Toothed Belt, Removing From Camshaft Sprockets

Toothed belt, removing from camshaft sprockets
Special tools and equipment:
- Pin wrench 3212
- Open end wrench 3312
- Socket attachment 3078 (22 mm)
- Set screw 3242
- Camshaft clamps T40005
- Special tool T40001
- Pin T40011

Removing
- Remove air intake hose to air cleaner.
- Remove front bumper, Refer to Body and Frame. [1][2]Procedures
- Adjust lock carrier to service position. [1][2]Procedures





- Remove outer ring for viscous fan -arrows-
- Remove electric fan.





- Counter-hold viscous fan pulley with pin wrench 3212 and remove fan with wrench 3312 (left hand thread).
- Remove fan with fan shroud.
- Remove 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 belt runs in right direction and is seated properly on belt pulleys.





- To loosen ribbed belt, turn tensioner in direction of arrow with 19 mm ring wrench until two holes are aligned. Hold in position with pin 3204.
- Remove ribbed belt.





- Move crankshaft by hand to TDC. Markings -A- and -B- must be aligned.
- Remove right and left timing belt covers by disengaging spring clips.





- Check position of camshafts: larger holes in securing plates on 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 sprockets 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 pin T40011 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 noise insulation.
- Install engine cover panel.

Camshaft Pulley 55 Nm (40 ft. lbs.)
Idler 45 Nm (33 ft. lbs.)
Cover For Cylinder Head 10 Nm (7 ft. lbs.)
Outer Ring Of Fan To Radiator 10 Nm (7 ft. lbs.)
Viscous Fan - Using Torque Wrench 1331 And Open End Wrench 3312 37 Nm (27 ft. lbs.)
Viscous Fan - Using Torque Wrench Without Open End Wrench 3312 70 Nm (52 ft. lbs.)
Outer Ring Of Fan To Radiator 10 Nm (7 ft. lbs.)