Existing timing belts

Refit

1. Clean timing gears and pulleys.

CAUTION: If the sintered gears have been subjected to prolonged oil contamination, they must be soaked in a solvent bath and then thoroughly washed in clean solvent before refitment. Because of the porous construction of sintered material, oil impregnated in the gear will emerge and contaminate a new belt.

2. Check correct alignment of timing marks for 90° BTDC.

NOTE: Ensure dots on crankshaft gear are aligned with flange onoil pump and camshaft gear aligns with mark on rear cover.

3. Fit timing belt over crankshaft gear and then over camshaft gear, keeping belt taut from crankshaft to camshaft gears.

CAUTION: Existing timing belts - ensure direction of rotation mark is facing correct way.

4. Using fingers only, ease timing belt over tensioner pulley and coolant pump drive gear, ensuring belt is positioned centrally around gears and pulley.
5. Fit timing belt lower cover, ensuring correct position of seal.
6. Fit bolts securing lower cover and tighten to 10 Nm.

7. Fit crankshaft pulley to crankshaft gear, ensuring indent on pulley locates over gear lug.
8. Fit crankshaft pulley bolt and washer and tighten bolt to 205 Nm.
9. Remove tool 18G 1571 from flywheel.
10. Position starter motor to flywheel housing.
11. Fit starter motor. See ELECTRICAL, Repairs.
12. Fit engine RH mounting bracket to engine and tighten bolts to 60 Nm.
13. Fit engine RH mounting. See this section.
14. Remove jack.

Existing timing belts

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