Toothed Belt, Removing From Camshaft Sprockets
Special tools and equipment:
- Pin wrench 3212
- Open end wrench 3312
- Socket attachment 3078 (22 mm)
- Clamping bolt 3242
- Camshaft clamps T40005
- Special tool T40001
- Pin T40011
Removing
- Remove cover -1-.
- Remove air intake hose -2- to air cleaner.
- Remove noise insulation -arrows-.
- Remove noise insulation -arrows-.
- Remove cover for cylinder heads -1and -2-.
- Remove outer ring for viscous fan -arrows-.
- Remove electric fan.
- Counter hold fan pulley with pin wrench 3212 and remove fan with open-end wrench 3312 (left-hand thread).
- Remove fan together with outer ring.
- Remove ribbed belt pulley for fan.
CAUTION!
- Mark the running direction of the belt with crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt.
- When installing a used ribbed belt be sure the belt runs in the right direction and is seated correctly on the belt pulleys.
- To loosen ribbed belt, turn tensioner in direction of arrow with 19 mm ring wrench until the two holes are aligned. Hold in position with pin 3204.
- Remove ribbed belt. Service and Repair
- Move crankshaft by hand to TDC. Markings -A- and -B- must be aligned.
- Remove right and left hand timing belt covers through loosening of fastening spring clips.
- Check position of camshafts: the larger holes (arrow) in the securing plates on the camshaft sprockets must be in line with each other and facing inward. If not, turn crankshaft for one revolution.
- Remove plug (arrow) from left side of cylinder block.
- TDC drilling in crankshaft must be behind sealing plug hole (feel to check).
- Screw clamping bolt 3242 for crankshaft into plug hole and tighten.
Note: The toothed belt tensioning element is oil-damped and can be compressed slowly by applying constant pressure.
- Using 8 mm Allen key, turn toothed belt tensioning lever -1- in direction of arrow until tensioning element-2 is compressed far enough to insert pin T40011 in drilling and plunger.
- Install camshaft bar T40005 on securing plates of both camshafts.
- Loosen both camshaft bolts by approximately 5 turns.
- Remove camshaft bar T40005.
- Pull off both camshaft sprockets with puller T40001.
- Remove toothed belt together with camshaft sprocket for cylinder bank 1-4.
Installing
- Place toothed belt over camshaft sprocket for cylinder bank 1-4 and install sprocket on camshaft.
- Hand-tighten both camshaft sprockets with securing plates.
Note: The camshaft must be tight enough on the camshaft tapers to be turned but not moveable axially.
- Attach camshaft bar T40005.
- Using 8 mm Allen key, turn toothed belt tensioning lever-1- in direction of arrow until spring pin can be removed.
- Tighten bolts on camshaft sprockets.
Note: Camshaft clamp T40005 is used to prevent camshafts from turning.
- Remove camshaft bar T40005.
- Remove crankshaft clamping bolt 3242 and install sealing plug.
- Turn crankshaft by 2 revolutions.
- Check dimension -a- of belt guard with feeler gauge.
Dimension -a- = 1 mm (0.0393 inch)
Right cover, adjusting
- Turn crankshaft until all bolts -arrows are exposed.
- Loosen all bolts -arrows- of cover.
- Adjust dimension -a- using feeler gauge to 1 mm (0.0393 inch).
- Check dimension -a- of belt guard with feeler gauge.
Dimension -a- = 1 mm (0.0393 inch)
Left cover, adjusting
- Turn crankshaft until all bolts -arrows are exposed.
- Loosen all bolts -arrows- of cover.
- Adjust dimension -a- using feeler gauge to 1 mm (0.0393 inch).
Note: When installing a used ribbed belt, be sure that the belt runs in the correct direction and seats properly on the belt pulleys.
- Install ribbed belt on crankshaft pulley and idler wheels first. Install belt on tensioning roller last.
- To tension ribbed belt, turn tensioner clockwise (arrow) with 19 mm ring wrench and remove pin 3204.
- Start engine and check that belt runs correctly.
- Install viscous fan with outer ring (fan has left-hand thread).
- Counter-hold fan pulley with pin wrench 3212 and tighten fan using open-end wrench 3312 and torque wrench (fan has left-hand thread).
- Install electric fan
- Install noise insulation.
- Install engine cover panel.
Tightening Torques (Part 15 Of 18):
Tightening Torques