Belt Drive, Assembly

Belt drive, assembly

Special tools:
999 5747 Socket 999 5747 Socket
999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
999 5433 COUNTERHOLD 999 5433 Counterhold

Note! As 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.

Tightening torque
For tightening torques not in the text, see Tightening torque Tightening Torque.

Installing the water pump




Install the rear timing cover.
Screw into place at the three mounting points.
Install the water pump with a new gasket.
Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten the screws crosswise.

Installing the oil pump




Use a new gasket and a new O-ring around the oil pump housing and new screws. Alternatively, apply thread sealant 11 61 056 to the underside of the old screw heads.
Screw sliding sleeve 999 5747 Socket 999 5747 Socket into place at the front of the crankshaft journal.
Press in the pump over the sliding sleeve.
Install the screws as a guide.
Carefully tap in the oil pump with a rubber mallet.
Tighten the oil pump crosswise. See Tightening torque Tightening Torque.
Remove the sliding sleeve 999 5747 Socket 999 5747 Socket.

Installing front crankshaft seal
See Oil pump / crankshaft seal, front, replacing, B5244T5 Service and Repair.

Installing the crankshaft timing gear pulley





Note! The timing gear pulley can only be installed in one position on the crankshaft journal splines (see the illustration).

Carefully tap in the timing gear pulley with a rubber mallet.

Installing the idler pulley and belt tensioner





Install:
- idler pulley. Tighten
- the belt tensioner and the center screw so that the tensioner fork is centered over the cylinder block rib. Do not tighten
- the lower belt guard at the oil pump
- the fuel delivery line.

Installing the timing gear pulley for the camshafts

Note! The purpose of the "Installing the timing gear pulley" section described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.





Note! Do not turn counter clockwise during this procedure.

Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit and timing gear pulley onto the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly. Turn the variable valve timing unit counter-clockwise as far as it will go. Remove the center screw.
Position the upper timing cover.
Turn the timing gear pulley clockwiseuntil the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1 cogs before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes. Tighten the center screw in the variable valve timing unit. Tighten. See Tightening torque Tightening Torque.
Check that the variable valve timing unit does not rotate when tightening. Install and tighten the center plug. See Tightening torque Tightening Torque.
Turn the variable valve timing unit clockwise to the limit position.
Turn the timing gear pulley so that the markings correspond.

Installing the variable valve timing (VVT) unit on the intake camshaft





Note! Do not turn counter clockwise during this procedure.

Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit. Press the variable valve timing unit and timing gear pulley onto the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Turn the variable valve timing unit counter-clockwise as far as it will go. Remove the center screw. Position the upper timing cover.
Turn the timing gear pulley clockwiseuntil the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 1-1/2 cogs before the marking on the upper timing cover.




Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw in the VVT unit. See Tightening torque Tightening Torque.
Check that the variable valve timing unit does not rotate when tightening. Install the center plug. Tighten. See Tightening torque Tightening Torque.
Turn the variable valve timing unit clockwise to the limit position. Turn the timing gear pulley so that the markings correspond.

Finishing
Tighten the center screw on the timing belt tensioner. Tighten to 5 Nm.

Installing the timing belt





Install the belt in the following order:
- crankshaft
- the idler pulley
- intake camshaft
- exhaust camshaft
- coolant pump
- belt tensioner.

Note! The variable valve timing units do not have a return spring and are easily dislodged when reinstalling the timing belt. Check that the markings are correct.

Adjusting the timing belt




This adjustment is to be made with a cold engine. A suitable temperature is approximately 20°C/68°F.
At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position and reaches the limit position.
Tighten the 3 screws on the exhaust camshaft timing gear pulley. Tighten. See Tightening torque Tightening Torque.
Tighten the 3 screws on the intake camshaft timing gear pulley. Tighten. See Tightening torque Tightening Torque.





Note! Check that the variable valve timing units are in the limit position.

Turn the eccentric back so that the indicator reaches the marked position in the center of the window.
Remember to hold the center screw secure at the same time.
Hold the eccentric secure. Tighten the center screw. Tighten. See Tightening torque Tightening Torque.
Check that the indicator is in the correct position.





Remove:
- camshaft adjustment tools 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool from the rear edge of the camshafts
- crankshaft stop 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
- the plug with a new sealing washer. Tighten. See Tightening torque Tightening Torque.

Checking the markings and belt tension




Press the timing belt to check that the indicator on the belt tensioner moves easily.
Position the upper timing cover.
Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond.
Check that the indicator on the belt tensioner is within the marked area.
Remove the upper timing cover.

Installing the vibration damper





Install:
- the vibration damper. Use counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold
- the crankshaft center nut. Tighten. See Tightening torque Tightening Torque. Remove counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold
- the 4 screws. Tighten. See Tightening torque Tightening Torque. Use the crankshaft center screw as a counterhold.

Checking the markings and belt tension




Press the timing belt to check that the indicator on the belt tensioner moves easily.
Position the upper timing cover.
Turn the crankshaft two turns. Check that the markings on the crankshaft and timing gear pulley match up with the markings on the oil pump and upper timing cover respectively.
Check that the indicator on the belt tensioner is within the marked area.