Tensioning a new camshaft timing belt (page 6 of 7)

Refit

1. Clean timing gears and pulleys.
2. Check correct alignment of dots on crankshaft gear with flange on oil pump.
3. Check correct alignment of timing marks on crankshaft and camshaft gears.
4. Fit timing belt tensioner ensuring that index wire is positioned over pillar bolt and that tensioner lever is at 9 o’clock position.
5. Fit new Patchlok bolt and tighten bolt until it is just possible to move tensioner lever.
6. Fit timing belt over crankshaft gear and then over camshaft gears, keeping belt taut between crankshaft gear and exhaust camshaft gear.
7. Position belt using fingers only over tensioner and coolant pump drive gear.
8. Check that timing belt is positioned centrally around all gears and pulley.
9. Fit and align lower timing belt cover, ensuring correct position of rubber seal.
10. Fit lower timing belt cover screws and tighten to 9 Nm.
11. Fit crankshaft pulley to crankshaft gear ensuring that indent on pulley locates over lug on gear.
12. Fit crankshaft pulley bolt with washer and tighten to 205 Nm.
13. Remove camshaft and flywheel locking tools.
14. Clean mating faces of starter motor and gearbox.
15. Fit starter motor.
16. Fit bolts and tighten to 80 Nm.
17. Fit leads to starter solenoid and tighten terminal nut.
18. Connect Lucar to starter solenoid.
19. Fit flywheel cover and tighten bolt to 9 Nm.
20. Fit exhaust manifold heat shield and tighten bolts to 9 Nm.
21. Position buttress assembly to subframe and manoeuvre into position.
22. Secure buttress assembly with bolts.
23. Fit nut to engine mounting centre bolt but do not tighten.
24. Fit nut and bolt securing tie rod to buttress but do not tighten.
25. Fit bolts securing arm assembly to engine and tighten to 45 Nm.
26. Tighten engine mounting centre bolt nut to 82 Nm.
27. Tighten bolt securing tie rod to buttress to 85 Nm.
28. Secure hydragas pipe to buttress clips.
29. Remove jack.
30. Fit drive belt to alternator and crankshaft pulleys and adjust tension. See ELECTRICAL, Adjustments.
31. Models with A/C: Position A/C compressor, tighten bolts to 45 Nm.
32. Fit alternator drive belt. See ELECTRICAL, Repairs.

33. All models: Using a 6 mm Allen key, rotate tensioner anti-clockwise and align the pointer to the index wire.