Belt Drive, Assembly

Timing belt, assembling

Special tools:
999 5747 Socket 999 5747 Socket

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.

Installation

Installing water pump








Install the rear timing gear casing.
Tighten down the cover's three attaching points.
Install the water pump with a new gasket.
Apply thread sealant 11 61 056 on the screws for the water pump. Tighten crosswise.

Installing oil pump




Use a new gasket and new O-ring around the oil pump housing.
Tighten down: 999 5747 Socket 999 5747 Socket sliding sleeve at the front on the crankshaft journal.
Press in the pump over the sliding sleeve.
Install new screws as guide.
Carefully tap in the oil pump with a plastic mallet.
Tighten down the oil pump crosswise with 10 Nm.
Remove: 999 5747 Socket 999 5747 Socket.
Install the lower belt guard.

Installing tension pulley and idler pulley





Caution! The tension pulley and idler pulley must always be replaced when replacing the timing belt.

Install:
- a new tension pulley with the center screw.
Screw in the center screw by hand.
Ensure that the tensioner fork is centered over the cylinder block's rib.
Make sure that the Allen head hole on the eccentric is in position 10 o'clock.
- new idler pulley. Tighten the screws.

Installing the crankshaft's timing belt pulley





Note! The timing belt pulley can only be installed in one position in case of splines on the crankshaft journal, see illustration.

Carefully tap in the timing belt pulley with a plastic mallet.

Installing the timing belt




Install the new belt in the following order:
- the crankshaft
- the idler pulley
- camshaft pulley
- the water pump
- belt tensioner.




Pull out the pin.
Check that the tensioner tensions the belt,

Tighten the center screws that hold the VVT-units on both camshafts. Tighten according to: Tightening torque, B5254T7 Tightening Torque
Install the plugs for the VVT-units. Tighten according to: Tightening torque, B5254T7 Tightening Torque.

Removal

Removing the adjustment tools





Remove:
- 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool from the rear edge of the camshafts
- 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool.
Install the plug with a new seal washer.
Tighten, see: Tightening torque, B5254T7 Tightening Torque.

Check

Checking the markings and belt tension




Press on 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 position. Adjust as needed.
Remove the upper timing cover.

Installation

Installing rotor




Install the rotor and screw them on the camshafts' trailing edge.

Installing the cover




Install the covers in the trailing edge of the camshaft. Use a plastic hammer and tap in the covers until they are flush with the camshaft cover and cylinder head.