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 4 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) While 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.
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 mounting bolt to the specified torque.
- Tightening torque - 8 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 - 83 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 surface of the coolant pump.
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, 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 pulleys in the following order:
- (1) crankshaft pulley,
- (2) intermediate pulley,
- (3) coolant pump pulley,
- (4) oil pump pulley,
- (5) injection pump pulley,
- (6) camshaft pulley,
- (7) timing belt tensioner pulley.
b) Using a screwdriver, install the tension roller spring.
Note: Do not use pliers when tensioning the spring tension roller.
V) 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 pulley 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) Loosen the crankshaft pulley bolt.
9. Tighten the tensioner pulley mounting bolt.
- Tightening torque - 38 Nm
Note: When tightening the bolt, do not move the idler pulley bracket.
10. Install the bracket for the right engine mount by tightening the 4 mounting bolts.
- Tightening torque - 38 Nm
11. Install the timing belt guide as shown.
12. Install the timing belt cover No. 1 by tightening the 5 mounting bolts.
- Tightening torque - 8 Nm
13. Install timing belt cover #2 by tightening 5 bolts and 3 fastening nuts.
- Tightening torque - 8 Nm
14. Install the right engine mount.
A) Install the shock absorber on the right engine mount by tightening the 3 mounting bolts.
- Tightening torque - 73 Nm
b) Install the shock absorber bracket by tightening the mounting bolts and nuts.
Torque:
- bolt - 36 Nm
- nut - 53 Nm
V) 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.
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 washer.
22. Install the right side of the engine protection.
23. Check and adjust the injection advance angle.