Models with intercooler (page 2 of 4)

66. Using fingers only, fit timing belt to gears. Ensure the belt run between the crankshaft gear and camshaft gear is kept taut during the fitting procedure.

CAUTION: If original belt is to be refitted ensure direction of rotation is correct.

67. Check sealing strips are correctly located in camshaft timing belt lower cover.
68. Fit lower cover, fit bolts and tighten to 5 Nm.
69. Clean and fit crankshaft pulley, fit bolt and tighten to 63 Nm + 90°.

70. Loosen tensioner pulley Allen bolt until tensioner moves easily without tipping.
71. Release camshaft timing belt tensioner plunger using 18G 1719.
72. Remove tool 18G 1719 from camshaft timing belt tensioner and tighten Allen bolt to 55 Nm.

CAUTION: Do not exceed specified torque figure.

73. Fit access plug to camshaft timing belt rear cover.
74. Remove timing pin 18G 1523.
75. Using a socket and extension bar on the crankshaft pulley bolt, rotate crankshaft two turns clockwise until the flywheel timing pin can be re-fitted.
76. Check the camshaft gear timing mark is correctly aligned with the back cover timing mark

77. Loosen Allen bolt securing belt tensioner pulley, to allow tensioner to react, then tighten to 55 Nm.

CAUTION: Do not exceed specified torque figure.

78. Remove timing pin 18G 1523.
79. Restrain camshaft using 18G 1521 and tighten bolt retaining camshaft timing belt gear to 20 Nm + 90°.
80. Fit timing pin 18G 1523 into hole in flywheel.

CAUTION: Ensure pin is fully inserted into hole in flywheel.