Refit - Engines fitted with manual timing belt tensioner (page 2 of 2)

3. Ensure dots on crankshaft gear are aligned with flange on oil pump and that tool is locking flywheel.
4. Loosen tensioner backplate bolt and ensure tensioner moves freely through its adjustment range and returns under spring tension.
5. Push tensioner down to OFF position and tighten backplate bolt to 10 Nm.
6. Using fingers only, fit timing belt, ensure belt run between the crankshaft gear and the exhaust camshaft gear is kept taut during the fitting procedure.

CAUTION: If the original belt is to be refitted, ensure the direction of rotation mark is facing the correct way.

7. Check that timing belt is positioned centrally around all gears and tensioner pulley.
8. Fit timing belt lower front cover. See this section.

NOTE: Do not fit timing belt upper front cover at this stage.

9. Raise engine on jack, fit RH mounting bolts and tighten to 155 Nm.
10. Lower jack supporting power unit and remove from beneath vehicle.
11. Remove camshaft gear locking tool 18G 1570.

Tensioning existing timing belt

12. Unhook tensioner spring from pillar bolt.
13. Loosen tensioner backplate bolt.
14. Position tensioner to align mark on backplate with mark on cylinder head.
15. Tighten tensioner backplate bolt to 10 Nm.
16. Tighten tensioner pulley Allen bolt to 45 Nm.
17. Connect tensioner spring to pillar bolt.

Tensioning replacement timing belt

18. Loosen tensioner backplate bolt and tension timing belt by applying finger pressure to backplate and pushing tensioner pulley against belt.
19. Hold tensioner in this position and tighten backplate bolt to 10 Nm.
20. Rotate crankshaft clockwise 2 complete revolutions and align camshaft timing gear marks.

CAUTION: Do not use camshaft gears, gear retaining bolts or timing belt to rotate crankshaft.

21. Loosen backplate bolt and check that belt tension is being applied by tensioner spring.
22. Tighten tensioner backplate bolt to 10 Nm.
23. Tighten tensioner pulley Allen bolt to 45 Nm.

All timing belts

24. Fit camshaft timing belt upper front cover. See this section.
25. Remove stand(s) and lower vehicle.
26. Connect battery earth lead.