Camshaft pulley
Removing
1. Remove the upper timing belt covers as described in paragraph 6.
2. Now loosen the camshaft sprocket bolt. The camshaft must be kept from turning when loosening the sprocket bolt, and this can be done in one of two ways, as described below (pic. 8.2, a, b). Do not remove the camshaft sprocket bolt at this stage.
Pic. 8.2, a. Using a homemade tool, hold the camshaft sprocket from turning
Pic. 8.2b. Hold the camshaft with a wrench on the rectangular section between cams No. 3 and 4
A) Make a tool similar to the one shown and use it to hold the toothed pulley using the holes in the toothed pulley.
b) Remove the cylinder head cover as described in paragraph 4. Hold the camshaft from turning by holding it with a suitable wrench on the rectangular section between cams No. 3 and 4.
3. Align the engine/camshaft assembly mounting holes as described in paragraph 3 and lock the camshaft sprocket, high pressure fuel pump sprocket and flywheel. Do not attempt to crank the engine with the locking bars installed.
4. Loosen the timing belt tensioner axle nut and adjusting bolt, then turn the tensioner bracket counterclockwise to release the tension and tighten the adjusting bolt again to hold the tensioner in the released position. To rotate the tensioner bracket against the force of the spring, use a 10mm square-head wrench to be inserted into the hole provided. Remove the timing belt from the toothed pulley.
5. Turn out previously released bolt of fastening of a gear pulley of a camshaft and remove it together with a washer.
6. Turn out a bolt of blocking of a toothed pulley of a camshaft in the TDC position.
7. Remove the toothed pulley from the end of the camshaft (pic. 8.7). If the dowel pin on the back of the toothed pulley is loose, remove it and store it in a safe place. Inspect the camshaft seal for signs of oil leakage and replace if necessary as described in paragraph 16.
Pic. 8.7. Removing the camshaft pulley
Installation
8. If applicable, install the key on the end of the camshaft and then install the camshaft sprocket. Please note that the toothed pulley can only be mounted on one side (protruding central hub to the camshaft), because the end of the camshaft is tapered.
9. Screw in a bolt of fastening of a toothed pulley (don't forget to install the washer). Tighten the bolt to the specified torque, preventing the camshaft from turning as if removed.
10. If applicable, install the cylinder head cover as described in paragraph 4.
11. Align the holes in the camshaft sprocket and engine front plate and screw in the 8mm bolt to lock the camshaft.
12. Put the timing belt on the gear pulley of the high pressure fuel pump (if applicable) and the camshaft sprocket and tighten the timing belt as described in paragraph 7.
13. Install the upper timing belt covers as described in paragraph 6.
Crankshaft pulley
Removing
14. Remove the crankshaft pulley as described in paragraph 5.
15. Continue as described in paragraphs 3 and 4.
16. Remove the timing belt from the crankshaft sprocket and remove the sprocket from the end of the crankshaft (pic. 8.16).
Pic. 8.16. Removing the crankshaft sprocket
17. Remove the segment key from the groove on the crankshaft and store it in a safe place along with the toothed pulley (pic. 8.17).
Pic. 8.17. Removing the key from the end of the crankshaft
18. Inspect the crankshaft seal for signs of oil leakage and, if necessary, replace it as described in paragraph 16.
Installation
19. Install the keyway into the groove at the end of the crankshaft, and then install the crankshaft sprocket (flange towards the cylinder block).
20. Place the timing belt on the crankshaft sprocket and tighten the timing belt as described in paragraph 7. Install the timing belt covers as described in paragraph 6.
21. Install the crankshaft pulley as described in paragraph 5.
High pressure fuel pump sprocket
Removing
22. Follow the steps described in paragraphs 1.3 and 4.
23. Mark the relative position of the high pressure fuel pump sprocket and timing belt to properly align the sprocket and timing belt during installation.
24. Turn out bolts of 8 mm of fixing of a gear pulley of the high pressure fuel pump in the TDC position.
25. On some models, the sprocket may be equipped with an integral puller, which is a plate bolted to the sprocket. Plate contains a cage nut (toothed pulley nut), which is screwed into the shaft of the high pressure fuel pump. On models not equipped with a built-in puller, the corresponding puller can be made from a short metal plate and two M7 bolts that are screwed into the holes provided in the toothed pulley.
26. The shaft of the high pressure fuel pump should be kept from turning when unscrewing the nut of the toothed pulley, and this can be ensured using a tool similar to the one shown (pic. 8.26). Use a tool to hold the toothed pulley in the holes provided in the pulley.
Pic. 8.26. Use a homemade tool to prevent the high pressure fuel pump sprocket from turning
27. On models with a built-in puller, loosen the sprocket retaining nut until the sprocket is off the taper on the pump shaft, then remove the sprocket. Remove the key from the slot on the end of the pump shaft if it is not secured. If desired, the puller assembly can be removed from the toothed pulley by unscrewing the two screws and removing them together with the washers.
28. On models not equipped with a built-in puller, partially unscrew the nut securing the toothed pulley, and then install a homemade puller and tighten the two bolts (tightening the bar to the toothed pulley nut) so that the toothed pulley comes off the cone on the pump shaft (pic. 8.28). Remove the toothed pulley and remove the segment key from the groove on the pump shaft if it is not secured. Remove the puller from the toothed pulley.
Pic. 8.28. Homemade puller mounted on the gear pulley of the high pressure fuel pump
Installation
29. If applicable, fit the key into the groove on the pump shaft, making sure it is properly seated in the groove.
30. If built-in puller (if available) was removed from the toothed pulley, install it and tighten the two screws to the prescribed torque. Don't forget to install washers.
31. Install the toothed pulley, then tighten the nut to the specified torque, keeping the pump shaft from turning as in removal.
32. Make sure the 8mm bolts are inserted into the camshaft and high pressure fuel pump sprockets and the rod/drill is inserted into the pilot hole in the flywheel.
33. Put the timing belt on the high pressure fuel pump gear pulley, ensuring that the marks made on the belt and the gear pulley are aligned before removal.
34. Tighten the timing belt (see paragraph 7).
35. Install the upper timing belt covers as described in paragraph 6.
Coolant pump sprocket
36. The coolant pump sprocket is integrated with the pump and cannot be removed.