Models with air conditioning

Refit

1. Clean seal recess and camshaft.
2. Grease outer edge of new seal.
3. Lubricate the inner lip of seal with clean engine oil.

4. Ensure seal fitting tool 18G 1716 is clean.
5. Locate new oil seal to seal housing, position tool 18G 1716 to seal and drift seal into housing.
6. Remove tool 18G 1716.
7. Clean camshaft gear and mating face.
8. Fit camshaft gear to belt and position gear to camshaft.

CAUTION: Ensure timing marks on camshaft gear and back cover are aligned.

9. Apply clean engine oil to threads of new camshaft gear bolt.
10. Fit but do not tighten camshaft gear bolt.

CAUTION: Ensure camshaft does not rotate.

NOTE: Bolt is tightened after timing belt has been tensioned.

11. Lower RH side of engine to body.
12. Fit restraint bar to mounting studs.
13. Fit 2 nuts securing RH engine mounting and tighten to 45 Nm.
14. Remove jack.
15. Tighten nut securing bracket to engine mounting to 105 Nm.
16. Fit engine upper tie bar and tighten bolts to 80 Nm. Tighten bolt tie bar to body last.

Models with air conditioning

17. Align air conditioning pipe clips and fit bolts.

All models

18. Slacken tensioner pulley Allen bolt until tensioner moves easily without tipping.
19. Release camshaft timing belt tensioner plunger using tool 18G 1719.
20. Remove tool 18G 1719 from camshaft timing belt tensioner, tighten Allen bolt to 55 Nm.

CAUTION: Do not exceed specified torque.

21. Fit access plug in timing belt rear cover.
22. Remove timing pin 18G 1523 from flywheel.
23. Using crankshaft pulley bolt, rotate crankshaft 2 complete revolutions clockwise and align camshaft gear timing marks.

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

24. Fit timing pin 18G 1523 into hole in flywheel ensuring pin is fully inserted in hole.
25. Loosen tensioner pulley Allen bolt until tensioner moves to tension belt then tighten Allen bolt to 55 Nm.
26. Fit access plug in timing belt lower cover.
27. Remove timing pin 18G 1523 from flywheel.