Removal - Timing Belt Installation

Transcript

Removal - Timing Belt Removal 1. Remove: Engine upper cover. Coolant expansion tank. PAS reservoir (if required). Turbocharger air hoses. Auxiliary drive belt and tensioner. Timing belt upper cover [1] . Injection pump belt cover. 2. Raise and support front of vehicle. 3. Remove: Splash guard. RH front wheel. RH wheel arch liner. 4. Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [2] or [3] . 5. Ensure injection pump timing marks aligned [4] . NOTE: If not: Turn crankshaft one turn clockwise. 6. Slacken injection pump locking bolt [5] . Remove keeper plate [6] . Tighten locking bolt to 30 Nm [5] . 7. Hold camshaft sprocket. Use tool No.999 5644. 8. Slacken camshaft sprocket bolt one turn [7] . 9. Loosen camshaft sprocket from taper using a drift through hole in timing belt rear cover. 10. Lock crankshaft pulley. Use tool No.999 5645. NOTE: Ensure crankshaft does not move. 11. Slacken crankshaft pulley centre bolt [8] . 12. Slacken crankshaft pulley bolts [9] . 13. Remove: Crankshaft pulley locking tool. Crankshaft pulley bolts [9] . Crankshaft pulley centre bolt [8] . Crankshaft pulley [10] . Timing belt lower cover [11] . Tensioner. Timing belt. Installation - Timing Belt Installation 1. Ensure rear timing belt cover screw is marked with white dot [12]. If not: Remove rear timing belt cover screw [12]. Clean threads. Apply locking compound. Fit screw and tighten. Tightening torque: 10 Nm. Mark screw with white dot. 2. 3. 4. 5. 6. Fit new tensioner pulley. Lightly tighten tensioner pulley bolt [13]. Ensure timing marks aligned [3] & [4]. Ensure injection pump locked in position with bolt [5]. Fit timing belt in anti-clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. NOTE: Ensure engine temperature below 30°C before adjusting timing belt. 7. Slacken tensioner pulley bolt [13]. Adjust belt tension until pointer is 2 mm below fixed mark [14]. Use tool No.999 5649 Manufacturer: Volvo Engine code: D5252T Model: 850 2,5D TDI Output: 103 (140) 4000 Valid forever. 10.08.2014 Tuned for: Year: 1996-97 V8.500- Пожалуйста, зарегистрируйте свою копию pdfFactory Pro www.pdffactory.com © Autodata Limited 2010 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. [15]. NOTE: If distance between pointer and fixed mark is exceeded: Back off tensioner pulley completely and repeat tensioning procedure. Tighten tensioner pulley bolt to 20 Nm [13]. Fit crankshaft pulley. Fit crankshaft pulley bolts [9]. Use new bolts. Fit crankshaft pulley centre bolt. Use new bolt. Lock crankshaft pulley. Use tool No.999 5645. NOTE: Ensure crankshaft does not move. Tighten crankshaft pulley centre bolt. Tightening torque: 160 Nm + 180° [8]. Tighten crankshaft pulley bolts. Tightening torque: 20 Nm + 90° [9]. Remove crankshaft pulley locking tool. Tool No.999 5645. Ensure timing marks aligned [2] or [3]. Hold camshaft sprocket. Use tool No.999 5644. Tighten camshaft sprocket bolt according to identification number [7]. Class 8.8 - 85 Nm. Class 10.9 - 100 Nm. NOTE: Class number identified on bolt head. Slacken injection pump locking bolt [5]. Insert keeper plate [6]. Tighten locking bolt to 12,5 Nm [5]. Turn crankshaft 2 turns clockwise. Ensure timing marks aligned [2], [3] & [4]. Ensure tensioner pointer 2 mm below fixed mark [14]. If not: Repeat tensioning procedure. Install components in reverse order of removal. Removal - Injection Pump Belt Removal 1. 2. 3. 4. Access timing belt. Remove injection pump belt cover. Turn crankshaft to TDC on No.1 cylinder. Ensure timing marks aligned [2] or [3] . Ensure injection pump timing marks aligned [4] . NOTE: If not: Turn crankshaft one turn clockwise. 5. If timing belt has not been replaced: Check distance between tensioner pointer and fixed mark [16] : If distance exceeds 14 mm: Renew timing belt and tensioner. If distance less than 14 mm: Adjust tensioner until pointer and lower edge of fixed mark aligned [17] & [18] . NOTE: Ensure camshaft sprocket can rotate freely during timing belt adjustment. 6. Slacken injection pump locking bolt [5] . Remove keeper plate [6] . Tighten locking bolt to 30 Nm. 7. Slacken guide pulley nut [19] . Turn guide pulley away from belt. 8. Remove: Tensioner. Injection pump belt. Installation - Injection Pump Belt Installation 1. 2. 3. 4. 5. 6. 7. Fit new tensioner pulley. Lightly tighten tensioner pulley bolt [20] . Ensure timing marks aligned [2] or [3] . Ensure injection pump timing marks aligned [4] . Ensure injection pump locked in position with bolt [5] . Fit injection pump belt. Ensure belt is taut between sprockets on guide pulley side. Manufacturer: Volvo Engine code: D5252T Model: 850 2,5D TDI Output: 103 (140) 4000 Valid forever. 10.08.2014 Tuned for: Year: 1996-97 V8.500- Пожалуйста, зарегистрируйте свою копию pdfFactory Pro www.pdffactory.com © Autodata Limited 2010 7. 8. 9. 10. Turn guide pulley until pointer aligned with cylinder head flange contour [21] . Use Allen key [22] . Tighten guide pulley nut to 25 Nm [19] . Slacken injection pump locking bolt [5] . Insert keeper plate [6] . Tighten locking bolt to 12,5 Nm [5] . Turn tensioner pulley anti-clockwise until pointers aligned [23] . Use Allen key [24] . NOTE: If floating pointer passes fixed pointer: Back off tensioner pulley completely and repeat tensioning procedure. 11. Tighten tensioner pulley bolt to 20 Nm [20] . 12. Install components in reverse order of removal. Manufacturer: Volvo Engine code: D5252T Model: 850 2,5D TDI Output: 103 (140) 4000 Valid forever. 10.08.2014 Tuned for: Year: 1996-97 V8.500- Пожалуйста, зарегистрируйте свою копию pdfFactory Pro www.pdffactory.com © Autodata Limited 2010 Manufacturer: Volvo Engine code: D5252T Model: 850 2,5D TDI Output: 103 (140) 4000 Valid forever. 10.08.2014 Tuned for: Year: 1996-97 V8.500- Пожалуйста, зарегистрируйте свою копию pdfFactory Pro www.pdffactory.com © Autodata Limited 2010