Replacing the Timing Belt/Idler Pulley/Belt Tensioner

Replacing The Timing Belt/Idler Pulley/Belt Tensioner

Special Tools: 999 5433.

NOTE: As the illustrations in the information are used for different model years and/or models, certain variations may occur. However, the essential information in the illustrations is always correct.

Remove components

CAUTION: Remove the ignition key from the ignition switch before beginning work.

NOTE: The crankshaft or camshaft must not be rotated under any circumstances other than those listed below. Failure to follow these instructions may cause damage to the valves.

Remove:







- the upper timing belt cover.
- the servo reservoir and the expansion tank.

Lift up and place on top of the engine.

NOTE: Take care not to spill servo oil from the bleed hole in the cap.

Place paper wipe around the reservoir and then cover with a plastic bag as protection.

Spilled servo oil is highly inflammable.

- the auxiliaries belt.
- the front camshaft belt cover.

Position The Engine According To The Marking







- Remove the right front wheel.
- Remove the nut for the cover in the fender liner.
- Install the upper camshaft belt cover.
- Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
- Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond.

The markings are shown in figure.

- Remove the upper camshaft belt cover.

Removing The Camshaft Belt

Slacken Off The Belt Tensioner







- Slacken off the belt tensioner center screw slightly.
- Hold the center screw still and turn the tensioner eccentric clockwise with a 6 mm (15/64 ) Allen key to "10 O'clock".
- Remove the camshaft belt from the tension pulley, camshaft pulley and idler pulley.

Remove The Vibration Damper

Raise The Car







- Remove the vibration damper.
- Use counterhold 999 5433.
- Work the vibration damper loose.

- Remove the camshaft belt.

Checking The Tension And Idler Pulleys







Check bearing wear:

Replace if necessary.

- Idler pulley:
- Spin the idler pulley and listen for noise.
- If replacing with a new idler pulley, tighten to 24 Nm (18 lb.ft).

- Tension pulley:
- When replacing, screw the tension pulley into place with the center screw.
- Screw in the center screw by hand.
- Ensure that the tensioner fork is centered over the cylinder block rib.
- Ensure that the Allen key hole on the eccentric is at 10 O'clock.

As shown in above figure.

Installing The Camshaft Belt

Install The New Belt As Follows:







- Install the new camshaft belt over the crankshaft pulley wheel.
- Install the vibration damper.
- Tighten the center nut to 180 Nm (133 lb.ft).
- Use counterhold 999 5433.

- Remove the counterhold and install new screws.
- Tighten the screws to 25 Nm (18 lb.ft). Angle tighten 30 degree.

Then Install The New Belt In The Following Order:
1. Idler pulley.
2. Intake camshaft pulley.
3. Exhaust camshaft pulley.
4. Water pump.
5. Belt tensioner.

Tighten The Timing Belt
- This adjustment is to be made with a cold engine.
- A suitable temperature is approximately 20 degree C / 68 degree F.
- At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.







- The figure shows the indicator position when adjusting the belt tensioner at different engine temperatures.

Tighten The Timing Belt As Follows:







- Carefully turn the crankshaft clockwise until the camshaft belt is tensioned.

The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft.

- Hold the belt tensioner center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
- Then turn the eccentric back so that the needle reaches the marked position corresponding to the relevant temperature.

At 20 degree C (68 degree F) the needle must be centered in the window. See the above figure.

- Hold the eccentric secure and tighten the center screw to 20 Nm (15 lb.ft).

Check that the indicator is in the correct position.
- A new alignment must be carried out if the indicator is not in the correct position.

Check

Checking Markings:







- Press the belt to check that the indicator on the belt tensioner moves easily.
- Install the upper timing belt cover.
- Turn the crankshaft 2 turns and check that the markings on the crankshaft and camshaft pulley correspond.
- Check that the indicator on the belt tensioner is within the marked area.

Reinstall
- The front camshaft belt cover.
- Tighten to 12 Nm (8.8 lb.ft).

- The upper camshaft cover.
- Tighten to 8 Nm (6 lb.ft).

- Install the auxiliaries belt.







- The servo reservoir.
- Wipe clean.
- Check the fluid level. Top up if necessary.

- The expansion tank.

NOTE: Ensure that the hoses are correctly positioned.

- Wipe clean and check the engine compartment.
- The cover in the fender liner.
- The front wheel.

Checking Work

NOTE: Write the date and mileage on the decal. Stick it on the camshaft belt cover.

Function test:
- Test drive the engine.
- Wipe the steering wheel and gear selector lever clean.