Removal and installation of an intermediate shaft — removal and installation

Removal and installation of an intermediate shaft

Withdrawal

1. Disconnect ground wire from battery.

2. Loosen the alternator mounting bolts and remove the alternator drive V-belt.

3. Remove toothed belt guard.

4. Remove the pulley from the crankshaft and its thrust washer.

5. Set the piston of the 1st cylinder to TDC, mark the position of the distributor rotor and remove the ignition distributor.

6. Unscrew the pulley bolt on the intermediate shaft.

7. Loosen tensioner and remove toothed belt.

8. Remove the fuel pump and its drive tappet.

9. Unscrew the intermediate shaft cover, the mounting plate and remove the intermediate shaft.

10. Remove the O-ring from the intermediate shaft cover.

Installation

1. Install the intermediate shaft seal in the cover.

2. Fix the intermediate shaft and the mounting plate to the cylinder block. Check intermediate shaft axial play (if necessary, replace the mounting plate, adjusting its thickness accordingly).

3. Lubricate the edges of the sealing ring with oil and install it on the intermediate shaft with the cover using special tool 21.009 A.


4. Install the pulley on the intermediate shaft.

5. Insert the pusher of the fuel pump drive into the hole in the cylinder block and fix the pump.

6. Install the pulley on the intermediate shaft so that the pulley reinforcing ribs point towards the cylinder block.

7. Check whether the positions of the crankshaft, camshaft and ignition distributor correspond to the position of the piston of the 1st cylinder at TDC. Fix the ignition distributor and check its correct installation.

8. Install toothed belt and adjust its tension.

9. Install the thrust washer on the crankshaft, and then fix the pulley on the crankshaft.

10. Install the toothed belt guard.

11. Install the alternator and fan drive V-belt, adjust its tension (deflection should be 10 mm midway between the crankshaft and alternator pulleys).

12. Install the ignition distributor, connect the high voltage wires and ground wire to the battery.