Timing Belt and Drive Assembly Removal
SPECIAL TOOLS- Gauge tool No. 998 8500, or equivalent
- Counterhold tool No. 999 5433, or equivalent
- Compressor tool No. 999 5456, or equivalent
PROCEDURE
1. Align camshaft and crankshaft timing marks
- Remove front timing belt cover.
- Align timing marks as shown.
2. Measure belt tension
- Place gauge tool No. 998 8500, or equivalent, midway between exhaust camshaft pulley and coolant pump.
- Read gauge. Belt tensioner must be replaced if reading is out of limits.
- Belt tension should be within the following limits:
21 mm belt: 3.5-4.6 units
23 mm belt: 2.7-4.2 units
28 mm belt: 2.5-3.5 units
3. Remove vibration damper
- Use counterhold tool No. 999 5433, or equivalent, attach to vibration damper.
- Remove vibration damper.
- Remove upper transmission cover.
4. Remove timing belt
- Remove lower belt guard (snowguard).
- Undo and remove upper tensioner bolt.
- Undo lower belt.
- Twist tensioner to free pulley.
- Remove lower bolt, tensioner and timing belt.
- Check there are no visible leaks.
5. Compress belt tensioner
- Compress belt tensioner using compressor tool No. 999 5456, or equivalent.
- Place tensioner in tool and tighten center tool nut fully.
- Wait until tensioner is fully compressed (approx. 5 min.) and insert locking pin (0 - 2mm) in piston.
NOTE: Tensioner must be replaced if leakage is visible, if there is no resistance to compression or if component cannot be compressed.
6. Remove belt drive pulley from crankshaft
- Use universal extractor and two vibration damper bolts.
- Hand-tighten the two bolts in the pulley as far as they will go.
- Attach extractor so that arms act on bolts (not on the pulley itself).
NOTE: Make sure that tool arms do not damage pulley teeth. Check bolts and pulley for any signs of damage.
7. Remove tensioner and idler pulleys
- Check pulley surfaces and bearings.
- Spin pulleys and listen for noise, check for any play in bearings.
- Check that pulley surfaces are smooth and clean.
8. Remove oil pump
- Remove four oil pump mounting bolts.
- Pry pump off carefully, using a screwdriver inserted behind the prising lug.
- Clean joint faces and mating surfaces.
- Remove oil cooler thermostat casing.
9. Dismantle oil pump
- Clean and inspect all components.
- Inspect components for damage and wear, paying particular attention to half-moon-shaped insert (surface between suction and delivery sides).
- Replace complete pump if any component is defective. (Relief valve parts available separately.)
Spring Tension (Part 1 Of 2):
10. Test relief valve springs:
Early Version (P/N 1397819)
Load and Length
No Load: 76.22 mm
52 ± 4 N: 56.10 mm
85 ± 8 N: 39.90 mm
Later Version (P/N 9135202)
Load and Length
No Load: 76.22 mm
59 ± 4 N: 56.10 mm
108 ± 8 N: 39.90 mm
11. Put pump wheel in casing and check for clearance/play
- Lay large pump wheel in position with marking facing upwards.
- Put small wheel in position.
- Check clearance/play. If excessive, replace complete pump. Reassemble pump.
NOTE: If the measured clearance between the outer rotor and casing is greater than 0.35 mm and the oil pressure is less than 1 bar (14.5 psi) at an oil temperature of 100° C (112° F), the oil pump should be replaced. Measure clearance with a feeler gauge.
12. Remove coolant pump and inner transmission cover
- Remove coolant pump.
- Clean joint face and mating surfaces, removing all remains of original gasket.
- Remove inner transmission cover.
13. Greasing automatic tensioner pulley (Applies to earlier types)
- Remove center tensioner bolt and dismantle as shown in picture.
- Apply grease part No. 1 161 246-2 (509) or 1 161 247-0 (5009) between friction plate and cover, and to the four spring holes (arrowed).
- Reassemble belt tensioner, tighten center bolt. 20 Nm (15 ft.lb.).
- For later types: replace tensioner if necessary.
14. Remove coolant thermostat
- Remove thermostat and gasket (Torx 40 bolts).
- Clean joint faces and mating surfaces.
- Remove thermostat casing.
15. Thermostat, checking opening
- Thermostat can be tested in hot water.
- Maximum opening should be reached in two minutes in water at specified opening temperature.
Marking: 87
Starts opening at: 87° C (187° F)
Wide open at: 102° C (216° F)
Marking: 90
Starts opening at: 90° C (194° F)
Wide open at: 105° C (221° F)