Diesel engine timing gear drive
- 1 - mounting clip;
- 2 - the upper casing of the toothed belt;
- 3 - toothed belt. Before removing the toothed belt, it is necessary to put an arrow on it indicating the direction of the toothed belt;
- 4 - nut, 20 Nm;
- 5 - eccentric;
- 6 - tension roller of the toothed belt;
- 7 - bolt, 45 Nm;
- 8 - camshaft pulley;
- 9 - bolt, 25 Nm;
- 10 - guide roller;
- 11 - bolt, 10 Nm;
- 12 - rear casing of the toothed belt;
- 13 - fuel pump;,
- 14 - bracket;
- 15 - console;
- 16 - fuel pump pulley;
- 17 - nut, 55 Nm;
- 18 - fuel pump pulley of two sections;
- 19 - intermediate shaft pulley;
- 20 - crankshaft toothed belt pulley;
- 21 - crankshaft pulley mounting bolt, 90 Nm + tighten by 90°;
- 22 - bolts for fastening the composite pulley of the high-pressure fuel pump, 20 Nm + tighten by an angle of 90°. At installation it is necessary to use new bolts;
- 23 - lower casing of the toothed belt;
- 24 - vibration damper/auxiliary drive belt pulley. The pulley can only be installed in one position after the holes are aligned.
All operations for removing and installing a toothed belt on a diesel engine are similar to the operations for removing and installing a toothed belt on four-cylinder gasoline engines. The rest of this subsection describes operations that are unique to 1.9-I-TDI engines.
Tool required for fixing the camshaft of diesel engines
Order of execution
1. Using a wrench, turn the poly V-belt tensioner counterclockwise to the stop and in this position of the roller, remove the upper timing belt cover.
2. Turn the crankshaft of the engine to the position of setting the piston of the first cylinder to the top dead center.
3. To block the camshaft and the high pressure fuel pump pulley in the TDC position of the piston of the first cylinder in the compression stroke, it is necessary to use special blocking tools, see fig. A device necessary for fixing the camshaft of diesel engines.
4. Install the locking tool into the groove in the end of the camshaft.
5. With the locking tool installed in the camshaft, rotate the camshaft (turning the crankshaft clockwise) so that one side of the locking tool is pressed against the surface of the cylinder head. Using a feeler blade, measure the clearance between the second end of the locking tool and the cylinder head. Turn the camshaft slightly back and on both sides between the blocking tool and the cylinder head, install two feelers with a thickness equal to half the previously measured clearance.
6. Through the hole in the clutch housing, check that the TDC mark on the flywheel is aligned with the pointer.
Engines with monobloc fuel pump pulley
PROCEDURE
1. Insert the lock pin through the high pressure fuel pump pulley mounting hole into the hole in the bracket behind the fuel pump pulley.
2. The blocking pin can be made independently according to the dimensions in fig. A device necessary for fixing the camshaft of diesel engines.
Engines with two-piece fuel pump pulley
1. Lock the fuel pump pulley with the locking pin.
2. Unscrew the bolts from the fuel pump pulley (1) and in their place, screw in new bolts, tightening them with a torque of 20 Nm. Do not unscrew the central nut securing the fuel pump pulley, as this may move the pulley.
3. Loosen the toothed belt tension by unscrewing the tensioner pulley nut.
4. Unscrew a bolt and remove a directing roller of a gear belt.
To reinstall the toothed belt, note the direction of rotation.
5. Loosen the camshaft pulley bolt half a turn. Remove the camshaft timing belt pulley from the camshaft alignment cone using a drift through the hole in the rear timing belt housing.
6. Install the toothed belt guide pulley and secure it with the bolt, tightening it to 25 Nm.
7. Install the timing belt on the crankshaft pulley, fuel pump pulley and camshaft pulley.
8. Install the toothed belt with the flat side on the countershaft pulley and tensioner pulley.
9. Remove the high pressure fuel pump blocking pin.
10. Check that the front of the toothed belt is taut and that the slack in the belt should be on the side of the tensioner roller.
11. Using a wrench, turn the timing belt tensioner clockwise until the marks on the pulley and tensioner hub are aligned.
12. Check the toothed belt tension by turning it in the center between the intermediate shaft and the camshaft. In this case, the belt must only rotate 90°.
13. After adjusting the toothed belt tension, tighten the tensioner locknut to 45 Nm.
14. Tighten the camshaft pulley bolt to the required torque.
15. Remove the camshaft lock tool.
16. Rotate the engine two full revolutions in the normal direction of rotation and reset the No. 1 cylinder to TDC on the compression stroke. Check that the locking pin can be installed in the high pressure fuel pump pulley mounting hole. Check and, if necessary, readjust the toothed belt tension.
17. Install the toothed belt guards, vibration damper/auxiliary drive belt pulley and cylinder head cover.
18. Install the V-ribbed auxiliary belt.
19. Check the injection timing of the high pressure fuel pump.
Warning: On a fuel pump gear consisting of two sections, after setting the injection timing of the fuel pump, tighten the three gear mounting bolts to 20 Nm, and then tighten them by an angle of 90°.
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