Assembling the Belt Drive
Assembling the belt drive
Special tools:
999 5747 Socket 999 5747 Socket
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.
Installing the water pump
Install the rear timing cover.
Screw into place at the three mounting points.
Install the water pump with a new gasket .
Apply thread sealant, P/N 11-61 056, to all the screws for the water pump. Tighten crosswise.
Installing the oil pump
Use a new gasket and a new O-ring around the oil pump housing.
Screw sliding sleeve 999 5747 into place at the front of the crankshaft journal.
Press in the pump over the sliding sleeve.
Apply thread sealant, P/N 11-61 56, to all the screws for the oil pump.
Install the screws as a guide.
Carefully tap in the oil pump with a rubber mallet.
Tighten the oil pump crosswise to 10 Nm .
Remove sliding sleeve 999 5747 .
Installing the crankshaft timing gear pulley
Note! The timing gear pulley can only be installed in one position on the crankshaft journal splines (see the illustration).
Carefully tap in the timing gear pulley with a rubber mallet.
Installing the idler pulley and belt tensioner
Install the idler pulley. Tighten.
Install the belt tensioner and the center screw so that the fork on the tensioner is centered over the cylinder block rib. Do not tighten.
Install the fuel delivery line.
Installing the timing gear pulley for the camshafts
Timing gear pulleys with variable valve timing unit
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit and timing gear pulley onto the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Do not tighten.
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in their respective limit positions.
Hold the variable valve timing unit. Turn clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw for the variable valve timing unit to 120 Nm .
Note! Check that the variable valve timing unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm .
Timing gear pulleys without variable valve timing units
Install the timing gear pulley on the camshaft with two screws. Do not tighten.
Check that the markings on the timing gear pulley and the upper timing cover correspond.
Installing the timing belt
Tighten the center screw on the timing belt tensioner to 5 Nm .
Turn the variable valve timing unit clockwise until stop. Use a Tx 55 torx wrench applied at the center plug.
Hold the variable valve timing unit secure in the limit position.
Install the timing belt.
Note! Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.
Check that the markings on the timing gear pulleys and the upper timing cover correspond.
Tighten the timing belt
Turn the eccentric on the tensioner counter-clockwise until the tensioner indicator reaches its limit position. Ensure that the center screw does not rotate.
Tighten the three screws securing the timing gear pulley to the variable valve timing unit. Tighten to 10 Nm .
Install the third screw at the timing gear pulley without variable valve timing. Tighten the screws to 20 Nm .
Note! The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
Turn the eccentric back (clockwise) so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.
Secure the eccentric. Tighten the center screw to 20 Nm .
Check that the indicator is in the correct position.
Remove
- the camshaft adjustment tools 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
- the crankshaft stop 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
Install the plug with a new blind cover plug . Tighten to 40 Nm .
Check
Press the toothed belt to check that the indicator on the tensioner moves easily.
Installing the vibration damper
Install the vibration damper. Use counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold.
Tighten the center nut. Tighten to 180 Nm .
Remove counterhold 999 5433.
Tighten the four screws. Tighten to 25 Nm . Angle-tighten 30° .
Check
Turn the crankshaft two turns.
Check that the markings on the crankshaft and camshaft timing gear pulley correspond with the marking on the upper timing cover and on the oil pump.