Recommendation: If the belt is replaced before the belt warning light comes on (the lamp turns on after one hundred thousand kilometers), then it is necessary to reset the belt counter readings, which is part of the speedometer, to zero.
1. Remove the drive belts of the attachments.
2. Remove the water pump pulley (see the relevant section).
3. Remove the glow plugs.
a) Remove the plastic protective caps.
b) (Only for fixed delay preheating system). Remove the four bolts and the glow plug wire.
c) For other types of preheating system.
a) Remove the four glow plug wire mounting nuts.
b) Remove the nut securing the glow plug wire to the intake manifold.
c) Remove the two heat-insulating elements and the glow plug wire.
d) Using a socket wrench, remove the four glow plugs.
4. Remove the crankshaft pulley.
a) Using a special tool, unscrew the pulley bolt.
b) Using a puller, remove the pulley.
5. Remove the front timing belt cover.
Remove the eleven bolts, washers, timing belt cover, two gaskets and TDC indicator plug.
6. Remove the timing belt guide.
7. Set the piston of the first cylinder to TDC.
a) Temporarily install the crankshaft pulley bolt. Turn the shaft by the bolt until TDC of the first cylinder.
b) Check the alignment of the marks located on the camshaft pulley and the rear timing belt cover. If the marks are not aligned, turn the crankshaft one revolution (360°).
8. Remove the timing belt.
Recommendation: If the belt is to be reused, apply a rotation direction arrow to the belt and alignment marks to the belt and pulleys.
a) Loosen the bolt (A) of tension pulley No.1, move it to the left as far as possible.
b) Temporarily tighten the pulley bolt (A).
c) Remove the timing belt.
9. Remove tension pulley No.1.
a) Remove two bolts (A and B).
b) Loosen bolt (C), remove bolt, tension roller and spring.
10. Remove the camshaft pulley.
a) Using a special tool, unscrew the pulley bolt.
b) Using a puller, remove the pulley and key.
11. Remove the fuel injection pump drive pulley.
a) Using a special tool, unscrew the pulley bolt.
b) Using a puller, remove the drive pulley.
12. Remove tensioner pulley #2. Remove the bolt, tensioner pulley and spacer sleeve.
13. Remove the crankshaft pulley using a puller.
