Timing/Balance Shaft Belts, Installation

Timing/Balance Shaft Belts, Installation

Special tools: 5799, 5284, 536Z 587Z 9988500





Install transmission mounting plates
Insert bolts:
- between camshafts
- under right-hand idler mounting
- in balance shaft housing
- in belt guide plate

Note: Spacer is fitted in bolted joint of right-hand balance shaft housing.





Install balance shaft pulleys
Use counterhold 5362.

Tighten to 50 Nm (37 ft.lb}.





Install timing/balance shaft belt drive pulleys and guide plates
Install:
- balance shaft belt drive pulley
- timing belt inner guide plate
- timing belt drive pulley
- timing belt outer guide plate

Note: Timing belt pulley is provided with milled slot which should face cylinder block and engage guide pin on balance shaft pulley.





Install crankshaft pulley (vibration damper)
Use counterhold 5284 and guide 5872. Ensure that slot in crankshaft pulley engages projection on timing belt pulley.

Secure counterhold to cylinder head using M8 x 80 flanged bolt inserted in right-hand timing belt idler pulley hole, with guide as spacer.

Tighten crankshaft bolt in two stages:
1. Tighten to 60 Nm (44 ft.lb).
2. Tighten through further 60°.

Check that No. 1 piston is at TDC. Adjust as required.





Install balance shaft tensioner and spacer
Do not tighten bolt fully; ensure that pulley is movable when belt is placed in position.





Balance shaft belt markings (3)
A. RH balance shaft (yellow or white dot).
B. Bottom of crankshaft (blue dot).
C. LH balance shaft (yellow or white dot).
A-B = 18 teeth B-C = 34 teeth





Check balance shaft and crankshaft markings
Check that balance shaft markings are aligned with markings on transmission mounting plate.

Check that crankshaft marking is aligned with TDC marking on cylinder block.

Adjust as required.





Install balance shaft belt
Carefully work belt in under crankshaft pulley assembly.

Ensure that marking B (blue dot) is opposite TDC marking on belt guide plate (at bottom of crankshaft).

Place belt around left-hand (upper) balance shaft with marking C (yellow or white dot) opposite marking on pulley.

Place belt on right-hand (lower) balance shaft with marking A (yellow or white dot) opposite marking on pulley.

Place belt around tensioner.

Check that shaft markings are still aligned.





Tighten tensioner
Tension belt using Allen key inserted in adjusting hole in tensioner.

Turn crankshaft carefully through a few degrees to either side of TDC position to ensure that belt engages properly in pulleys.

Return crankshaft to TDC position.

Adjusting hole in tensioner must be immediately below "3 o'clock" when tightening locking bolt.

Tighten locking bolt to 40 Nm (30 ft.lb). Use Allen key inserted in adjusting hole as counterhold.





Check belt tension
Use gauge 9988500.

Position gauge immediately above location of dismantled idler.

Belt tension must be within 1-4 unit range.

Note: If belt tension is outside above range, slacken tensioner and repeat adjustment.





Assemble tensioner
Clamp spring carrier pin and spring between soft jaws in vice.

Mount spring and roller bracket.

Compress spring by hand and hold in position with 3 mm drift.





Install tensioner and spacer
Mount spacer on stud with collar facing away from block.

Mount tensioner on cylinder block.

Tighten tensioner locknut.

Remove drift.





Install timing belt idlers
Tighten to 25 Nm (18 ft.lb).





Install camshaft pulleys
Use counterhold 5199.

Slot in pulley should engage guide pin on shaft.

Install center bolts and tighten to 50 Nm (37 ft.lb).

Note: Camshafts must not be allowed to rotate when installing bolts.





Install timing belt
Position belt so that double-line marking is aligned with marking on guide plate (at top of crankshaft).

Stretch belt around crankshaft and place over tensioner roller and right-hand idler.

Place belt on camshaft pulleys, ensuring that single- line markings are aligned with pulley markings.

Place belt around oil pump drive pulley and press over left-hand idler.





Slacken tensioner locknut and turn crankshaft clockwise
Rotate crankshaft through one revolution until pulley markings again coincide with those on transmission mounting plate.

Note: Engine must not be rotated counterclockwise while belt is being tensioned.





Turn crankshaft further clockwise
Turn crankshaft further clockwise until pulley markings are 1 1/2 teeth past markings on housing.

Note: Turn crankshaft smoothly and evenly.





Tighten tensioner locknut
Tighten locknut to 50 Nm (37 ft.lb) when timing belt tension has been checked after running engine at working temperature.





Check/adjust balance shaft belt tension
Use gauge 998 8500. Measure tension above location of dismantled idler.

Belt tension should be 3.8 ± 0.3 units at 20°C (68°F). If belt tension is too low: Correct by adjusting tensioner clockwise. Only small adjustments are required.

Note: Tensioner may be adjusted clockwise only. Only small adjustments are required.





Install balance shaft belt idler*
Mount idler in seat.

*Operation may be omitted if engine is to be installed immediately in car.





Install:
- transmission cover (3)
- transmission cover (2)*
- transmission cover (1)*

*Covers (1) and (2) need not be installed if engine is to be installed immediately in car.





Install spark plugs
Screw in each plug until sealing ring is in firm contact with cylinder head.

Alt.1 Tighten through further 90° (new plugs).
Alt.2 Tightening torque 25 Nm (18 ft.lb).





Check tension of timing/balance shaft belts when thermostat has opened
Perform check following first running of engine at working temperature.

Note: Timing belt tension should be rechecked after 10000 km (6250 miles). USA/Canada: 5000 miles (8000 km)