Toothed Belt, Removing and Installing

Toothed belt, removing and installing

Removing
- Engine installed
- Lock carrier in service position, [1][2]Procedures

Special tools and equipment
- V159 pin wrench

- Remove ribbed belt and ribbed belt tensioner. Service and Repair
- Remove viscous clutch (with belt pulley), V-Belt and ribbed belt, routing overview, See , Fig. 1. Service and Repair
- Remove upper toothed belt cover.

CAUTION! Before removing toothed belt, note direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a used belt can destroy the belt.




- Turn crankshaft at central bolt of toothed belt gear in direction of engine rotation to TDC Cyl.1 marking (arrows).




- Remove vibration damper.




- Remove lower toothed belt cover (arrows).




- Using Torx wrench T45, loosen toothed belt tensioner (lower arrow).
- Push toothed belt tensioner downward.
- Remove toothed belt.

Installing (adjust valve timing)

Note:
- Use the following procedure to adjust toothed belt, even for repairs that only require removal of toothed belt from camshaft gear.
- Adjustments can be made on a hot or cold engine.

CAUTION! When turning camshaft, crankshaft may not be at TDC for any cylinder. Valves and/or piston heads may be damaged.




- Align marking on camshaft gear to marking on cylinder head cover.
- Place toothed belt on crankshaft gear noting direction of rotation.
- Install lower toothed belt cover.
- Using a bolt, secure vibration damper/belt pulley (note locating point).
- Set crankshaft to TDC Cyl. 1 position.
- Place toothed belt on belt tensioner and camshaft gear.




- Tighten toothed belt by turning tensioner -A- to right using 2 pin spanner (i.e. Matra V159 pin wrench) until cylinder -1- is fully extended and tensioner -2- is raised by approximately 1 mm.
- Tighten mounting bolt -3- hand tight.
- Turn crankshaft 2 rotations in running direction.




- Check area -A- for proper alignment with the upper edge of piston -2- (Fig. A13-0012) and adjust if necessary.
- Area -A-: adjustment OK
- Area -B-: wear limit
- Area -C-: re-adjust and check belt drive including tensioner for wear

Note: If edge of piston is located in area -A-, measurement -D- is between 25-29 mm (0.984 - 1.142 inch).




- Counterhold toothed belt tensioner using 2 pin spanner -B- and tighten mounting screw 3-.




- Turn crankshaft at central bolt for toothed belt gear two rotations in direction of engine rotation, until camshaft and crankshaft markings align with their respective reference points.
- Install vibration damper/belt pulley.
- Install upper toothed belt cover.
- Install ribbed belt and ribbed belt tensioner, Service and Repair

Note: When installing the ribbed belt, make sure it is seated correctly on the pulley.




Tightening torques