Note: Be sure to replace the timing belt, toothed belt tensioner with bolt and crankshaft pulley bolt with new ones.
1. Install a new timing belt tensioner pulley.
2. Insert the foot (14) timing belt tensioner pulley into the groove of the cylinder head (15).
3. Make sure the label (18) high pressure fuel pump toothed pulley is opposite the mounting hole (19).
4. Make sure that the crankshaft rests against the TDC locating pin (Mot. 1489) (key (20) timing gear sprockets must point upwards).
5. Make sure that the crankshaft rests against the TDC locating pin (Mot. 1489) (21), trying to turn it over the old crankshaft pulley bolt.
6. Loosen the bolt (22) from the hub of the camshaft pulley.
7. Loosen the remaining camshaft pulley bolts one turn.
8. Install a new timing belt, starting from the crankshaft sprocket:
- Align the mark on the crankshaft sprocket with the mark on the inside of the timing belt.
- Align the outer marks on the toothed belt with the marks on the camshaft pulleys and the injection pump.
9. With 6mm Allen key (hex key) place the regulator pointer (23) tension roller opposite the groove (24), by turning the tension roller counterclockwise. Tighten tensioning roller bolt to 27 Nm.
Note: Make sure that the camshaft pulley hub bolts do not rest against the edges of the pulley grooves.
10. Install bottom bolt (25) camshaft pulley hubs.
11. Tighten the camshaft pulley hub bolts.
12. Remove TDC locating pin (Mot. 1489) and the pin from the set of dowel pins for the camshaft and crankshaft pulleys (Mot. 1430).
13. Turn the crankshaft two turns clockwise (from the timing drive) behind the old crankshaft pulley bolt to make the hole (26) camshaft pulley hub mounted against the hole (27) in the cylinder head.
14. Screw in the TDC locating pin (Mot. 1489) into the cylinder head.
15. Slowly rotate the crankshaft clockwise (from the timing drive) behind the old crankshaft pulley bolt so that the crankshaft rests against the TDC locating pin (Mot. 1489).
16. Install the camshaft pulley hub with the pin (28) from a set of dowel pins for camshaft and crankshaft pulleys (Mot. 1430).
Note:
If the dowel pin from the dowel pin kit for the camshaft and crankshaft pulleys (Mot. 1430) not inserted:
- loosen the camshaft pulley hub bolts one turn,
- using an 18 mm ring wrench, turn the camshaft pulley hub to correctly install the pulley,
- Do not tighten the camshaft pulley hub bolts.
17. Loosen the camshaft pulley hub bolts one turn.
Note: After two revolutions of the crankshaft, the idler adjuster pointer can be in two different positions. The rotation of the tension roller eccentric depends on the position of the pointer.
The first position of the index of the tension roller regulator
18. Loosen idler bolt and - one turn while holding ghoul mount pointer with 6mm Allen wrench (hex key).
19. Gradually align the timing belt tensioner adjuster pointer with the center of the setting window by turning the key counterclockwise.
The second position of the index of the tension roller regulator
20. Loosen the idler bolt one turn while holding the adjuster pointer with a 6mm Allen key (hex key).
21. Gradually align the timing belt tensioner adjuster pointer with the center of the setting window by turning the key clockwise.
General continuation
22. Tighten the timing belt tensioner bolt to 27 Nm
23. Tighten the camshaft pulley hub bolts to 14 Nm
24. Remove TDC locating pin (Mot. 1489) and the pin from the set of dowel pins for the camshaft and crankshaft pulleys (Mot. 1430).
25. Turn the crankshaft two turns clockwise (from the timing drive) behind the old crankshaft pulley bolt so that the hole / stub of the camshaft pulley aligns with hole 6 in the cylinder head.
2b. Screw in the TDC locating pin (Mot. 1489) into the cylinder block.
27. Slowly turn the crankshaft clockwise (from the timing drive) behind the old crankshaft pulley bolt so that the crankshaft rests against the TDC locating pin (Mot. 1489).
28. Install the camshaft pulley hub using the pin from the set of dowel pins for the camshaft pulley and crankshaft pulley (Mot. 1430).
29. If the pin from the set of dowel pins for the camshaft and crankshaft pulleys (Mot. 1430) not inserted, repeat the timing belt installation procedure from the beginning.
30. Apply a drop of silicone sealant to the threads of the TDC pin hole and tighten the plug to 25 Nm.
31.Install the lower timing cover by placing the bar (29) into the hole (30) inside the lid.
32. Hook the bottom cover of the timing gear.
33. Install the upper timing cover.
34. Tighten the bolt of the top cover of the timing gear.
35. Hook the top cover of the timing gear.
36. Install the crankshaft pulley and implement drive belt.
37. Install right engine mount.
38. Install the front right fender liner.
39.Install the engine protection tray.
40. Install the front right wheel.
41. Connect the battery.