Note: If the pulleys were not removed, proceed to step 6.
1. Install the crankshaft timing pulley.
a) Align the keyway on the pulley with the key on the front nose of the crankshaft.
b) Using a special mandrel (or a tube of suitable diameter) and a hammer, seat the toothed pulley on the crankshaft.
c) Hold the toothed pulley with a special device, install it and tighten the pulley mounting nut to the specified torque.
- Tightening torque - 47 Nm
2. Install the idler pulley.
- Tightening torque - 37 Nm
Note: Check that the pulley rotates smoothly.
3. Install the fuel injection pump drive toothed pulley.
a) Align the keyway on the pulley with the key on the nose of the fuel injection pump drive shaft.
b) Hold the pulley with a special device, install it and tighten the pulley mounting 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 filmed).
a) Install the tension roller on the cylinder head and tighten the roller bracket mounting bolt by hand so that the roller moves freely.
b) Install and tighten the roller mounting bolt to the specified torque.
- Tightening torque - 7.5 Nm
c) Check that the tension roller bracket can move freely left and right by hand.
5. Install the camshaft timing pulley.
a) Align the dowel pin hole on the pulley with the dowel pin on the front end of the camshaft.
b) Holding the camshaft pulley with a special device, install the mounting bolt together with the washer and tighten it to the specified torque.
- Tightening torque - 88 Nm
Note: Do not allow the camshaft to turn to avoid the valves hitting the piston crowns.
6. Align the timing marks on the camshaft pulleys, fuel injection pump drive shaft and crankshaft with the corresponding marks.
a) Align the mark on the camshaft pulley with the joint plane of the cylinder head cover and the cylinder head.
b) Align the timing mark (groove) on the crankshaft pulley with the mark on the oil pump housing.
Note: When aligning the marks on the crankshaft and camshaft pulleys, avoid turning the pulleys to avoid the valves hitting the piston crowns.
c) 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 timing marks made when removing the belt (see section "Removal 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 on the markings are legible when viewed from the rear of the engine.
a) Place the timing belt on the camshaft pulley.
b) Holding the fuel injection pump drive pulley mounting nut 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.
c) Place the timing belt on the coolant pump pulley and the crankshaft toothed pulley. Note: Make sure that the belt teeth are engaged and that there is no slack in the belt.
d) Place the timing belt on the oil pump drive pulley and tension roller.
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 tension roller spring.
- Loosen the tension roller mounting bolt until the spring tensions the timing belt.
8. Check the correct installation of the valve timing.
a) Temporarily install the crankshaft timing pulley mounting bolt.
b) Turn the crankshaft two revolutions until the timing mark on the camshaft pulley aligns with the upper plane of the cylinder head.
Note: Turn the crankshaft clockwise only. If the direction of rotation is incorrect, the belt teeth may come out of engagement due to a change in spring tension.
c) Make sure that the timing marks on the other pulleys match as shown in the figure.
If the marks do not match, repeat the procedure from point 6.
d) Loosen the crankshaft toothed pulley mounting bolt.
9. Tighten the tension roller mounting bolt to the specified torque.
- Tightening torque - 37 Nm
Note: When tightening the bolt, do not move the tensioner roller bracket.
10. Install the generator bracket and timing belt cover.
- Tightening torque - 37 Nm
Note: On vehicles with power steering, 14mm bolts are used.
11. Install the timing belt guide and cover No.1.
a) Install the belt guide on the toothed pulley of the crankshaft with the annular recess facing outward (as shown in the picture).
b) Install timing belt cover No.1 together with the gasket and tighten the five mounting bolts.
12. Install the crankshaft pulley.
a) Install the key into the groove.
b) Install the pulley using a drift and hammer.
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c) Holding the crankshaft pulley with a special device, install the pulley mounting bolt together with the washer and tighten it to the specified torque.
- Tightening torque - 98 Nm
13. Install the glow plugs.
14. Install the timing belt gasket and cover #2, three clamps and tighten the five bolts.
Note: It is better to glue the gasket to the timing belt cover No.2 with glue for easier installation.
15. (Models with power steering) Install the power steering pump and drive pulley.
a) Tighten the three bolts.
- Tightening torque - 39 Nm
b) Install the pump pulley and woodruff key onto the pump drive shaft.
c) Tighten the pump pulley mounting nut by hand.
16. Install and adjust the drive belts of the attachments.
17. (Models with power steering) Install the power steering pump pulley and tighten the nut.
- Tightening torque - 43 Nm
18. Check and adjust the injection advance angle (see the relevant section).