Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the cylinder head gasket.
ENGINE - Td4, Inlet and outlet camshafts, Cylinder head gasket: models with manual transmission.
ENGINE - Td4, Inlet and outlet camshafts, Cylinder head gasket: models with automatic transmission.
3. Remove the oil pump.
ENGINE - Td4, Inlet and outlet camshafts, Oil pump.
4. Remove the generator.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Generator - Td4 engine.
5. Remove the front crankshaft oil seal.
ENGINE - Td4, Inlet and outlet camshafts, Replacement of front crankshaft oil seal.
6. Remove the 4 power steering pump mounting bolts and secure the pump to the side.
7. Loosen the bolt and remove the auxiliary drive belt idler roller.
8. Unscrew the nut and remove the lever with the roller from the spring housing.
9. Remove and discard the tensioner lever seal.
10. Unscrew the two bolts and remove the lower cooling system pipe bracket.
11. Unscrew 14 bolts, move the cover away from the block and remove it. Unscrewing the bolts releases the auxiliary drive belt tensioner.
12. Remove the camshaft drive chain from the fuel pump sprocket.
13. Push the lower chain tensioner plunger fully into the tensioner housing to secure it with stud LRT-12-172.
14. Unscrew 3 bolts and remove the timing chain tensioner.
15. Remove the upper fuel pump drive chain guide.
16. Loosen the bolt and remove the lower fuel pump drive chain guide. Discard the bolt.
17. Holding the fuel pump drive sprocket, unscrew its mounting nut.
18. Install the LRT-12-178 puller on the fuel pump sprocket and, tightening the center bolt of the puller, remove the sprocket.
19. Remove the LRT-12-178 puller from the fuel pump sprocket.
20. Remove the sprockets and chains from the crankshaft and from the fuel pump.
21. Unscrew the bolt and remove the oil nozzle designed to lubricate the chain.
22. Using a sharp blade, separate the timing cover gasket and remove it.
Installation
1. Wipe the timing cover and mating surface, pins and pin seats.
2. Using a blade, separate and remove the coolant pump gasket, then install a new timing cover gasket.
3. Wipe the oil nozzle and the corresponding mating surface.
4. Install the oil nozzle in place and tighten the mounting bolt. Tightening torque 10 Nm.
5. Wipe the crankshaft sprockets, fuel pump and their installation locations.
6. Wipe the oil and fuel pump drive chains.
7. Lubricate the chains and sprockets.
8. Place the oil and fuel pump drive chains onto the crankshaft and fuel pump sprockets.
9. Place the sprockets with chains on the crankshaft and on the fuel pump.
10. Screw on the fuel pump sprocket mounting nut and tighten it. Tightening torque 65 Nm.
11. Wipe the fuel pump drive chain guides.
12. Place the lower fuel pump drive chain guide on the mounting pin and secure it with a new bolt. Tightening torque 24 Nm.
13. Install the upper fuel pump drive chain guide.
14. Wipe the timing chain tensioner and mating surface. Make sure the oil feed channel is clean.
15. Install the tensioner in place and tighten the mounting bolts. Tightening torque 10 Nm.
16. Press the tensioner plunger to remove stud LRT-12-172 and seat the plunger against the tensioner shoe.
17. Wipe the camshaft drive chain.
18. Lubricate the camshaft drive chain.
19. Install the camshaft drive chain to the fuel pump sprocket.
20. Wipe the timing cover.
21. Install the timing cover onto the cylinder block.
22. To ensure the correct position of the accessory drive belt tensioner, temporarily install the tensioner lever.
23. Tighten the timing cover mounting bolts evenly and consistently. Tightening torque 15 Nm.
24. Remove the accessory drive belt tensioner lever.
25. Install the seal on the belt tensioner lever bushing.
26. Install the tensioner lever in place and tighten the mounting bolts. Tightening torque 10 Nm.
27. Install the coolant pipe bracket on the pan, screw in the bolts and tighten them. Tightening torque 15 Nm.
28. Install the intermediate roller in place and tighten the mounting bolt. Tightening torque 24 Nm.
29. Install the power steering pump and tighten the mounting bolts. Tightening torque for M6 bolts is 10 Nm, for M8 bolts - 25 Nm.
30. Install the front crankshaft oil seal.
ENGINE - Td4, Inlet and outlet camshafts, Replacement of front crankshaft oil seal.
31. Install the generator.
ENGINE STARTING AND BATTERY CHARGING SYSTEM, REPAIR WORK, Generator - Td4 engine.
32. Install the oil pump.
ENGINE - Td4, Inlet and outlet camshafts, Oil pump.
33. Install the cylinder head gasket.
ENGINE - Td4, Inlet and outlet camshafts, Cylinder head gasket: models with manual transmission.
ENGINE - Td4, Inlet and outlet camshafts, Cylinder head gasket: models with automatic transmission.
34. Connect the negative battery terminal.
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