A) Install the pulley key into the crankshaft keyway.
b) Using a hammer, lightly tap the pulley with the flange inwards.
2. Install tensioner pulley #2.
A) Install the spacer and idler pulley with bolt. Tighten the bolt to a tightening torque of 33 Nm.
b) Check for smooth movement of the tensioner pulley.
3. Install the injection pump drive pulley.
A) Install the key into the keyway of the drive shaft.
b) Fit the drive pulley so that the TDC mark is facing out.
V) Using the special tool, install the bolt and tighten it to 64 Nm.
Caution: Do not tighten the nut with an impact tool.
4. Install the camshaft pulley.
A) Place the key into the keyway of the camshaft.
b) Align the locating key with the pulley keyway.
V) Fit the pulley so that the TDC mark is facing out.
G) Using the special tool, install the bolt and tighten to 98 N.m.
5. Temporarily install idler pulley #1 and tension spring.
Bolt length:
- A - 76.5 mm
- B - 42.9 mm (yellow color)
- C - 41.3 mm (color - silver)
Note: bolt "WITH" attaches tension roller
A) Install the tension roller with three bolts. Tighten two bolts (B and C) until tightening torque 19 N.m.
b) Install the tension spring.
V) Using the lever, move the tension roller bracket as far as possible to the left, tighten the bolt (A).
G) Check up smoothness of movement of a tension roller.
6. Set the piston of the first cylinder to TDC.
Install the pulleys in the appropriate positions.
Attention: the engine must be cold. When the crankshaft or camshaft rotates, the valve discs can hit the piston bottom, so do not turn the shafts more than the required angle.
7. Install the timing belt.
Note: If the belt is reused, align the alignment marks and install the belt according to the arrow indicating the direction of rotation of the motor.
A) Remove water or oil from each pulley (if they exist) and keep the pulleys clean.
b) Install the belt on the crankshaft pulley and idler pulley #1.
V) Using the special tool, slightly turn the injection pump drive pulley clockwise. Hang the belt on the injection pump drive pulley and align the marks located on the drive pulley and on the belt cover.
G) Check for slack in the belt between the crankshaft pulley and the injection pump drive pulley.
d) Using the special tool, slightly turn the camshaft pulley clockwise. Hang the belt on the pulley and align the TDC marks located on the pulley and on the belt cover.
e) Check that there is no slack in the belt between the injection pump drive pulley and the camshaft pulley.
and) Install the belt on the tension roller No. 2.
8. Check if the labels match.
A) Loosen the bolt (A) tension roller No. 1; tension the timing belt.
b) Rotate the crankshaft pulley four full turns.
Note: Always turn the crankshaft clockwise.
V) Check the alignment of the marks of each pulley with your benchmark, as shown in the figure. If the marks are not aligned, remove the belt and reinstall it.
G) tighten bolt (A) tension roller No. 1, torque 44 N·m.
9. Install the belt guide with its cup facing out.
10. Install the front timing belt cover.
A) Install two spacers and a spacer on the belt cover.
b) Install the belt cover by tightening the eleven bolts.
11. Install the crankshaft pulley,
A) Align the key with the keyway of the pulley.
b) Fit the pulley with light tapping.
V) Using the special tool, install the bolt and tighten to 167 Nm.
12. Install glow plugs
A) Using a socket wrench, install the four glow plugs and tighten to 13 Nm.
b) (Only for engines equipped with a preheating system with a fixed delay). Install the glow plug wire by tightening the four nuts.
V) Install the lower heat shield to the intake manifold.
G) Install the wire to the glow plugs and the lower heat insulator.
d) Install the top heat shield with spring washer and nut.
e) Install the four nuts securing the wire to the glow plugs.
and) Install four insulating sleeves.
13. Install the water pump pulley.
14. Install and adjust the tension of the implement drive belts.