- remove covers 3, 5 and 6 (pic. 9-29) timing drive;
- securely fix the flywheel with tool OUT0000049;
- loosen the crankshaft pulley bolts;
- remove the crankshaft pulley;
- securely fix the flywheel with tool OUT0000015;
- fix the camshaft and fuel pump pulleys with set bolts (tighten bolts by hand only);
- loosen nut 2 and bolt 4 (pic. 9-30);
- insert special key (square 10 mm) into the square-shaped hole 5 and turn the bracket clockwise to remove the spring 6;
- tighten bolt 4;
- remove the belt.
Pic. 9-29. Removal and installation of gas distribution mechanism covers:
1 - bolts for fastening the bottom cover; 2 - nut; 3 - bottom cover; 4 - bolts for fastening the left cover; 5 - left cover; 6 - right cover; 7 - bolt.
Pic. 9-30. Removal and installation of the timing belt:
1 - plunger; 2 - nut; 3 - tensioner roller; 4 - bolt; 5 - square hole; 6 - spring; 7 - fixed roller.
Install the timing belt in the following order:
- make sure that the flywheel, the camshaft pulleys and the fuel pump are in the installation position and fixed, the fixed roller 7 and the tensioner roller 3 rotate freely, that the plunger 1 and the spring 6 are free in the tensioner housing;
- install the belt, keeping it taut;
- wrap the belt around the pulleys and rollers in the following order: crankshaft pulley, fixed pulley 7, fuel pump pulley, camshaft pulley, belt tensioner, water pump;
- loosen bolt 4 to release the tensioner;
- remove the mounting bolts and the flywheel retainer;
- tighten bolt 4 and nut 2;
- make two turns of the crankshaft clockwise.
Tension check:
- tighten the set bolts and install the flywheel retainer;
- loosen bolt 4 and nut 2 to distribute the tension along the entire belt;
- tighten bolt 4 and nut 2 to 18 Nm;
- install the crankshaft pulley;
- coat bolt 20 with LOCTITE 243;
- fix the flywheel securely with tool OUT0000049;
- install the bolt and washer and tighten it to a torque of 40 Nm, then tighten it by 60°C;
- install bottom cover 3 (see fig. 9-29) and tighten with bolts 1 to 15 Nm;
- install cover 5, tighten with bolt 4 to 15 Nm;
- tighten the right cover 6 with bolt 7 to 10 Nm.
Note. If it is not possible to install at least one of the set bolts or the retainer, then repeat the entire procedure to install the belt.