Removal the timing gear and fuel injection pump drive gears
1. Remove the accessory drive belts, fan and water pump pulley.
2. Remove the timing belt and gears.
3. Remove 7 bolts and the rear timing belt cover.
4. Removing the vacuum pump.
a) Disconnect the vacuum hose.
b) Unscrew the two nuts and remove the pump.
c) Remove the two rubber sealing rings.
5. While holding the crankshaft pulley, unscrew the pulley mounting bolt.
Use a puller to remove the pulley.
6. Removing the gear cover.
a) Unscrew the bolt and nut, remove the washer and vacuum hose.
b) Unscrew 13 bolts and two nuts securing the gear cover
c) Place the screwdriver in the place shown in the figure, press on the cover and remove it.
d) Remove the sealing ring
7. Checking the axial clearance of the idler gear.
Install the indicator as shown in the figure and measure the axial clearance.
Nominal clearance - 0.05 - 0.15 mm
Maximum gap - 0.3 mm
If the gap is greater than the maximum, replace the thrust washer. If necessary, replace the gear or shaft.
8. Removing gears.
Note: Mark the face of each gear.
When assembling and disassembling, do not damage the gear teeth.
A Crankshaft gear.
a) Secure the clearance compensation gear to the idler gear with a bolt.
1 - idler gear, 2 - clearance compensation gears, 3 - tightening bolt M6x1-28mm.
Note: When removing the idler gear, make sure that the force of the clearance compensation springs is blocked by the tightening bolt.
b) Using a puller, remove the crankshaft gear
B. Idler gear.
Unscrew the two bolts, remove the thrust washer, the idler gear assembly with the clearance compensation gears and the idler gear shaft.
C. Fuel injection pump drive gear.
a) While holding the gear, unscrew the fastening nut
b) Remove the rubber sealing ring
c) Using a puller, remove the gear
Caution: tighten the puller bolts to a depth of more than 8 mm.
9. Disassembling the idler gear
a) Secure the idler gear and one of the compensation gears in a vice
b) Holding the second compensation gear, unscrew the tightening bolt M6x1-28
c) Remove the idler gear shaft retaining ring
d) Remove the spring washer (1), clearance compensation gear (2), clearance compensation spring (3).
d) Re-clamp the idler gear, repeat steps c) and d) to complete disassembly of the unit.