Preparing the Vehicle [VVT]
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.
Note! Crankshaft and camshafts must not be turned more than is stated in the method description! If the shafts are turned in any other way, the valves may be damaged.
Preparations
Remove:
- the cable from the battery's negative terminal. First read Note when disconnecting and connecting the battery lead.
- the inlet hose between air filter and throttle housing. Put it aside.
Remove:
- the brake servo's vacuum hose from its connection in the throttle housing. Loosen the hose by pressing down the plastic ring at the same time as the hose is pulled upwards. Move the hose aside.
- the fuel line and cabling from its clips in the cylinder head's trailing edge.
Remove:
- the cable channel's screws.
- camshaft's rear cover.
- the camshaft position (CMP) sensor housing.
- the trigger wheel.
- right engine protection cover (only turbo).
- the auxiliaries belt.
Removing timing gear covers
Remove:
- the upper timing cover.
- the front timing cover.
Installing the lifting beam and the lifting hook
- Loosen the servo hose's plate bracket from the auxiliary unit's rotation guard.
- Place lift tool 999 5006 slightly in front of the engine's front lifting eye. Use lift arm 999 5383 and lift hook 999 5460 to lift the engine a few mm at the leading edge.
Removing the right-hand engine mounting
Remove:
- the servo reservoir's screws.
- the engine mount's screws.
- the engine mounting.
- the lower timing cover.
Position the engine according to the marking
- Remove the right front wheel.
- Position the upper timing cover.
- Turn the crankshaft until the markings on the crankshaft and camshaft gear match.
- Turn another � turns clockwise on the crankshaft and then back until the markings match. Markings are shown in figure. Remove the upper timing gear cover.
Removing the timing belt
- Slacken off the center screw for the belt tensioner slightly.
- Hold and fixate the centre screw. Turn the tensioner's eccentric clockwise using a 6 mm Allen key to 10 o'clock.
- Remove the timing belt from the camshaft gears.
Removing the timing gear pulley
- Timing gear pulleys with variable valve timing unit
- Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
Timing gear pulleys with variable valve timing unit:
- Remove the plug at the front edge of the variable valve timing unit (TORX 55).
- Remove the centre screw in the VVT-unit (TORX 55).
- Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit. A small amount of oil may run out. Place paper underneath.
Timing gear pulleys without variable valve timing units:
- Remove the timing gear pulley's screws. Use counterhold 999 5199 .
- Remove timing gear pulley.
- Remove tool 999 5452 .
- Remove the screw that holds the inner timing gear cover to the cylinder head.
Replacing the camshaft seal
- Carefully press in tool 999 5651 between the sealing ring and the camshaft.
- Carefully pry out the seal.
- Oil the new seal.
- Install the new seal for the camshaft with VVT using drift 999 5718 .
- Install the new seal for the camshaft without VVT using drift 999 5719 .
- Install the screw holding the inner timing cover to the cylinder head.
Secure the crankshaft position
- Install the adjustment tool.
Remove:
- front air baffle.
- the support between the cylinder block and the intake manifold.
- the starter motor mounting screws.
- Place the starter motor to one side.
- Remove the blind cover plug and the sealing washer.
- Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.
- Install gauge 999 5451 . Make sure that the gauge bottoms against the engine block.
- Turn the crankshaft back counter-clockwise until it stops against the drift.
- Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing camshafts' timing gear pulleys
Timing gear pulley without VVT:
- install upper timing cover.
- install timing gear pulley without VVT on the camshaft. Use two screws positioned so that the markings on the timing belt gears/upper timing gear cover match. Do not tighten.
Timing gear pulley VVT:
- Install the timing gear pulley with the centre screw on the camshaft. Make sure that the markings on the timing gear pulleys/upper timing gear cover match, but do not tighten.
Installing the timing belt
- Install the timing belt on the timing gear pulleys.
Note! Adjust so that the screws in the timing gear pulley without variable valve timing do not reach the limit position in the oval holes.
Tension the timing belt
Note! This adjustment is to be made with a cold engine. Suitable temperature is approximately 20°C/67°F. At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.
- The image shows the indicator position at different engine temperatures.
- The belt shall be tight between the inlet camshaft gear, idler gear, and crankshaft.
- Fix the belt tensioner centre screw in position and turn the belt tensioner eccentric counter clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the centre of the window
- Hold the eccentric secure and tighten the centre screw. Torque tighten to 20 Nm .
Tightening timing gear pulley
- Tighten the centre screw on the timing gear pulley with VVT. Tighten to 90 Nm.
- Install the plug. Tighten to 35 Nm .
- Install the third screw on the camshaft without VVT. Tighten to 20 Nm .
- Remove the adjustment tools.
Check
- Press the belt to check that the indicator on the tensioner moves easily.
- Position the upper timing cover.
- Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond
Note! Check that the indicator on the belt tensioner is within the marked area.
- Remove the upper timing cover.
Installing the timing covers
Install:
- lower timing gear cover.
- the front timing gear cover. Tightening torque 12 Nm .
- the upper timing cover.
Installing the right-hand engine mounting
- Screw down the engine mount against the engine. Tightening torque 67 Nm .
Install:
- the screws on the body frame's console. Tighten with 50 Nm .
Finishing
Remove lifting beam and lifting hook.
Install:
- the servo reservoir.
- servo hose's metal console on the auxiliary unit belt's rotation guard.
- the auxiliaries belt
- turbo engines: right engine protection cover as well as the cover over right headlight unit.
- rear camshaft cover.
- blinder. Tightening torque 17 Nm .
- camshaft sensor housing. Tightening torque 5 Nm .
- cable channel.
- brake servo's vacuum hose.
- hose between inlet pipe and air filter housing.
- the blind cover plug.
- the starter motor mounting screws.
- the support between the cylinder block and the intake manifold.
- front air baffle.
- the cable from the battery's negative terminal. First read Note when disconnecting and connecting the battery lead .
Checking work
Function test:
- Carry out a road test.