Note: The marks on the gears must face the front of the vehicle.
A. Crankshaft gear.
a) Turn the crankshaft with the keyway facing up. Install the key and gear so that the "1" mark on the crankshaft and oil pump gears align.
b) Using a hammer blow through a mandrel, press the gear onto the shaft.
B. Fuel injection pump drive gear.
a) Install the key on the injection pump shaft.
b) Align mark "3" on the gears of balance shaft No.2 and the high-pressure fuel pump.
c) Install a new sealing ring on the fuel injection pump drive gear.
d) While holding the fuel injection pump gear, tighten the mounting nut to a torque of 64 N·m.
B. Idler gear.
a) Lubricate the idler gear shaft with engine oil.
b) Insert the shaft into the block.
c) Align mark "5" of the idler gear with mark "5" of the crankshaft gear, and mark "4" with mark "4" of the fuel injection pump drive gear.
d) Align the holes in the thrust washer with the holes in the idler gear shaft, insert the bolts and tighten them to 19 N·m.
d) Unscrew the idler gear tightening bolt installed earlier during assembly.
3. Installing the gear cover.
a) Install a new sealing ring into the block.
b) Remove any remaining old sealant from the cover, carefully coat the mating surfaces of the cover and block.
c) Apply sealant to the cover as shown in the figure.
d) Tighten the 13 bolts and 2 nuts to 13 Nm.
d) Secure the vacuum tube to the cover with a bolt and nut.
Tightening torque 13 Nm.
4. Checking the axial clearance on the fuel injection pump drive shaft.
a) Temporarily secure the camshaft drive gear to the shaft.
b) Measure the clearance by moving the gear wheel in the axial direction.
Nominal clearance 0.15-0.55 mm
If the gap is too small, loosen the two fuel injection pump flange mounting nuts and the three fuel injection pump rear support bolts and tighten them again. If this does not help, reinstall the gear cover.
5. Installing the crankshaft pulley,
a) Align the pulley key with the groove on the shaft.
b) Using a hammer, press the pulley onto the shaft through the mandrel.
c) While holding the pulley, tighten the pulley mounting bolt to 363 N·m. Do not forget to install a washer under the bolt.
6. Installing a vacuum pump
a) Install two new O-rings on the pump.
b) Tighten the two mounting nuts.
Tightening torque - 21 Nm
7. Install the rear timing belt cover, tighten the 7 mounting bolts.
Tightening torque - 9 Nm
8. Install the timing belt.
9. Install the water pump pulley, fan and accessory drive belts.