| Timing Belt, Remove and Install | |||
|---|---|---|---|
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
1. Disconnect battery negative lead
Release screw cap terminal (1)
| .P. S0005029.tif | 9 | 7,5 | tiff;; |
2. Remove heater air intake
Release 2x clip (1)
| .P. S0005034.tif | 9 | 7,5 | tiff;; |
3. Remove top cover (1) for timing belt
Pull off
Disconnect fuel return pipe clip
| .P. S0005030.tif | 9 | 7,5 | tiff;; |
4. Remove top right cover for timing belt
Remove 3x bolt
| .P. S0005031.tif | 9 | 7,5 | tiff;; |
5. Set No.1 cylinder to TDC
Note: No.1 cylinder is next to flywheel.
Rotate crankshaft clockwise and set No.1 cylinder at TDC
Remove blanking plug (arrowed) from cylinder block
| Fully install Crankshaft Positioning Pin KM-6031 | |||
|---|---|---|---|
| .P. T3046.tif | 9 | 7,5 | tiff;; |
| 6. Check valve timing and injection pump marks for alignment | |||
| .P. T3054.tif | 9 | 7,5 | tiff;; |
7. Remove lower cover for timing belt
Note: Illustration shows, Lower cover removed for clarity
| Remove 4x bolt (1) | |||
|---|---|---|---|
| .P. S0005032.tif | 9 | 7,5 | tiff;; |
8. Remove engine access panel from inside vehicle
Remove 3x plastic cover
Remove 3x nut
9. Remove Crankshaft Positioning Pin KM-6031
| Important: Do not use positioning pin to release crankshaft bolts | |||
|---|---|---|---|
| .P. T3057.tif | 9 | 7,5 | tiff;; |
10. Lock crankshaft
Rotate crankshaft clockwise until slot in flywheel appears at opening (1) in clutch housing
| Use suitable tool to lock flywheel | |||
|---|---|---|---|
| .P. S0005137.tif | 9 | 7,5 | tiff;; |
| 11. Release tension on ribbed V - belt – see operation “Ribbed V-belt Tension, Check and Adjust” |
12. Release crankshaft pulley bolt (1)
Remove locking tool from flywheel
13. Set No.1 cylinder at TDC
Fully install Crankshaft Positioning Pin KM-6031
| 14. Remove crankshaft pulley and ribbed V-belt | |||
|---|---|---|---|
| .P. S0005063.tif | 9 | 7,5 | tiff;; |
15. Release timing belt tensioner (1)
16. Remove timing belt (2)
| .P. T3064.tif | 9 | 7,5 | tiff;; |
|---|---|---|---|
| .D. ICON05.tif | 0,75 | 0,75 | tiff;; Install, Connect |
17. Install new timing belt
| Align timing marks for camshaft and injection pump Check directional arrows on timing belt | |||
|---|---|---|---|
| .P. T3063.tif | 9 | 7,5 | tiff;; |
18. Adjust tensioner (1)
Check tension of belt (2) 7.8mm (cold) under load (30 Nm)
| Secure bolt for tensioner roller (50 Nm) | |||
|---|---|---|---|
| .P. T3064.tif | 9 | 7,5 | tiff;; |
19. Remove Crankshaft Positioning Pin KM-6031
| Install blanking plug (arrowed) to crankcase | |||
|---|---|---|---|
| .P. T3046.tif | 9 | 7,5 | tiff;; |
20. Install crankshaft pulley, ribbed V–belt
Loosely install pulley bolt (1)
Rotate crankshaft clockwise, two revolutions
| Check timing marks for camshaft and injection pump | |||
|---|---|---|---|
| .P. S0005063.tif | 9 | 7,5 | tiff;; |
21. Rotate crankshaft until slot in flywheel appears at opening (1) in clutch housing
| 22. Install suitable locking tool to flywheel | |||
|---|---|---|---|
| .P. S0005137.tif | 9 | 7,5 | tiff;; |
| 23. Secure crankshaft pulley bolt (1) (20 Nm + 115) | |||
| .P. S0005063.tif | 9 | 7,5 | tiff;; |
24. Remove locking tool from flywheel
| 25. Tension ribbed V–belt – see operation “Ribbed V–belt, Check and Adjust” |
26. Install engine access panel
Install 3x nut
| Install 3x plastic cover | |||
|---|---|---|---|
| .P. T3057.tif | 9 | 7,5 | tiff;; |
27. Install lower cover for timing belt
| Install 4x bolt (1) | |||
|---|---|---|---|
| .P. S0005032.tif | 9 | 7,5 | tiff;; |
28. Install top right cover for timing belt
| Install 3x bolt (1) | |||
|---|---|---|---|
| .P. S0005031.tif | 9 | 7,5 | tiff;; |
29. Install top cover (1) for timing belt
| Push fit | |||
|---|---|---|---|
| .P. S0005030.tif | 9 | 7,5 | tiff;; |
30. Install heater air intake
| Secure 2x clip (1) | |||
|---|---|---|---|
| .P. S0005034.tif | 9 | 7,5 | tiff;; |
31. Connect battery negative lead
| Install screw cap terminal (1) | |||
|---|---|---|---|
| .P. S0005029.tif | 9 | 7,5 | tiff;; |
| 32. Program all volatile memories |