Toothed Belt

Toothed Belt

Special tools, testers and auxiliary items required

• Engine Support Bridge (10 - 222 A)

• Shackle (10 - 222 A /12)

• Adapter (T40093/6) qty. 2

Removing

- Remove the engine cover - arrows -.






- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Service and Repair.

- Remove the right front wheel.

- Remove the right noise insulation - arrows -.






- Loosen the front section of the wheel housing liner and push it to the rear.

- Remove the ribbed belt tensioner. Refer to => [ Ribbed Belt Tensioner ] Service and Repair.

- Remove the bolts - arrows - and the EVAP canister bracket.






• Ignore - 1 -.

- Remove the coolant hose - arrow -.






- Remove the coolant hoses - 1 - and - 2 -.






- Free up the electrical wiring harness on the coolant reservoir.






- Disconnect the connector - 1 - from the engine coolant level warning switch (F66).

- Remove the bolts - arrows - and remove the coolant reservoir.

- Remove the bolts - arrows - and the upper toothed belt guard.






- Remove the bolt and nut - arrows - and push the front coolant pipe to the side.






- Place the (10 - 222 A) on upper edge of web plates with the following tool parts:






• Engine brackets (10 - 222 A /1) , quantity: 2

• Spindle (10 - 222 A /11)

• Shackle (10 - 222 A /12)

• Adapter (T40093/6) qty. 2

- Attach the (10 - 222 A /11) and (10 - 222 A /12) to the engine lifting eye.

- Tighten the spindle to tension the engine/transmission.

- Remove the bolts - 1 - and - 2 - and the connecting brace.






- Remove the bolts - 3 through 6 - and the engine mount.

- Remove the bolts - 1, 2 and 3 -.






• The bolt is reached - 2 - from the wheel housing side.

Danger of damaging components and hoses.

• Be careful not to damage any parts or to overbend any hoses when lifting the engine.

- Lift the engine by the (10 - 222 A) until it is possible to remove the engine support.

Components could be destroyed by the toothed belt jump off.

• Only rotate the crankshaft in the direction of engine rotation.

- Turn the crankshaft by the toothed belt crankshaft sprocket bolt until the camshaft sprocket is at "TDC".

• The marking on the camshaft sprocket must align with the arrow on the toothed belt guard - top arrow -.






• The notch on the vibration damper must align with the arrow on the toothed belt guard - bottom arrow -.

- Remove vibration damper. Refer to => [ Vibration Damper ] Service and Repair.

The engine could be damaged.

• The "TDC" markings must align before the vibration damper can be removed.

• Crankshaft must not be rotated any more until "TDC" position is marked with an assisting mark.

- Remove the lower toothed belt guard - arrows -.






- Mark the "TDC" - arrow -.






A used toothed belt could be destroyed if the running direction is reversed.

• Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for installation later.

- Loosen the tensioning roller and remove the toothed belt.

Installing (Adjusting valve timing)






• For the correct tightening specifications, refer to => [ Toothed Belt Drive Overview ] Toothed Belt Drive Overview.

Risk of damaging valves and piston crowns.

• If camshafts are being rotated, crankshaft may not rest with any piston at "TDC".

• The engine must be no more than warm to touch.

- Make sure the camshaft and crankshaft are at "TDC":

• The markings on the camshaft - top arrow - and crankshaft - bottom arrow - must align.

- When reinstalling the toothed belt, note running direction marking:

• Crankshaft, tensioning roller, camshaft, coolant pump and idler roller - arrow -.






- Make sure the tensioning roller fits correctly inside the cylinder head.

• The bracket - arrow - must engage into the cut-out in the cylinder head.






- Tension the toothed belt as follows:

- Rotate the eccentric pulley clockwise using a socket wrench - arrow - until the notch - 2 - is above the tab - 3 - (toothed belt over-tensioned).






- Release the eccentric pulley back to its starting position (toothed belt relaxed).

- Rotate the eccentric pulley clockwise using a socket wrench - arrow - until the notch - 2 - is opposite the tab - 3 -.

- Tighten the tensioning roller nut - 1 -.

Components could be destroyed by the toothed belt jump off.

• Only rotate the crankshaft in the direction of engine rotation.

- Turn the crankshaft by the toothed belt pulley bolt 2 turns in the direction of engine rotation until the crankshaft is once again at "TDC".

• The last 45° (1/8 turn) must be turned uninterrupted.

- Check the toothed belt tension:

• The notch - 2 - and the tab - 3 - must align.

- Re-tension the toothed belt if necessary.

- Valve Timing, Checking:

• The markings on the camshaft - top arrow - and crankshaft - bottom arrow - must align.






- If the markings do not align, repeat setting the valve timing.

The rest of the installation is performed in reverse order of removal, noting the following:

- Install the lower toothed belt guard. Refer to => [ Toothed Belt Drive Overview ] Toothed Belt Drive Overview.

- Install vibration damper. Refer to => [ Vibration Damper ] Service and Repair.

- Check the valve timing one more time:






• The marking on the camshaft sprocket must align with the arrow on the toothed belt guard - top arrow -.

• The notch on the vibration damper must align with the arrow on the toothed belt guard - bottom arrow -.

- Install the engine support and the engine mount. Refer to => [ Engine and Transmission Mounts Overview ] Service and Repair and adjust => [ Subframe Mount, Adjusting ] Adjustments.

- Install the front right coolant pipe. Refer to => [ Right Front Coolant Pipe ] Right Front Coolant Pipe.

- Install the ribbed belt tensioner. Refer to => [ Ribbed Belt Tensioner ] Service and Repair.

- Fill the coolant. Refer to => [ Filling ] Service and Repair.