Note: if the pulleys were not removed, go to step 6.
1. Install the crankshaft sprocket.
A) Align the keyway on the pulley with the key on the front toe of the crankshaft.
b) Using a special mandrel (or a tube of suitable diameter) and a hammer, seat the toothed pulley on the crankshaft.
V) Holding the toothed pulley with a special tool, install it and tighten the pulley fastening nut to the specified torque.
- Tightening torque - 47 Nm
2. Install the intermediate pulley.
- Tightening torque - 37 Nm
Note: Check for smooth pulley rotation.
3. Install the injection pump drive gear pulley.
A) Align the keyway on the pulley with the key on the toe of the injection pump drive shaft.
b) Holding the pulley with a special tool, install it and tighten the pulley fastening nut to the specified torque.
- Tightening torque - 64 Nm
Warning: the nut must be tightened smoothly, without jerking.
4. Pre-install the tension roller (if it was taken).
A) Install the idler pulley to the cylinder head and tighten the idler bracket bolt by hand until the idler moves freely.
b) Install and tighten the roller fixing bolt to the specified torque»
- Tightening torque - 7.5 Nm
V) Check that the idler pulley bracket moves freely to the left and right by hand.
5. Install the camshaft sprocket.
A) Align the dowel pin hole on the pulley with the dowel pin on the front toe of the camshaft.
b) Holding the camshaft pulley with a special tool, install the mounting bolt with the washer and tighten it to the specified torque.
- Tightening torque - 88 Nm
Note: Do not rotate the camshaft to prevent the valves from hitting the piston crowns.
6. Align the alignment marks on the camshaft pulleys, injection pump drive shaft and crankshaft with the corresponding marks.
A) Align the mark on the camshaft pulley with the parting plane of the cylinder head cover and cylinder head.
b) Align the alignment mark (groove) on the crankshaft pulley with a mark on the oil pump housing.
Note: Aligning the marks on the crankshaft and camshaft pulleys, avoid turning the pulleys to prevent the valves from hitting the piston crowns.
V) Align the mark on the injection pump pulley with the mark on the coolant pump housing.
7. Install the timing belt.
Note:
- Installation is carried out on a cold engine.
- When reusing the belt, align the alignment marks made when the belt was removed (see section "Removing the timing belt"), and install the timing belt so that the arrow indicating the direction of rotation coincides with the direction of rotation of the crankshaft.
- When installing a new timing belt, check that the numbers and letters of the markings are readable when viewed from the rear of the engine.
A) Put the timing belt on the camshaft pulley.
b) While holding the nut securing the injection pump drive pulley with a wrench, put the timing belt on it.
Note: Make sure the belt teeth are engaged and there is no slack in the belt.
V) Slide the timing belt over the water pump pulley and the crankshaft toothed pulley. Note: Make sure the belt teeth are engaged and there is no slack in the belt.
G) Put the timing belt on the oil pump drive pulley and tensioner pulley.
Note: Make sure the belt is not twisted or too tight.
d) Using a screwdriver, install the tension roller spring.
Note:
- Do not use pliers when tensioning the idler spring.
- Loosen the tensioner bolt until the spring tensions the timing belt.
8. Check up correctness of installation of phases of gas distribution.
A) Temporarily install the crankshaft sprocket bolt.
b) Turn the crankshaft two turns until the alignment mark on the camshaft pulley aligns with the upper plane of the cylinder head.
Note: Turn the crankshaft only clockwise. If the direction of rotation is incorrect, the belt teeth may come out of engagement due to a change in spring tension.
V) Make sure the alignment marks on the other pulleys match as shown.
If the labels do not match, repeat the procedure from step 6.
G) Turn away a bolt of fastening of a gear pulley of a cranked shaft.
9. Tighten a bolt of fastening of a tension roller the specified moment.
- Tightening torque - 37 Nm
Note: When tightening the bolt, do not move the idler pulley bracket.
10. Install the alternator bracket and timing belt cover.
- Tightening torque - 37 Nm
Note: On vehicles with power steering, 14mm wrench bolts are used.
11. Install the timing belt guide and cover No. 1.
A) Install the belt guide on the crankshaft sprocket with the annular notch facing out (as it shown on the picture).
b) Install timing belt cover #1 with gasket and tighten the five mounting bolts.
12. Install the crankshaft pulley.
A) Install the key into the groove.
b) Install the pulley with a mandrel and a hammer.
V) While holding the crankshaft pulley with a special tool, install the pulley mounting bolt with washer and tighten it to the specified torque.
- Tightening torque - 98 Nm
13. Install glow plugs.
14. Install the gasket and timing belt cover No. 2, three clips and tighten the five bolts.
Note: It is better to glue the gasket to the #2 timing belt cover with glue for easier installation.
15. (Models with hydraulic booster) Install the power steering pump and drive pulley.
A) Tighten the three bolts.
- Tightening torque - 39 Nm
b) Install the pump pulley and slotted key on the pump drive shaft.
V) Tighten the pump pulley nut by hand.
16. Install and adjust the accessory drive belts.
17. (Models with hydraulic booster) Install the power steering pump pulley and tighten the nut.
- Tightening torque - 43 Nm
18. Check and adjust the injection advance angle (see relevant section).