Attention. It is important to degrease the crankshaft end, crankshaft sprocket bore, and drive belt pulley bearing surfaces to prevent any slippage between the timing belt and the crankshaft, which could result in engine damage.
1. Install the timing belt tensioner.
Note. Insert trunnion (1) timing belt tensioner into the groove of the cylinder head.
2. Insert TDC locating pin [KV113B0110 (Mot. 1430)] (A) into the camshaft pulley and cylinder head bore.
3. Make sure the label (2) high pressure fuel pump gear pulley is offset one tooth to the right of the vertical axis.
4. Rotate the crankshaft to insert the TDC locating pin [KV113B0110 (Mot. 1430)] (crankshaft groove (1) must be directed upward).
5. Tighten the old crankshaft pulley bolt with spacer (1), so that the toothed pulley mark does not overlap.
6. Insert TDC locating pin [KV113B0130 (Mot. 1430)] into the crankshaft.
7. Remove one bolt from the camshaft sprocket, and then loosen the other two bolts (1).
8. Install the timing belt, aligning the marks on the belt with the marks on the camshaft pulleys and the high pressure fuel pump (between the marks of the toothed pulleys there must be 19 teeth of the timing belt).
9. Using a 6 mm Allen key, move the movable pointer (F) drive belt tensioner to the position shown in the figure by turning the key counterclockwise.
10. Tighten the timing belt tensioner bolt to 27.0 Nm.
11. Make sure that the camshaft sprocket bolts do not rest all the way into the camshaft pulley grooves.
12. Install and tighten the camshaft sprocket bolts to 14.0 Nm.
13. Remove the TDC locating pin [KV113B0130 (Mot. 1489)] and TDC locating pin [KV113B0110 (Mot. 1430)].
14. Turn the crankshaft two turns clockwise (when viewed from the side of the pulleys). Directly opposite the hole (A) camshaft pulley has a hole (IN) in the cylinder head. Insert TDC locating pin [KV113B0130 (Mot. 1489)] into the cylinder block.
15. After that, slowly and smoothly turn the crankshaft until it stops against the TDC locating pin.
16. Insert TDC locating pin [KV113B0110 (Mot. 1430)] (A). If the pin cannot be inserted, do the following:
Remove TDC locating pin [KV113B0130 (Mot. 1489)]
Loosen the camshaft sprocket bolts.
Turn the camshaft pulley to adjust.
Make sure the crankshaft sprocket groove is pointing up.
Loosen the timing belt tensioner bolt.
Move the movable pointer of the drive belt tensioner to the position shown in the figure, as shown in the figure, by turning the key clockwise.
Tighten the toothed belt tensioner bolt to 27.0 Nm.
Install and tighten the camshaft sprocket bolts to 14.0 Nm.
Rotate the crankshaft two turns clockwise (when viewed from the side of the pulleys). Directly opposite the hole (A) camshaft pulley has a hole (IN) in the cylinder head, insert the TDC locating pin [KV113B0130 (Mot. 1489)] into the cylinder block.
Slowly and smoothly turn the crankshaft until it stops at the TDC locating pin.
17. Install the crankshaft pulley and tighten the bolt (1) torque 120 Nm.
18. Turn the bolt 95 degrees clockwise.
Attention. Check the angle of rotation using a special tool (KV1Q112100) or goniometer. Stretching is not recommended "approximately".
19. Remove TDC dowel pins [KV113B0130 (Mot. 1489)] and [KV113B0110 (Mot. 1430)].
20. Apply sealant to the threads of the TDC test plug.
21. Tighten the screw plug of the TDC test hole to 20 Nm.
22. Install suspension bracket (1) cylinder head and tighten the mounting bolts to 21 Nm.
23. Install the timing cover by placing the bar (M) into the hole (N) the inner cover of the timing gear drive.
24. Further installation is carried out in the reverse order of removal.