Table of contents: Removal ↓ Installation ↓
Removal
Turn the crankshaft in the direction of working rotation using the pulley mounting bolt until the piston of the fifth cylinder is at TDC of the compression stroke.
Remove the poly V-belt.
Release the wires from the clamps on the radiator fan shroud, unscrew the mounting screws and remove the electric radiator fan.
Take it off vibration damper from the crankshaft pulley.
Remove the front timing belt covers.
Fig. 3.4–27. Toothed belt covers: 1 – casing; 2 – bolt, 22 Nm; 3 – vibration damper with poly V-belt pulley; 4 – lower casing plug; 5 – bolt, 10 Nm; 6 – rubber bushing; 7 – casing; 8 – mounting sleeve; 9 – front right casing; 10 – front left casing; 11 – lower casing; 12 – bolt, 10 Nm
Fig. 3.4–29. Using special tool 3036 to prevent the camshaft pulley from turning
Alternately, using special device 3036 (Fig. 3.4–29), fix the camshaft pulley from turning and unscrew it three turns (but don't unscrew it completely) camshaft pulley mounting bolt.
Fig. 3.4–30. Releasing the toothed belt tension and fixing the tensioning mechanism with the T40011 device
Using an 8 mm socket wrench, turn the tension roller counterclockwise and secure it in this position using the T40011 tool (Fig. 3.4–30).
Use chalk, marker or paint to mark the direction of rotation of the timing belt. If a used timing belt is installed and rotated in the opposite direction, it will be damaged.
Fig. 3.4–31. Location of the eccentric roller mounting bolt
Loosen the eccentric roller mounting bolt (Fig. 3.4–31).
Fig. 3.4–32. Using the T40001 puller to remove the timing belt pulley from the camshaft
Using the T40001 puller (Fig. 3.4–32), remove both camshaft pulleys from their mounting cones. When removing the pulleys, the puller should rest against the camshaft pulley mounting bolts. The camshaft pulleys should rotate freely, but not dangle on their mounting cones.
Remove the bolt securing the right camshaft pulley and remove the toothed belt together with the pulley.
Installation
Fig. 3.4–28. Toothed belt: 1 – bushing; 2 – bolt, 45 Nm; 3 – tension roller washer; 4 – bolt, 45 Nm; 5 – tension roller; 6 – tension roller lever; 7 – bolt, 70 Nm; 8 – washer; 9 – bolt, 75 Nm; 10 – pulley of the toothed belt of the intake camshaft; 11 – bolt, 22 Nm; 12 – bolt, 10 Nm; 13 – rubber bushing; 14 – bolt, 10 Nm; 15 – rear right timing belt cover; 16 – bolt, 22 Nm; 17 – high pressure fuel pump; 18 – toothed belt; 19 – water pump; 20 – gasket; 21 – bolt, 10 Nm; 22 – toothed belt cover rear left; 23 – bolt, 10 Nm; 24 – exhaust camshaft timing belt pulley; 25 – washer; 26 – bolt, 75 Nm; 27 – guide roller; 28 – roller with eccentric; 29 – bolt, 45 Nm; 30 – crankshaft timing belt pulley; 31 – bolt, 200 Nm + turn further by 180°; 32 – tension lever washer; 33 – Timing belt tensioner; 34 – bolt, 10 Nm
When installing the toothed belt, use a new gasket 20 (see Fig. 3.4–28) and bolt 31.
Check that the position of the camshafts is fixed with locking pins 3458 and the crankshaft is fixed with set screw 3242.
The camshaft pulleys must turn freely.
Install the toothed belt on the pulleys in the following sequence:
- crankshaft;
- tension roller;
- eccentric roller;
- left camshaft;
- high pressure fuel pump;
- guide roller;
- water pump;
- right camshaft pulley, then install the pulley on the camshaft.
Fig. 3.4–33. Installing a 4 mm Allen key between the tension roller lever (1) and the tension mechanism (2)
Insert a 4 mm Allen key between the tensioner mechanism and the tension roller lever (Fig. 3.4–33).
Fig. 3.4–34. Using the special tool T4009 to tension the toothed belt by turning the roller with an eccentric
Using a special tool that fits into two holes in the eccentric roller, turn the roller counterclockwise to a torque of 3 N·m and in this position tighten the roller mounting bolt to a torque of 45 N·m (Fig. 3.4–34).
Remove the Allen key located between the tensioner mechanism and the tension roller lever.
Using an 8 mm socket wrench, turn the timing belt tension roller counterclockwise and make sure that the T40011 tool can be installed in this position (see Fig. 3.4–30).
Fig. 3.4–35. Turning the tension roller lever (1) to remove the 4 mm Allen key from the tensioner mechanism (2)
Using an 8 mm socket wrench, turn the timing belt tension roller clockwise, remove the Allen key located between the tensioner mechanism and the tension roller lever, and check that the tensioner mechanism plunger presses the tension roller lever (Fig. 3.4–35).
Tighten the camshaft pulley mounting bolts, holding the pulleys from turning with tool 3036.
Fig. 3.4–36. Location of camshaft positioning pin 3458
Remove the 3242 set screw and 3458 locks and turn the crankshaft two revolutions, set it to the TDC position of the fifth cylinder of the compression stroke and check the installation of the crankshaft and camshafts. To check the position of the crankshaft, unscrew the plug from the cylinder block and screw in the 3242 set screw instead. To check the position of the camshafts, install the 3458 locks that fix the positions of the camshafts (Fig. 3.4–36). If the 3242 set screw and 3458 locks are installed, then the crankshaft and camshafts are installed correctly.
Further installation is carried out in the reverse order of removal, taking into account the following.
Install a vacuum pump on the left cylinder head.
Install the poly V-belt.
Fill the cooling system with coolant.
Note:
Fig. 3.4–37. Front and rear cylinder block covers: 1 – sealing ring; 2 – threaded plug, 22.5 Nm; 3 – sealing ring; 4 – front cover; 5 – thrust ring; 6 – gasket; 7 – back cover with sealing ring; 8 – centering sleeve; 9 – support washer; 10 – leading disk; 11 – washer; 12 – bolt, 60 Nm + turn further by 180°; 13 – bolt, 10 Nm; 14 – gasket; 15 – bolt, 10 Nm
When installing, it is necessary to use new sealing ring 3 (Fig. 3.4–37), gaskets 6, 14 and bolts 12.