Note: The marks on the gears must face the front of the vehicle.
A. Crankshaft gear.
A) Turn the crankshaft with the keyway up Install the key and gear so that the mark «1» on the gears of the crankshaft and the oil pump matched.
b) Press the gear onto the shaft with hammer blows through the mandrel.
B. Injection pump drive gear.
A) Install the key on the injection pump shaft.
b) Align label «3» on the gears of the balancing shaft No. 2 and high pressure fuel pump.
V) Install a new O-ring on the injection pump drive gear.
G) While holding the injection pump gear, tighten the fastening nut to 64 Nm.
B. Parasitic gear.
A) Lubricate the idle gear shaft with engine oil.
b) Insert the shaft into the block.
V) Align label «5» parasitic gear with label «5» crankshaft gears, and the mark «4» labeled «4» injection pump drive gears.
G) Align the holes in the thrust washer with the holes in the idle gear shaft, insert the bolts and tighten them to 19 N.m.
d) Remove the idle gear pinch bolt installed earlier in assembly.
3. Installing the gear cover.
A) Install a new o-ring into the block.
b) Remove the remnants of the old sealant from the cover, carefully coat the mating surfaces of the cover and block.
V) Apply sealant to the cover as shown.
G) Tighten 13 bolts and 2 nuts to 13 Nm.
d) Attach the vacuum tube to the cover with a bolt and nut.
Tightening torque 13 N.m.
4. Checking the axial clearance on the injection pump drive shaft.
A) Temporarily secure the camshaft drive gear to the shaft.
b) By moving the gear wheel in the axial direction, measure the clearance.
Nominal gap 0.15-0.55mm
If the gap is too small, loosen the two nuts of the injection pump flange and the three bolts of the injection pump rear support and tighten them again. If this does not help, reinstall the gear cover.
5. Installation of the crankshaft pulley,
A) Align the pulley key with the groove on the shaft.
b) Press the pulley onto the shaft with hammer blows through the mandrel.
V) While holding the pulley, tighten the pulley mounting bolt to 363 Nm. Don't forget to install a washer under the bolt.
6. Vacuum pump installation
A) Install two new O-rings to the pump.
b) Tighten the two fastening nuts.
Tightening torque - 21 N.m
7. Install the rear timing belt cover, tighten the 7 mounting bolts.
Tightening torque - 9 N.m
8. Install the timing belt.
9. Install water pump pulley, fan and accessory drive belts.