Procedures

Replacing The Timing Belt

Special Tools
999 5006
999 5383
999 5460

Removing the auxiliaries belt





- Turbocharged engines: remove the right hand engine cover and the cover over the right headlamp
- Slacken off the auxiliaries belt by turning the screw on the tension pulley clockwise
- Remove the auxiliaries belt.

Removing the timing covers
Remove:





- the upper timing cover
- the front timing cover.

Installing the lifting beam and lifting hook





Remove the metal bracket for the servo hose from the rotation protection for the auxiliaries belt.





Position lifting beam 999 5006 slightly in front of the front lifting eyelet for the engine. Use lifting arm 999 5383 and lifting hook 999 5460 to raise the front of the engine a few millimeters.

Removing the right-hand engine mounting





- the screws for the servo holder
- the engine mounting 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 pulley correspond.
Turn the crankshaft a further l/4 turn clockwise and then back again until the markings correspond. The markings are illustrated. Remove the upper timing cover.

Removing the timing belt





Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still. Turn the tensioner eccentric clockwise using a 6 mm Allen key to 10 o'clock.
Remove the timing belt from the tension pulley, camshaft pulley and water pump.

Tensioning the tensioner pulley and the idler pulley
Spin the idler pulley and listen for noise. When replacing with a new idler pulley, tighten to 24 Nm.
Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw.
Screw in the center screw by hand.
Ensure that the tensioner fork is centered over the cylinder block rib.
Ensure that the Allen hole on the eccentric is at "10 o'clock".

Removing the splash guards under the engine
Remove:





- the front air baffle
- the rear air baffle.

Removing the timing belt (at the bottom)
Remove:





- the two screws from the lower belt cover
- the lower belt guard
- the timing belt using a twisting movement
- clean the surrounding area.

Installing the timing belt

Note: For additional Variable Valve Timing adjustment info see Variable Valve Timing, Adjustments Adjustments

Install the timing belt over the pulley on the crankshaft.

Install:
- the lower belt guard
- the front air baffle
- the rear air baffle.

Install the new belt in the following order:





- crankshaft
- the idler pulley
- intake camshaft
- exhaust camshaft
- water pump
- belt tensioner.





Note:
- This adjustment is to be made with a cold engine. Suitable temperature is approximately 20°C/67°F. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
- The illustration shows the position of the indicator at different engine temperatures.





- Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft
- Hold the belt tensioner center screw secure. 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 center of the window
- Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm.
Check that the indicator is in the correct position.

Check





- Press the belt to check that the indicator on the tensioner moves easily
- Install 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.

Installing timing covers
Install:





- the lower timing cover
- the front timing cover. Tighten to 12 Nm
- the auxiliaries belt.

Installing the right engine mounting





Screw the engine mounting into place on the engine.
Tighten to 67 Nm.

Install:
- the screws on the bracket for the bodywork. Tighten to 50 Nm
- the servo reservoir.

Finishing
Remove the lifting beam and lifting hook.

Install:





- the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt
- the front wheel according to Front brake pads replacement
- the auxiliaries belt
- turbocharged engines: the right hand engine cover and the cover over the right headlamp unit.

Checking work
Function test:
- Test drive the engine.