - intermediate pulley,
14 - toothed pulley of the oil pump drive.
Align the mark on the camshaft pulley with the cylinder head split line and the cylinder head cover. Turning the crankshaft pulley clockwise.
6. Remove the crankshaft pulley.
A) Install the special tool on the crankshaft pulley.
b) Holding the pulley from turning with a special tool, unscrew the bolt securing the crankshaft pulley.
V) Using a special puller, remove the crankshaft pulley.
7. Remove the five bolts and remove the timing belt cover No. 1 along with the gasket and belt guide.
8. Remove the timing belt cover and alternator bracket.
9. Remove the timing belt.
Note: When reusing the timing belt, put an arrow in the direction of rotation, marks on the timing belt and camshaft sprocket, and align them with the mark on the timing belt cover No. 1 as shown in the figure.
Timing belt installation.
1-, 3-, 6 - pulley alignment mark,
2 - mark on the cylinder head,
4 - groove on the coolant pump housing,
5 - groove on the oil pump housing.
A) Using a screwdriver, remove the timing belt tensioner spring.
Warning: When removing the spring, do not use pliers, etc.
b) Loosen the idler pulley bolt.
V) Remove the timing belt.
10 Remove the camshaft pulley (if it is needed).
A) Holding the pulley from turning with a special tool, unscrew the bolt securing the camshaft pulley.
Note: Do not rotate the camshaft to avoid hitting the valves with the piston crowns.
b) Using the special tool, remove the camshaft pulley.
11. Remove the tension roller.
12. Remove the injection pump drive gear pulley (if it is needed).
A) Holding the high-pressure fuel pump drive pulley from turning with a special device, unscrew the pulley fastening nut.
Note: When loosening the nut, do not use an inertial puller.
b) Using the special tool, remove the injection pump drive pulley.
Note: The pulley is spring loaded, so hold it while removing it.
13. Remove intermediate pulley (if it is needed).
14. Remove the oil pump drive pulley (if it is needed).
A) While holding the oil pump pulley from turning with a special tool, unscrew the pulley mounting nut.
b) Remove the oil pump pulley.
15. Using a special tool, remove the crankshaft sprocket (if it is needed).
During this operation, the crankshaft can turn, and since it is not synchronized with the camshaft, under certain circumstances it can bend the valves.