Table of contents: Cars with 2.1L XUD series engines 🠇 Cars with 2.5L DK5ATE engine 🠇
Cars with 2.1L XUD series engines
1. Jack up the front of the car, place it on stands and remove the front right wheel and fender liner.
2. Disconnect the negative (-) battery terminal from the battery.
3. Remove the water pump drive belt.
4. Remove the generator drive belt.
5. Unscrew the glow plugs.
6. Place a garage jack or suitable support with a wooden block under the engine to avoid damaging the oil pan and lift the engine to relieve the weight on its mounts
7. Remove the engine mount support.
8. Remove the timing drive protective covers.
9. Engage fifth gear, apply the parking brake.
10. Turn the crankshaft in the direction of engine rotation so that the piston of cylinder No.1 is at TDC.
11. Lock the flywheel with a suitable stop shoe.
12. Lock gear 1 of the camshaft and gear 2 of the high-pressure fuel pump (HPFP) using M8x40 bolts and inserting them into the aligned holes on the gears and on the rear cover of the timing drive (see illustration).
2.12 Lock gear 1 of the camshaft and gear 2 of the fuel injection pump with M8x40 bolts
13. Loosen the tensioner roller mounting nut, carefully move the roller away from the belt, thereby loosening its tension, and remove the timing belt.
Cars with 2.5L DK5ATE engine
14. Remove the accessory drive belt to gain access to bolt 1, which secures the timing cover (see illustration).
2.14 Remove the accessory drive belt to gain access to bolt 1
Attention! Depending on the location of the roller 7(see illustration 2.14), to gain access to bolt 1, the accessory drive belt does not need to be removed (see illustration 2.14).
15. Install the stop pin "a" 0178-Q (see illustration 2.14).
16. Unscrew bolts 1 and 2 and remove protective cover 3 of the timing drive (see illustration 2.14).
17. Remove the engine protection.
18. Lock the crankshaft by installing the stop "a" 0153-N in the corresponding hole under the exhaust manifold (see illustration).
2.18 Lock the crankshaft by installing the stop "a" 0153-N in the corresponding hole under the exhaust manifold
19. Lock the camshaft gear with stop "a" 0178-A, and the fuel injection pump gear with stop "b" 0178-B (see illustration).
2.19 Lock the camshaft gear with stop "a" 0178-A, and the fuel injection pump gear with stop "b" 0178-B
20. Loosen the tension roller nut 4 and move the roller away from the toothed belt 3, thereby loosening its tension (see illustration 2.19).
21. Carefully remove the timing belt 3 (see illustration 2.19).
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22. Remove the tension roller 4 of the toothed belt, and then remove the belt 5 of the balance shafts (see illustration 2.19).