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 4 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) Holding 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.
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 - 8 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 - 83 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 surface of the coolant pump.
7. Install the timing belt.
Note:
- - Installation is performed on a cold engine.
- - When reusing the belt, align the timing marks made when removing the belt and install the timing belt so that the arrow indicating the direction of rotation matches 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 pulleys in the following order:
- (1) Crankshaft toothed pulley,
- (2) intermediate pulley,
- (3) coolant pump pulley,
- (4) oil pump pulley,
- (5) fuel injection pump pulley,
- (6) camshaft pulley,
- (7) timing belt tensioner roller.
b) Using a screwdriver, install the tension roller spring.
Note: Do not use pliers when tensioning the spring tension roller.
c) 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 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 pulley mounting bolt.
9. Tighten the tensioner roller mounting bolt.
- Tightening torque - 38 Nm
Note: When tightening the bolt, do not move the tensioner roller bracket.
10. Install the right engine mount bracket by tightening the 4 mounting bolts.
- Tightening torque - 38 Nm
11. Install the timing belt guide as shown in the figure.
12. Install timing belt cover No.1 by tightening the 5 mounting bolts.
- Tightening torque - 8 Nm
13. Install timing belt cover No.2 by tightening 5 bolts and 3 fastening nuts.
- Tightening torque - 8 Nm
14. Install the right engine mount.
a) Install the right engine mount shock absorber by tightening the 3 mounting bolts.
- Tightening torque - 73 Nm
b) Install the shock absorber bracket by tightening the bolts and nuts.
Tightening torque:
- bolt - 36 Nm
- nut - 53 Nm
c) Tighten the fastening nuts.
- Tightening torque - 53 Nm
15. Install the crankshaft pulley.
- Tightening torque - 200 Nm
16. Install the power steering pump by tightening the 3 mounting bolts.
Tightening torque:
- M10 - 40 Nm
- M12 - 73 Nm
17. Install the power steering pump pulley.
- Tightening torque - 44 Nm
18. Connect the hydraulic tube clamp.
19. Install the alternator drive belt.
20. Install the power steering pump drive belt.
21. Install the washer.
22. Install the right side of the engine guard.
23. Check and adjust the injection advance angle.