Withdrawal
1. Remove the accessory drive ribbed belt (see relevant chapter).
2. Remove the cap from the oil filler neck.
3. Turn the crankshaft in the direction of engine rotation by the central pinion bolt until the inscription appears in the oil filler hole «FROM» (top dead center) on the camshaft (see illustration).
2.3. Turn the crankshaft in the direction of engine rotation by the central pinion bolt until the inscription appears in the oil filler hole «FROM» (top dead center) on the camshaft
4. Unscrew a carving stopper on the block of cylinders approximately at the level of the average cylinder.
5. Replace the plug with a locking pin, catalog number 3242 (see illustration). Make sure that the pin goes into the hole on the cheek of the crankshaft and stops the shaft.
2.5. Replace the plug with a locking pin, catalog number 3242
6. Unscrew bolts of fastening of a broad tank of a cooling liquid (see arrows 1 in the illustration).
2.6. Remove the coolant expansion tank bolts (see arrows 1)
7. Disconnect the plug of the coolant level sensor at the bottom of the expansion tank and move the tank away from the place of work without disconnecting the hoses from it 2 (see illustration 2.6).
8. Unscrew the bolts 1 for fastening the vacuum pump and turn the pump on the front side of the left cylinder head to the left (see arrow in illustration).
2.8. Unscrew the bolts 1 for fastening the vacuum pump and turn the pump on the front side of the left cylinder head to the left (see arrow)
9. Remove the vacuum pump by pushing it back and without disconnecting the low pressure hoses from it.
10. Disconnect the plug 1 of the mass air flow sensor, then loosen the clamp 2 fastening the air supply duct to the air filter housing (see illustration).
2.10. Disconnect the plug 1 of the mass air flow sensor, then loosen the clamp 2 fastening the supply air duct to the air filter housing
11. Disconnect the hose 3, unscrew the bolt 4 and remove the air filter (see illustration 2.10).
12. Unscrew the fastening nut, remove the fuel filter from the bracket and move it away from the place of work without disconnecting the fuel lines from it.
13. Unscrew the mounting bolts (see arrows in illustration) and remove the air duct connecting the turbocharger and intercooler on the right cylinder head.
2.13. Unscrew the fastening bolts (see arrows) and remove the air duct connecting the turbocharger and intercooler on the right cylinder head
14. Remove the covers that cover the ends of the camshafts by prying off the covers with a screwdriver (see arrow in illustration).
2.14. Remove the covers that cover the ends of the camshafts by prying off the covers with a screwdriver (see arrow)
Attention! Covers are damaged when removed and must therefore be replaced after each disassembly. Be careful not to damage the seating surface of the cover on the cylinder head.
15. Insert the lock plates, catalog number 3458, into the grooves on the ends of the camshafts of both cylinder heads, and connect the chains to them to prevent the plates from falling out (see illustration). If there are no such stoppers, then use suitable rulers 40 mm wide and 5 mm thick, or make the plates yourself.
2.15. Insert the lock plates, catalog number 3458, into the grooves on the ends of the camshafts of both cylinder heads, and connect the chains to them to prevent the plates from falling out
Attention! The said locking plates cannot be used as a stop to keep the shafts from turning when the camshaft gear bolts are unscrewed.
16. Unscrew the bolts 1 and remove the vibration damper from the injection pump gear (see illustrations 2.16 and 2.16a).
2.16. Unscrew the bolts 1 and remove the vibration damper from the injection pump gear
2.16a. High pressure fuel pump drive (injection pump):
1 - radiator fan bracket with viscous coupling
2 - nut for fastening the tension roller of the timing belt of the injection pump drive. Tightening torque - 36 Nm
3 - bolt for fastening the vibration damper of the injection pump gear. Tightening torque - 22 Nm
4 - vibration damper
5 - toothed drive belt injection pump
6 - high pressure fuel pump (injection pump)
7 - gear wheel injection pump
8 - gasket washer
9 - bolt for fastening the gear of the injection pump. Tightening torque - 22 Nm
10 - tension roller for the timing belt of the injection pump drive
Attention! Do not unscrew nut 2 (see illustration 2.16), as this can lead to a violation of the basic adjustment of the injection pump. Subsequent adjustment of the injection pump is not possible even in a workshop.
17. Mark with chalk, marker or paint the direction of travel of the injection pump drive timing belt if it is to be reinstalled. Failure to follow the previous course of the toothed belt during its further operation leads to its damage or rupture.
18. Loosen the injection pump drive timing belt by turning the pulley with a socket wrench and remove the injection pump drive timing belt from the camshaft gear (see illustration).
2.18. Loosen the tension of the injection pump drive timing belt by turning the pulley with a socket wrench and remove the injection pump timing timing belt from the camshaft gear
19. Unscrew eight bolts 1 and remove the accessory drive belt pulley from the crankshaft. The central bolt 2 is attached to the crankshaft, the timing gear is attached, therefore, when removing the belt pulley, it is not necessary to unscrew the central bolt (see illustration).
2.19. Unscrew eight bolts 1 and remove the accessory drive belt pulley from the crankshaft. The central bolt 2 does not need to be unscrewed
20. Remove the lower part 4 of the protective cover of the timing drive (see illustration).
2.20. Remove the lower part 4 of the protective cover of the timing drive
21. Remove bolts 1, 2 and 3 and remove the viscous fan mounting bracket (see illustration 2.20). On the same bracket are guide rollers.
22. Remove the three bolts (see arrows in illustration) and remove gear 1, from which the injection pump is driven by a toothed belt.
2.22. Remove three screws (see arrows) and remove the gear wheel 1 of the injection pump drive
23. Loosen the bolts securing the camshaft gears to their hubs, holding the gears from turning with a special tool, catalog number 3036 (see illustration).
2.23. Loosen the camshaft gear bolts, holding them from turning with a special tool, catalog number 3036
Attention! It is not necessary to completely unscrew the camshaft gear mounting bolts.
24. Slowly turn the toothed belt tensioner with an 8 mm Allen key to the right (see arrow in illustration) so that the tensioner plunger enters the body and the holes on the body and plunger are aligned. Insert a suitable pin into the aligned holes, for example, the pin, the catalog number of which is T40011, thereby fixing the plunger in the tensioner body.
2.24. Slowly turn the toothed belt tensioner with an 8 mm Allen key to the right (see arrow) so that the tensioner plunger enters the body and the holes on the body and plunger are aligned. Insert the T40011 pin into the aligned holes
Attention! The timing belt tensioner has an oil-filled plunger and therefore the plunger should be pressed into the tensioner body slowly with uniform force. Excessive force may damage the idler pulley.
25. Remove the gear together with the toothed belt from the camshaft hub of the left cylinder head using a suitable two-jaw puller, for example, a T40001 puller, resting its bolt against the central hub mounting bolt (see illustration).
2.25. Remove the gear together with the toothed belt from the camshaft hub of the left cylinder head using the T40001 two-jaw puller, resting its bolt on the central hub mounting bolt
26. Remove the timing belt from the gears and idlers.
Installation and adjustment
27. Lay the toothed belt on the crankshaft gear, then on the camshaft gear of the right cylinder head, tension and guide rollers and the water pump.
28. Lay the toothed belt on the removed camshaft gear of the left cylinder head, and then put the gear together with the belt on the shaft hub and screw in the gear mounting bolts (see illustration).
2.28. Laying direction of timing belt
Attention! The final tightening of the bolts for fastening the camshaft gears to the hubs should not be performed at this stage. Their tightening should be such that the gears can be turned, but they should not move on the hubs in the axial direction.
29. Turn the tension roller with a socket wrench 8 mm to the right (see arrow in illustration) so that you can remove the pin T40011, which fixed the tensioner plunger.
2.29. Turn the tension roller with a socket wrench 8 mm to the right (see arrow) so that you can remove the pin T40011, which fixed the tensioner plunger
30. Tension the toothed belt by turning the eccentric of the tension roller with a torque wrench with a force of 15 Nm counterclockwise and in this position of the eccentric tighten the roller fastening bolt (see illustration).
2.30. Tension the toothed belt by turning the tensioner eccentric with a torque wrench with a force of 15 Nm counterclockwise
31. Perform the final tightening of the camshaft gear bolts, holding them from turning with a tool, catalog number 3036 (see illustration).
2.31. Complete the final tightening of the camshaft gear bolts, holding them from turning with a tool, catalog number 303S
32. Replace and secure with bolts 1-4 (see illustration 2.20) viscous fan mounting bracket. Tightening torques: bolt 1-45 Nm, bolt 2-10 Nm, bolt Z-22 Nm, bolt 4-10 Nm.
33. Lock the injection pump gear with a thrust roller, catalog number 3359, by inserting it into the hole on the gear and the corresponding hole on the cylinder block (see illustration). If there is no such thrust roller, then use a punch of a suitable diameter and length.
2.33. Lock the injection pump gear with a thrust roller, catalog number 3359, by inserting it into the hole on the gear and the corresponding hole on the cylinder block
34. Install gear 1 of the injection pump timing belt on the camshaft of the left cylinder head and secure it with three bolts (see arrows in illustration). Do not final tighten the bolts at this stage.
2.34. Install gear 1 of the injection pump timing belt on the camshaft of the left cylinder head and secure it with three bolts (see arrows)
35. Turn the gear on the camshaft so that the bolts of its fastening are located in the center of their longitudinal holes.
36. Lay the injection pump drive timing belt. If the old belt was installed, then observe the direction of its course.
37. Turn the injection pump timing belt tensioner counterclockwise until the arrows align (see illustration).
2.37. Turn the injection pump timing belt tensioner counterclockwise until the arrows align 1
38. Remove the locking devices that were used to lock the camshafts, the injection pump drive gear and remove the lock pin 3242 that was used to lock the crankshaft (see illustration).
2.38. Remove lock pin 3242 which was used to lock the crankshaft
39. Turn the crankshaft in the direction of engine rotation and set the cylinder piston to TDC. Lock the crankshaft again by inserting the lock pin 3242 into the appropriate hole on the cylinder block (see illustration 2.38).
40. Verify that the camshafts can be blocked using the stoppers 3458 (see illustration). Otherwise, repeat the toothed belt tension adjustment.
2.40. Make sure the camshafts can be locked using the 3458 stoppers
41. Remove all locking devices that were used to block the camshafts and crankshafts.
42. Make sure that the tension of the injection pump drive timing belt is correct: arrows 1 and 2 of the tension roller must be aligned (see illustration).
2.42. Make sure arrows 1 and 2 of the injection pump timing belt tensioner are aligned
43. Install the vibration damper, the gears of the injection pump drive timing belt.
44. Install the ribbed belt pulley. The locking tab of the pulley must be positioned as shown in the illustration (see arrow).
2.44. The locking tab of the ribbed pulley must be positioned as shown (see arrow)
45. Screw the plug into the hole on the cylinder block, into which the locking pin was installed to fix the crankshaft, pre-seal the plug with a new one. The tightening torque of the plug is 10 Nm.
46. Install a vacuum pump on the left cylinder head.
47. Install the camshaft covers (see arrow in illustration) on the right and left cylinder heads.
2.47. Install the camshaft covers (see arrow) for right and left cylinder heads
Further, the installation of the dismantled components is carried out in the reverse order of removal.
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