Assembling the Belt Drive
Assembling the belt drive
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Tightening
For tightening torques not in the text see Tightening torque Tightening Torque.
Installing the thermostat housing and water pump
Install
- the coolant outlet pipe on the cylinder head.
Use a new gasket. Tighten to 17 Nm (12 lb.ft).
- the rear timing cover. Screw into place at the three cover mounting points.
- thermostat housing / cable duct. Use a new gasket. Ensure that the coolant temperature sensor cable / cable duct lies correctly.
- the thermostat. Use a new gasket.
- the thermostat cover. Tighten.
- the water pump with new gasket. Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten.
Installing the oil pump
Use a new gasket and new O-ring around the pump housing.
Screw sliding sleeve into place. 999 5747 Socket 999 5747 Socket at the front of the crankshaft journal.
Press in the pump over the sliding sleeve.
Apply thread sealant, P/N 11-61 056, to all the screws for the oil pump.
Install the screws as a guide.
Carefully tap in the oil pump with a rubber mallet.
Tighten the oil pump crosswise.
Remove the sliding sleeve 999 5747.
Install the fuel delivery line.
Installing the crankshaft timing gear pulley
Note! The timing gear pulley can only be installed in one position on the crankshaft journal (see the illustration).
Carefully tap in the timing gear pulley with a rubber mallet.
Installing the tensioner / damping unit and the idler pulley
Install
- idler pulley. Tighten to 25 Nm (18 lb.ft).
- tensioner pulley lever Tighten to 30 Nm (22 lb.ft).
- the tensioner / damping unit. Tighten to 25 Nm (18 lb.ft).
Installing the camshaft timing gear pulley, B6xx4T
Timing gear pulleys with variable valve timing units
Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit / timing gear on to the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Do not tighten.
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.
Continue turning clockwise until the timing gear pulley marking is 1½cogbefore the marking on the upper timing cover.
Check that the timing gear pulley is still in its limit position at the oval holes.
Tighten the center screw for the variable valve timing unit to 120 Nm (88 lb.ft). Check that the variable valve timing unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm (26 lb.ft).
Timing gear pulleys without variable valve timing units
Install the timing gear pulley on the camshaft with 2 screws. Do not tighten.
Installing the camshaft timing gear pulley, B6xx4S
Timing gear pulleys with variable valve timing units
Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit / timing gear on to the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit anti-clockwise as far as it will go.
Slacken off the center screw
Position the upper timing cover.
Turn the timing gear pulley clockwiseuntil the screws at the oval holes are in the limit position.
Continue turning clockwise until the timing gear pulley marking is 1½cogbefore the marking on the upper timing cover.
Note! Do not turn anti-clockwise during this procedure.
Check that the timing gear pulley is still in its limit position at the oval holes.
Tighten the center screw for the variable valve timing unit to 120 Nm (88 lb.ft). Check that the variable valve timing unit does not rotate when tightening. Install the center plug. Tighten to 35 Nm (26 lb.ft).
Turn the variable valve timing unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.
Timing gear pulleys without variable valve timing units
Install the timing gear pulley on the camshaft with 2 screws. Do not tighten.
Installing the timing belt
Note! Applies only to B62x4T.
Turn the variable valve timing unit clockwise until stop.
Hold it secure in limit position.
Install the belt in the following order:
1. Crankshaft
2. Idler pulley
3. Intake camshaft
4. Exhaust camshaft
5. Water pump
6. Tensioner pulley
Note! The variable valve timing unit on engines without a turbocharger (TC) does not have a return spring. It is easily dislodged when reinstalling the timing belt. Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.
Pull the lock pin out of the tensioner / damping unit.
Optimize the timing belt tension by pressing it between the camshaft timing gear pulleys and between the water pump and exhaust camshaft.
Tighten the three timing gear pulley screws on the variable valve timing unit to 10 Nm (7.4 lb.ft).
Install the third screw at the timing gear pulley without variable valve timing unit. Tighten to 20 Nm (15 lb.ft).
Note! Applies to turbocharged engines:The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
Install the deflection limiter washer on the piston rod for the tensioner / damping unit.
Remove
- The camshaft adjustment tools 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool.
- The crankshaft stop 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
Install plug with a new blind cover plug. Tighten to 40 Nm (29 lb.ft).
Installing the vibration damper
Install
- the crankshaft pulley for the auxiliaries belt.
- counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold.
- the crankshaft center nut. Tighten to 300 Nm (221 lb.ft).
Remove counterhold 999 5433.
Install the vibration damper. Use new screws. Tighten to 35 Nm (26 lb.ft). Angle tighten 50°. Use the crankshaft center nut as a counterhold.
Check
Turn the crankshaft two turns.
Check that the markings on the crankshaft and camshaft timing gear pulley correspond with the marking on the upper timing cover and on the oil pump.