Dismantling
1. Remove the 4 bolts securing the motor bracket to the front plate and remove the bracket.
2. Loosen and remove the implement drive belt from the remaining rollers.
3. Turn away 2 bolts of fastening of a tensioner of a belt of a drive of hinged units and remove a tensioner.
4. Turn away a bolt of fastening of an intermediate roller to a forward plate of the engine and remove a roller.
5. Remove the cover from "positive" generator outlet, unscrew the nut and disconnect the battery bus from the generator.
6. Disconnect block from the generator.
7. Turn away the bottom bolt and the top bolt with a nut of fastening of the generator to a forward plate of the engine.
8. Release the generator and remove it.
9. Turn away 3 bolts of fastening of a cover of a back timing belt on the left head of cylinders and remove a back cover.
10. Remove the inlet receiver (if available).
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIRS, Intake reservoir seals: vehicles manufactured before May 2003.
11. Turn away 2 bolts of fastening of the heat-shielding screen of the right back timing belt to a head of cylinders and remove the screen.
12. Turn away 3 bolts of fastening of a cover of a back timing belt on the right head of cylinders and remove a cover.
13. Installing the socket head on the crankshaft pulley mounting bolt, turn the crankshaft clockwise until the marks are aligned "SAFE" on a pulley with an arrow "ARROW" on the front of the engine. Check the alignment of the marks on the rear gears, as shown in the figure.
ATTENTION: It is forbidden to turn the engine by the camshaft gear bolts or by the timing belt. Do not use the arrow on the oil pump housing as a match mark.
14. Insert the LRT-12-232 pin through the oil pan hole so that the pin fits into the hole in the drive plate.
15. Turn away 3 bolts of fastening of a forward cover of a forward timing belt on the left head of cylinders and remove a cover.
16. Turn away 3 bolts of fastening of a forward cover of a forward timing belt on the right head of cylinders and remove a cover.
17. Turn away 2 bolts of fastening of a casing of an oil probe to the block of cylinders.
18. Wring out shoulders and take out from the pallet a casing of an oil dipstick.
19. Assemble tools LRT-12-161 and LRT-12-199 together by bolting them together.
20. Install tool LRT-12-161 with LRT-12-199 on the crankshaft pulley, loosen and remove the crankshaft pulley bolt.
CAUTION: The crankshaft must not rotate when performing the above procedure.
21. Remove the LRT-12-161 and LRT-12-199 from the crankshaft pulley.
22. Remove the pulley from the crankshaft.
23. Turn away 3 bolts of fastening of the lower part of a cover of a timing belt to the block of cylinders and remove a cover.
24. Turn away 3 bolts of fastening of a forward plate of the engine and a lifting eye to the block of cylinders.
25. Turn away a bolt of fastening of a lifting eye to the right head of cylinders and remove an eye.
26. Remove the rubber plug located next to the timing belt tensioner.
27. Turn away 5 bolts and 2 bolts with fastening hairpin.
28. Turn away 2 bolts of fastening of an arm of a distributing box to a forward plate of the engine.
29. Carefully release and remove the front plate from the engine.
30. Insert a pin with a diameter of 1.5 mm into the holes of the body and the stem of the tension regulator.
NOTE: If the holes in the body and stem do not line up, use a wide-blade screwdriver to move the tensioner lever to push the stem in until the holes line up to allow the pin to be inserted.
31. Unscrew and dispose of the 2 bolts securing the belt tension regulator to the cylinder block and remove the regulator.
WARNING: Be very careful not to use too much force when loosening the bolts. If the bolt is difficult to loosen, then you must first moisten it with a lubricant such as "liquid key". DO NOT LOSE the hex socket bolt that secures the idler pulley.
32. If further use of the timing belt is expected, then mark the direction of its movement before removal.
33. Carefully, without the use of tools, release the belt from the gears and remove the belt.
CAUTION: Do not rotate the crankshaft and camshafts with the timing belt removed.
CAUTION: The timing belt must be replaced if the cylinder head is to be removed, new gears, a new tensioner or coolant pump to be installed. Timing belts require careful handling and storage. Timing belts should be stored on edge and not allowed to have a bend radius of less than 50 mm. Do not use a timing belt that has been twisted or folded in half as the cords may be damaged. Do not use the timing belt if other than dusty wear particles are found on the belt cover (crumbs, thread). Do not use the timing belt if there has been a partial wedging of the engine Belts that have passed 72,000 km must be replaced. Do not use timing belts whose surface is contaminated with oil or coolant. The cause of the contamination must be eliminated.
34. Remove and dispose of the right and left exhaust shaft seals.
35. Install LRT-12-196 on the intake camshaft gears and on the exhaust camshaft toe.
CAUTION: These mandrels must be installed whenever the gear bolts are tightened or loosened to prevent damage to the camshafts.
36. Loosen and discard the bolts securing the gears to the camshafts.
37. Remove mandrels LRT-12-196 from the gears of the intake camshafts and from the toes of the exhaust camshafts.
38. Remove the camshaft drive gears with hubs.
Installation
NOTE: It is possible that after replacing the front or rear timing belt and setting the crankshaft pulley to the 'SAFE' position, the position marks on the rear cogwheels will no longer align. Such a mismatch is acceptable provided that the belt replacement procedure was carried out without errors.
1. Wipe the rims of the gears and their hubs, the crankshaft drive gear, the tensioner pulley and the coolant pump pulley.
WARNING: If sintered gears (powder metallurgy technology), have been in contact with oil for a long time, then, before installation, they must be soaked in a solvent and then washed in a pure solvent. The porous structure of the sintered material absorbs oil, which, if released, will contaminate the timing belts.
2. Install the hubs on the gears and install the gears on the camshafts.
3. Install new gear bolts and tighten just enough to allow the gears to turn without wobble.
4. Put the timing belt on the crankshaft gear.
NOTE: To prevent the belt from jumping off the crankshaft gear when putting it on, it must be pressed with an object inserted between the belt and the protective protrusion on the oil pump housing.
5. Install tool LRT-12-197, in turn, into each of the exhaust camshafts.
6. With the help of a partner, turn the exhaust camshaft slightly until the marks on the right and left rear gears match.
7. Remove mandrel LRT-12-197.
8. Install mandrels LRT-12-175 on the left and right rear gears.
9. Turn both front gears clockwise as you look at the front of the engine.
10. Only with your hands, without the help of any tools, put on the toothed belt, routing it counterclockwise. In doing so, the padded portion of the belt must be kept as taut as possible, the gear wheels turning counterclockwise only as far as the belt can be put on.
WARNING: Gears must not be turned counterclockwise by more than one tooth.
11. Using an L-shaped hex wrench, tension the belt with the tensioner roller.
12. With the help of a partner, install the tensioner, screw in new mounting bolts and tighten them to a torque of 25 Nm.
CAUTION: Check that the tensioner rod touches the tensioner arm.
13. Remove the LRT-12-175 from the rear gears.
14. Install drift LRT-12-196 on both gear wheels of the intake camshafts and on the toe of the exhaust camshafts.
CAUTION: These mandrels must be installed whenever the gear bolts are tightened or loosened to prevent damage to the camshafts.
15. Tighten the front gear bolts:
- Stage 1: 27 Nm
- Step 2: Turn 90°
16. Remove mandrels LRT-12-196 from the intake camshaft gears and from the exhaust camshaft toes.
17. Remove the toothed belt stopper from under the crankshaft gear.
18. Remove the pin from the timing belt tensioner.
19. Wipe the seals on the toe of the exhaust camshafts and install new seals.
CAUTION: The sealing lips and mating surface must be clean and dry.
20. Install the front plate on the engine, screw in the bolts, but do not completely tighten them.
21. Screw in the bolts securing the transfer case bracket to the engine front plate, but do not completely tighten them.
22. Tighten the bolts in the sequence shown in the figure:
- Bolt M10 No. 1: 25 Nm
- Bolt M10 No. 5: 45 Nm
- Bolts No. 2, 3, 4, 6 and 7 - 85 Nm
23. Install the lifting eye on the engine, screw in the bolts of the lifting eye and the engine front plate to the cylinder block and to the right cylinder head and tighten:
- Bolt M8: 25 Nm
- Bolts M10: 45 Nm
24. Insert the rubber plug.
25. Wipe the end of the dipstick housing.
26. Install the dipstick, screw in the bolt and tighten it to 9 Nm.
27. Wipe the bottom of the front timing belt cover.
28. Install the lower timing belt cover and tighten the mounting bolts to 9 Nm.
29. Remove pin LRT-12-232.
30. Wipe the crankshaft pulley.
31. Install the crankshaft pulley onto the crankshaft drive gear, making sure that the notch on the pulley is aligned with the lug on the gear.
32. Screw in the pulley mounting bolt with washer, install the LRT-12-161 tool with LRT-12-199 on the crankshaft pulley. Tighten the pulley bolt to 160 Nm.
33. Remove tools LRT-12-161 and LRT-12-199.
34. Wipe the attachment drive belt tensioner.
35. Install the accessory drive belt tensioner, screw in the bolts and tighten them to a torque of 25 Nm.
36. Wipe the left and right front timing belt covers.
37. Replace the left and right front timing belt covers, screw in the bolts and tighten them to a torque of 4 Nm.
38. Wipe the intermediate roller, install the roller on the engine front plate and tighten the fastening bolt to 45 Nm.
39. Install the generator on the engine front plate.
40. Insert a bolt of fastening of the generator to a forward plate of the engine, get on a nut and tighten the moment of 45 Nanometers.
41. Connect the generator connector.
42. Connect the battery bus to the generator output, fit and tighten the nut to a torque of 8 Nm.
43. Wipe the cover of the left rear timing belt.
44. Replace the cover of the left rear timing belt, screw in the bolts and tighten them to a torque of 4 Nm.
45. Wipe the cover of the right rear timing belt.
46. Replace the cover of the right rear timing belt, screw in the bolts and tighten them to a torque of 4 Nm.
47. Install the heat shield, screw in the bolts and tighten the M6 bolts to 9 Nm and the M8 bolts to 25 Nm.
48. Install intake reservoir (if available).
MANIFOLDS AND EXHAUST SYSTEM: MOD. K, move. V6, REPAIRS, Intake reservoir seals: vehicles manufactured before May 2003.
49. Install the accessory drive belt on the crankshaft and alternator pulley.
50. Install the engine support bracket on the front plate and tighten the bolts to 45 Nm.
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