Refit - Engines fitted with manual timing belt tensioner

Refit - Engines fitted with manual timing belt tensioner

1. Clean crankshaft pulley, timing belt gears, coolant pump drive gear and tensioner pulley.

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 refitting. Because of the porous construction of sintered material, oil impregnated in the gears will emerge and contaminate the belt.

2. Check correct alignment of camshaft timing marks for 90° BTDC and that tool 18G 1570 is locking camshaft gears.

3. Ensure dots on crankshaft gear are aligned with flange on oil pump and that tool 18G 1742 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 camshaft gears 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 cover. See this section.

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

9. Fit RH engine mounting to body and engine.
10. Fit through bolt securing RH engine mounting to body but do not tighten.
11. Fit 2 new nuts securing RH engine mounting to engine and tighten to 100 Nm.
12. Tighten RH engine mounting to body through bolt to 75 Nm.
13. Lower jack supporting power unit and remove from beneath vehicle.
14. Remove camshaft gear locking tool 18G 1570.

Tensioning existing timing belt

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