Installation Procedure

Camshaft Drive, To Fit





1. Fit the camshaft belt as marked on the belt and in the correct direction of rotation. Use Adjustment tools, cam sprockets and timing belt KM-800-30 to hold the belt in place. Fit the lower tensioning pulley loosely. Make sure the washer is in place.
Lightly adjust the tensioning pulley by hand so that the belt does not jump. Adjust anticlockwise. Make sure the markings on the camshaft belt and the corresponding markings on the camshaft sprockets and crankshaft are aligned. Remove the tools, KM-800-30.

Fit locking tool KM-800-10, position a piece of camshaft belt and fit Belt tension meter part no. 83 93 985 to measure the belt tension.

Tighten the centre bolts of the adjuster rollers lightly. Adjust the lower adjuster roller anticlockwise until a tension of 275-300 Nm is obtained. Use tool 83 94 983. Tighten the adjuster roller's bolt. Use tool 83 94 983 as a counterstay. Check the belt tension again and adjust as necessary.
Tightening torque: 40 Nm (30 ft. lbs.).

Remove the belt-tension meter and piece of the toothed belt.

Important: Adjustment of belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.





2. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tighten.
Tightening torque: 20 Nm (15 ft. lbs.).

Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprocket are aligned with the corresponding markings on KM-80020. Tighten. Use tool 83 94 983 as a counterstay.
Tightening torque: 40 Nm (30 ft. lbs.).

Remove KM-800-20 and the other locking tools.

3. Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.

Important: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.





4. Raise the car and fit the crankshaft pulley.
Tightening torque: 20 Nm (15 ft. lbs.).
5. Lower the car and fit the timing cover.
Tightening torque: 8 Nm (6 ft. lbs.).
6. Fit the belt tensioner and the generator air intake.
7. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
8. Fit the multigroove belt.
9. Tighten the retaining bolts on the pulleys.
Tightening torque:
Belt pulley/coolant pump: 8 Nm (6 ft. lbs.).
Belt pulley/power steering pump: 20 Nm (15 ft. lbs.).





10. Fit the right-hand engine attachment with bracket and engine mount.
Tightening torque: To body 63 Nm (46.5 ft. lbs.).
11. Fit the power steering hose in the holder
12. Fit the mass air flow sensor with hose.
13. Raise the car.





14. Lower the engine by carefully removing the wedges.





15. Fit the lower spoiler sections.
16. Lower the car and remove the wing protectors.