Belt Drive, Assembly
Timing belt, assembling
Special tools:
999 5747 Socket 999 5747 Socket
999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
999 5433 COUNTERHOLD 999 5433 Counterhold
Note! 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.
Assembly
Installing water pump
Install the rear timing gear casing.
Tighten down the cover at its three attaching points.
Install the water pump with a new gasket.
Apply thread sealant, part number 1161056, on the screws for the water pump. Tighten crosswise.
Installing oil pump
Use a new gasket and a new O-ring around the oil pump housing.
Tighten down: 999 5747 Socket 999 5747 Socket at the front on the crankshaft journal.
Press in the pump that is located over the sliding sleeve.
Install the new screws as guide.
Carefully tap in the oil pump with a plastic mallet.
Tighten down the oil pump crosswise with 10 Nm.
Remove: 999 5747 Socket 999 5747 Socket.
Install the lower belt guard.
Installing new tension pulley and idler pulley
Caution! When replacing the timing belt, the tension pulley and idler pulley must always be replaced.
Install:
- a new tension pulley together with the center screw. Screw in the center screw by hand. Make sure that the tensioner fork is centered over the cylinder block rib and make sure that the Allen hole on the eccentric is in position at 10 o'clock
- a new idler pulley and tighten the screws.
Installing the crankshaft's timing belt pulley
Note! The timing belt pulley can only be installed in one position in case of splines on the crankshaft journal, see illustration.
Carefully tap in the timing belt pulley with a plastic mallet.
Installing the timing belt
Caution! Make sure that the camshaft pulley still stands according to the marking on the upper timing belt cover, if not repeat until the marking corresponds.
Tighten the center screw in the timing belt tensioner. Tighten to 5 Nm in the 9 o'clock position.
Install the belt in the following order:
- the crankshaft
- the idler pulley
- the intake camshaft pulley
- the exhaust camshaft pulley
- the water pump
- the tension pulley.
This adjustment is done on a cold engine. A suitable temperature is approx. 20 °C/68 °F. At higher temperatures, e.g., with the engine at operating temperature or a higher ambient temperature, the indicator assumes a position farther to the right. The figure shows the position of the indicator when setting the timing belt tensioner at different engine temperatures.
Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position and reaches the limit position. Tighten.
Tighten the center screw that holds the VVT-unit (variable valve timing unit). Tighten according to: : Tightening torque Tightening Torque Tightening torques.
Tighten the screws for the exhaust timing belt pulley and make sure that the screws are not in end-position. Tighten according to: Tightening torque Tightening Torque.
Install the plug for the VVT-unit. Tighten according to: Tightening torque Tightening Torque.
Adjusting belt tension
Slacken off the screw for the timing belt tensioner. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time. Hold the eccentric in place and tighten the center screw.
Tighten. See Specifications. Tightening Torque. Check that the indicator is in the correct position.
Removing the adjustment tools
Remove:
- 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool from the trailing edge of the camshafts
- 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
Install the plug together with a new seal washer. Tighten according to: Tightening torque Tightening Torque
Checking the markings and belt tension
Press on the timing belt to check that the indicator on the belt tensioner moves easily. Fit the upper timing gear casing.
Turn the crankshaft two revolutions and check that the markings on the crankshaft and camshaft pulleys correspond.
Check that the indicator on the belt tensioner is within the marked position, adjust as needed. Remove the upper timing casing.
Installing the vibration damper
Install the vibration damper. Tighten according to: Tightening torque Tightening Torque. Use: 999 5433 COUNTERHOLD 999 5433 Counterhold
Remove the counterhold and install the new screws. Tighten according to: Tightening torque Tightening Torque.
Installing rotor
Install the rotor and tighten it down on the intake camshaft's trailing edge.
Installing the cover
Install the covers in the trailing edge of the camshaft. Use a plastic hammer and tap in the covers until they are flush with the camshaft cover and cylinder head.