Removing
1. Remove the toothed belt.
Camshaft pulley
2. Screw the camshaft pulley clamping bolt into the cylinder head and unscrew the pulley mounting bolt.
3. Unscrew the clamping bolt and remove the pulley from the end of the camshaft.
Fuel pump pulley
4. Using the special tool, secure the fuel pump pulley from turning.
5. Unscrew the clamping bolt fixing the pulley and unscrew the nut securing the fuel pump pulley.
6. Remove the pulley from the fuel pump shaft.
7. After removing the pulley from the fuel pump shaft, remove the segment key.
Warning! The fuel pump pulley is mounted on a cone, so a puller must be used to remove it.
crankshaft pulley
8. Loosen the crankshaft pulley bolt. To prevent rotation of the crankshaft, the assistant must engage any gear and apply the brake.
9. Remove the crankshaft pulley bolt.
10. Remove the pulley.
11. Remove the flange gasket from the crankshaft.
Oil pump pulley
12. Unscrew the bolt securing the oil pump pulley, while holding the pulley from turning by inserting a steel rod through the hole in the pulley.
13. Remove the pulley from the oil pump shaft.
Tension mechanism
14. Unscrew the bolts and remove the tensioner from the engine.
idler pulley
15. Unscrew the bolts and remove the idle pulley from the engine.
Installation
Camshaft pulley
1. Check that the camshaft pulley locating pin is in the end of the camshaft.
2. Install the camshaft pulley by aligning the hole in the pulley with the dowel pin.
3. Install the camshaft pulley clamping bolt, then screw in the pulley mounting bolts, tightening them to the required torque.
4. Install the toothed belt.
Fuel pump pulley
5. Install the slotted key in the groove of the fuel pump shaft and install the pulley, aligning the slot on the pulley with the slotted key.
6. Secure the pulley with a nut, tightening it to the required torque, while holding the pulley from turning with a special tool.
7. Rotate the fuel pump pulley to align the mounting holes and secure with the clamp bolt.
8. Install the toothed belt.
crankshaft pulley
9. Install the flange gasket on the crankshaft, with the convex surface of the flange gasket on the other side of the oil pump.
10. Check that the segment key is installed in the crankshaft and install the crankshaft pulley so that the groove on the pulley aligns with the key.
11. Secure the crankshaft pulley with a bolt while holding the engine crankshaft from turning.
12. Install the toothed belt.
Oil pump pulley
13. Install the pulley on the oil pump shaft and secure with a nut, tightening it to the required torque.
14. Install the toothed belt.
Tension mechanism
15. Install the tensioner to the engine and secure with bolts.
16. Install the toothed belt.
idler pulley
17. Install idler pulley and secure with bolt.
18. Install the toothed belt.
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