12.65.18.01 Camshaft Timing Belt

12.65.18.01 Camshaft timing belt

Remove






1. Remove 4 bolts securing engine mounting bracket to engine front plate and remove bracket.
2. Release and remove ancillary drive belt from remaining pulleys.






3. Remove 2 bolts securing ancillary drive belt tensioner and remove tensioner.






4. Remove Torx screw securing idler pulley to front mounting plate and remove pulley.






5. Release alternator battery lead terminal cover, loosen terminal nut and disconnect lead from terminal
6. Disconnect multiplug from alternator.
7. Remove lower bolt and upper nut and bolt securing alternator to front mounting plate.
8. Release alternator and remove.






9. Remove 3 bolts securing camshaft timing belt LH rear cover and remove cover.
10. Remove inlet manifold chamber - if fitted. *** 30.15.37 Seals - inlet manifold chamber - up to 03MY ***






11. Remove 2 bolts securing RH rear timing belt cover heat shield to cylinder head; remove heat shield.
12. Remove 3 bolts securing RH rear timing belt cover; remove cover.






13. Using a socket on crankshaft pulley bolt, rotate crankshaft in a clockwise direction and align the engine "SAFE" position - notch on crankshaft pulley aligned to the "ARROW" on front mounting plate. Check that the timing marks on the rear camshaft gears are aligned as illustrated.

CAUTION: Do not use the camshaft gear bolts or timing belts to rotate the crankshaft. Do not use the arrow on the oil pump body as a timing reference.






14. Insert timing pin LRT-12-232 through hole immediately adjacent to side of lower crankcase ensuring that pin is located in hole in drive plate.






15. Remove 3 bolts securing camshaft timing belt LH front cover and remove cover.






16. Remove 3 bolts securing camshaft timing belt RH front cover and remove cover.






17. Remove bolt securing dipstick tube to cylinder block.
18. Depress locking collar, release and remove dipstick tube from engine sump.
19. Assemble LRT-12-161 to LRT-12-199 and secure with clamp bolt.






20. Insert LRT-12-161 with LRT-12-199 into crankshaft pulley, loosen and remove pulley bolt.

CAUTION: Ensure crankshaft does not rotate during above operation.

21. Remove LRT-12-161 and LRT-12-199 from crankshaft pulley.
22. Remove crankshaft pulley.






23. Remove 3 bolts securing camshaft timing belt lower cover to cylinder block and remove cover.






24. Remove 3 bolts securing engine front mounting plate and lifting bracket to cylinder block.
25. Remove bolt securing lifting bracket to RH cylinder head and remove lifting bracket.






26. Remove rubber blanking plug from around camshaft timing belt tensioner.






27. Remove 5 bolts and 2 pillar bolts securing engine front mounting plate to cylinder block.
28. Remove 2 bolts securing IRD support bracket to engine front mounting plate.
29. With care, release and remove front mounting plate from engine.






30. Fit a suitable 1.5 mm diameter pin through hole in tensioner body and into hole in plunger.

NOTE: If holes in body and plunger are not aligned, move tensioner backplate using a broad bladed screwdriver; this will move the plunger sufficiently to align the holes and allow the pin to be inserted.

31. Remove and discard 2 Patchlok bolts securing tensioner to cylinder block and remove tensioner.

CAUTION: Exercise great care when removing bolts, do not apply excessive torque. If bolts appear to be seized, apply suitable anti-seize lubricant prior to removing bolts. DO NOT loosen Allen screw securing tensioner pulley.

32. If camshaft timing belt is to be refitted, mark direction of rotation on timing belt before removal.
33. With care, ease camshaft timing belt from gears using fingers only and remove timing belt.

CAUTION: Do not rotate crankshaft or camshafts with timing belt removed.

CAUTION: Camshaft timing belt must be replaced if cylinder head is to be removed or new drive gears, tensioner or coolant pump are to be fitted. Camshaft timing belts must be stored and handled with care. Always store a camshaft timing belt on its edge with a bend radius greater than 50 mm (2.0 in). Do not use a camshaft timing belt that has been twisted or bent double as this will damage the reinforcing fibres. Do not use a camshaft timing belt if debris other than belt dust is found in timing belt covers. Do not use a camshaft timing belt if partial engine seizure has occurred. Do not use a camshaft timing belt if mileage exceeds 72,000 km (45,000 miles). Do not use an oil or coolant contaminated timing belt, cause of contamination must be rectified.






34. Remove and discard LH and RH exhaust camshaft cap seals.






35. Position tools LRT-12-196to LH and RH front inlet camshaft gears and into the end of each exhaust camshaft.

CAUTION: Special tools must be fitted when tightening or loosening gear retaining bolts, otherwise damage to camshafts may occur.

36. Remove and discard bolts retaining front inlet camshaft gears to camshafts.
37. Remove tools LRT-12-196 from both inlet camshaft gears and exhaust camshafts.
38. Remove camshaft drive gears and hub assemblies.

Refit

NOTE: Following front or rear timing belt refitment, it is possible that, after rotating the engine and positioning the crankshaft pulley to the 'SAFE' position, the timing marks on the rear timing gears may be misaligned. This misalignment is acceptable provided that the timing belt refitting procedure was carried out correctly.

1. Clean camshaft gears and hubs, crankshaft gear, tensioner and water pump pulleys.

CAUTION: If sintered gears have been subjected to prolonged oil contamination, they must be soaked in solvent and then thoroughly washed in clean solvent before refitting. Because of the porous construction of sintered material, oil impregnated in the gears will emerge and contaminate the timing belts.

2. Fit hubs to camshaft gears and fit gears to camshafts.
3. Fit new camshaft gear bolts; tighten bolts sufficiently to allow gears to rotate without tipping.
4. Position timing belt to crankshaft gear.

NOTE: To prevent the timing belt from disengaging from the crankshaft gear when fitting, fit a suitable wedge between the belt and oil pump belt guard.






5. Fit tool LRT-12-197 into each exhaust camshaft in turn.






6. Using assistance, rotate each exhaust camshaft slightly and align timing marks on LH and RH rear camshaft gears.
7. Remove tool LRT-12-197.
8. Fit tools LRT-12-175 to LH and RH rear camshaft gears.
9. Rotate both front camshaft gears fully clockwise as viewed from front of engine.
10. Using fingers only, fit timing belt to gears, starting at the crankshaft gear and working in an anti-clockwise direction, keeping the belt run as taut as possible and turning the camshaft gears only a minimum amount anti-clockwise to fit timing belt.

CAUTION: Gears must not be rotated anti-clockwise more than one tooth.






11. Position an Allen key in tensioner backplate and hold tensioner pulley against timing belt.
12. With assistance, position timing belt tensioner, fit new Patchlok bolts and tighten to 25 Nm (18 lbf ft).

CAUTION: Ensure tensioner plunger is contacting underside of tensioner backplate.

13. Remove tools LRT-12-175 from rear timing belt gears.






14. Fit tools LRT-12-196to both front inlet camshaft gears and into the end of each exhaust camshaft.

CAUTION: Special tools must be fitted when tightening or loosening gear retaining bolts, otherwise damage to camshafts may occur.

15. Tighten front inlet camshaft gear bolts to:
Stage 1 - 27 Nm (20 lbf ft)
Stage 2 - Further 90°;

16. Remove tools LRT-12-196 from both inlet camshaft gears and exhaust camshafts.
17. Remove wedge from between drive belt and oil pump belt guard.
18. Remove 1.5 mm diameter pin from tensioner.
19. Clean exhaust camshaft front cap seal locations and fit new cap seals.

CAUTION: The sealing edge of the cap seal and mating face must be clean and dry.

20. Position engine front mounting plate and manoeuvre plate into position; fit bolts but do not tighten at this stage.
21. Fit bolts securing IRD support bracket to front mounting plate; do not tighten bolts at this stage.






22. Tighten bolts in the sequence shown:
M10 bolt - No.1 - 25 Nm (18 lbf ft)
M10 bolt - No. 5 - 45 Nm (33 lbf ft)
Bolts Nos. 2, 3, 4, 6 and 7 - 85 Nm (63 lbf ft)

23. Position engine lifting bracket, fit bolts securing lifting bracket and front mounting plate to cylinder block and RH cylinder head and tighten to:
M8 bolt - 25 Nm (18 lbf ft)
M10 bolts - 45 Nm (33 lbf ft)

24. Fit rubber blanking plug around tensioner.
25. Clean end of dipstick tube.
26. Position dipstick tube to sump and cylinder block, fit bolt and tighten to 9 Nm (7 lbf ft).
27. Clean lower timing belt cover.
28. Position lower timing belt cover, fit and tighten bolts to 9 Nm (7 lbf ft).
29. Remove timing pin LRT-12-232.
30. Clean crankshaft pulley.
31. Fit crankshaft pulley to crankshaft gear and ensure that the indent on pulley locates over the lug on crankshaft gear.
32. Fit crankshaft pulley bolt and washer, position LRT-12-161 with LRT-12-199 into crankshaft pulley. Tighten pulley bolt to 160 Nm (118 lbf ft).
33. Remove tools LRT-12-161and LRT-12-199.
34. Clean ancillary drive belt tensioner.
35. Position ancillary belt tensioner, fit bolts and tighten to 25 Nm (18 lbf ft).
36. Clean LH and RH front timing belt covers.
37. Position LH and RH front timing belt covers,fit and tighten bolts to 4 Nm (3 lbf ft).
38. Clean idler pulley, position pulley to engine front mounting plate and tighten Torx bolt to 45 Nm (33 lbf ft).
39. Position alternator to front mounting plate.
40. Fit bolt and nut and bolt securing alternator to front mounting plate and tighten to 45 Nm (33 lbf ft).
41. Connect alternator multiplug.
42. Connect battery lead to alternator, fit and tighten nut to 8 Nm (6 lbf ft), fit terminal cover.
43. Clean LH rear timing belt cover.
44. Position LH rear timing belt cover, fit and tighten bolts to 4 Nm (3 lbf ft).
45. Clean RH rear timing belt cover.
46. Position RH rear timing belt cover, fit bolts and tighten to4 Nm (3 lbf ft).
47. Position heat shield, fit bolts and tighten M6 bolt to 9 Nm (7 lbf ft) and M8 bolt to 25 Nm (18 lbf ft).
48. Fit inlet manifold chamber - if fitted. 30.15.37 Seals - Inlet Manifold Chamber - Up to 03MY
49. Position ancillary drive belt to crankshaft and alternator pulleys.
50. Position engine mounting front bracket to engine front plate and tighten bolts to 45 Nm (33 lbf ft).