Timing Belt Tensioner: Service and Repair

Thermo tension roller, removing and installing

Required tools
- 3299 ribbed belt installation tool
- Hazet 2587D V159 or US4493 special wrench

Removing ribbed belt and V-belt
- Remove air cleaner with hot air intake and intake air duct.
- Release tension on ribbed belt tensioner using 3299 and remove ribbed belt at generator.
- Remove ribbed belt tension roller and upper drive (timing) belt guard.
- Remove lower V-belt cover.
- Hold hydraulic pump pulley using VAG1590 or mandrel and remove fasteners for coolant pump pulley.
- Remove coolant pump pulley and V-belt

Removing drive (timing) belt

- Remove vibration damper/pulley.






- Turn flywheel -A- or driveplate -B- to align mark (arrows) and place No.1 cylinder at TDC (top dead center).
- Remove lower drive (timing) belt guard.
- Remove fastener for drive (timing) belt thermo tension roller.
- Remove belt and roller.

Note:
- Mark the running direction on the drive (timing) belt.

- Remove drive (timing) belt thermo tensioner.

Installing thermo tension roller






- Assemble new thermo tension roller and install on engine block.
- Bolt/washer assembly (2x) tightening torque. 7-11 Nm (62-97 in.lb)
- Collar screw and 6 mm fastening nut tightening torque 7-11 Nm (62-97 in.lb)

CAUTION: Do not turn the camshaft while any piston is at TDC position. There is risk of damage to valves and piston crowns.

Installing drive (timing) belt

- Align mark on camshaft drive sprocket with mark on cylinder head cover and/or drive (timing) belt guard.
- Place drive (timing) belt on crankshaft gear (note running direction of belt).






- Turn tension roller to the right using two-pin spanner -B-, with one pin inserted in hole in roller and other pin in slot at bottom of roller pivot bracket until:
- Piston -1- is driven all the way out
- Piston -2- lifts up approx. 1.0 mm (0.040 in.)
- Tighten mounting bolt -3- by hand.
- Rotate engine 2 revolutions in running direction.
- Counter-hold thermo tension roller with two-pin spanner and tighten mounting bolt -3- to 25 Nm (18 ft lb).
- Install lower drive (timing) belt guard.
- Install vibration damper/pulley.

Installing V-belt and ribbed belt

- Install ribbed belt tension roller.
- Adjust tension on ribbed belt tensioner using 3299 and position belt.
- Position V-belt and bolt coolant pump pulley to coolant pump.
- Install upper drive (timing) belt guard.
- Install air cleaner with pre-heated air hose and intake air duct.

Tightening torque











CAUTION!

- Part Numbers are for reference only. Always check with your Parts Dept for the latest in formation.