Belt Drive, Dismantling

Timing belt, dismantling

Special tools:
999 5304 SEPARATOR 999 5304 Separator
999 5433 COUNTERHOLD 999 5433 Counterhold

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Aligning the engine according to the marking




Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft's timing belt pulley and the camshafts' timing belt pulleys correspond with the markings on the oil pump and the upper timing belt cover.
Remove the upper timing belt cover.

Marking on the crankshaft's timing belt pulley and the oil pump.





Removal

Removing vibration damper




Remove the screws, 4 pcs. Use the crankshaft's center nut as counterhold.
Install: 999 5433 COUNTERHOLD 999 5433 Counterhold and remove the center nut.
Remove: 999 5433 COUNTERHOLD 999 5433 Counterhold.
Wiggle/pull loose the vibration damper.

Removing the timing belt




Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key
Remove the timing belt from the camshafts' timing belt pulleys.
Remove the timing belt.

Removing the crankshaft's timing belt pulley





Caution! The crankshaft must not rotate!

Use: 999 5304 SEPARATOR 999 5304 Separator and two screws (M8 x 45 mm) with washers.
Pull loose the timing belt pulley.

Removing the belt tensioner and idler pulley




Remove the belt tensioner and the idler pulley.
Check the roller surfaces and bearings.
Listen for any noise and feel for any clearance in the bearings.
Check that the roller surfaces are smooth and clean.

Removing oil pump




Remove the belt guard from the oil pump.
Remove oil pump's screws, 4 pcs.
Carefully wiggle out the oil pump. Use a screwdriver at the pry lugs.
Carefully pull the oil pump past the crankshaft end.
Thoroughly clean the gasket surfaces and contact faces.

Check

Checking the oil pump




Dismantle the oil pump.
Clean and check all parts.
Check the parts for damage and wear.
In case of defects, replace the oil pump.

Assembly

Assembling oil pump




Place the outer and inner pump rotors in the oil pump housing. The inner pump rotor has a face-recessed surface around the hole for fitting against the crankshaft. This face-recessed surface shall be placed facing against the seal ring in the oil pump housing.
Install the reducer valve's piston and spring.
Assemble the pump and tighten the screws according to: Tightening torque, B5254T7 Tightening Torque.

Removal

Removing coolant pump and timing belt cover




Remove the screws.
Tap carefully with a plastic mallet on the pump rotor.
Wiggle/pull loose the pump.
Thoroughly clean the gasket surfaces and contact faces.
Remove the inner timing belt cover.