Timing Belt and Drive, Water Pump and Oil Pump Dismantling
Special Tools:
- Counterhold Tool No. 999 5433, or equivalent
- Compression Tool No. 999 5456, or equivalent
Universal Tools:
- Belt Tension Gauge tool No. 993 8500, or equivalent
NOTE: For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Reconditioning". Tools and Equipment
Procedure
1. Align camshaft/crankshaft timing marks:
- Remove front timing belt cover.
- Align camshaft and crankshaft timing marks as shown.
2. Measure belt tension:
- Belt tensioner must be replaced if reading is out of limits.
- Put gauge tool No. 998 8500, or equivalent midway between exhaust camshaft pulley and water pump. Read off gauge.
For 21 mm belts, 3.5-4.6 units.
For 23 mm belts, 2.5-4.0 units
NOTE: Calibrate belt tension gauge after every 100 readings or so or if subjected to minor shocks.
3. Remove vibration damper:
- Using counterhold 999 5433, or equivalent, attach fast to vibration damper.
- Remove vibration damper.
- Remove upper transmission cover.
4. Remove timing belt:
- Remove lower timing belt cover (snowshield).
- Undo and remove upper tensioner bolt.
- Undo lower bolt.
- Turn tensioner until piston is free.
- Remove lower bolt, tensioner and timing belt.
5. Compress belt tensioner:
- Check there are no visible leaks.
- Compress tensioner using tool No. 999 5456, or equivalent.
Put the tensioner in the tool and screw the tool center nut right down.
Wait until tensioner is fully compressed (about 5 minutes) and insert locking pin (2 mm) in piston.
NOTE: Tensioner must be replaced if there are visible leaks, if there is no resistance to compression, or if component will not compress.
6. Remove belt drive pulley from crankshaft:
- Use universal extractor and two vibration damper bolts.
- Screw the two bolts into the pulley as far as they will go by hand.
- Fit extractor so arms act on bolts (not on pulley itself).
NOTE: Ensure that tool arms do not damage pulley teeth. If bolts are damaged, fit new ones.
7. Remove tensioner and idler pulleys:
- Inspect pulley surfaces and bearings.
- Spin pulleys and listen for noise. Check for bearing play.
- Check that pulley surfaces are smooth and clean.
8. Remove oil pump:
- Undo four oil pump bolts.
- Pry pump off carefully using screwdriver inserted behind prying lug.
- Clean joint faces and mating surfaces.
- Turbo: Remove oil thermostat casing.
9. Dismantle oil pump:
- Clean and inspect all components.
- Check 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 are available separately.)
10. Test relief valve springs:
Load / Length
L: 0 N / 76.22 mm
L1: 52 ± 4 N / 56.10 mm
L2: 85 ± 8 N / 39.90 mm
Turbo:
Load / Length
L: 0 N / 76.22 mm
L1: 59 ± 4 N / 56.10 mm
L2: 108 ± 8 N / 39.90 mm
11. Put pump wheel in casing and check for clearance/play:
- Put large pump wheel in position with marking facing upwards.
- Put small wheel in place.
- Check clearance/play. If excessive, replace complete pump. Assemble pump.
IMPORTANT: If the measured clearance between the outer rotor and casing is greater than 0.35 mm [and oil pressure is less than 1 bar (14.5 psi) at 100°C (112°F) oil temperature], pump should be replaced. Measure clearance with feeler gauge.
12. Remove water pump and inner transmission cover
- Remove water pump.
- Clean joint face and mating surfaces, removing all remains of original gasket carefully.
- Remove inner transmission cover.
13. Greasing automatic tensioner pulley
- Undo tensioner center bolt and dismantle as shown in picture.
- Apply grease part No. 1 161 246-2 (50 gram container) or 1 161 247-0 (500 gr. container), or equivalent, between friction plate and cover, and in the four spring holes (arrows).
- Assemble belt tensioner.
Tighten center bolt to 20 Nm (15 ft lb).
NOTE: Later versions cannot be dismantled and must be repaired if worn.
14. Remove:
- coolant thermostat and gasket (Torx 40 screws).
- thermostat casing.
- Clean joint faces and mating surfaces.
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.
Turbo:
Markings: 87
Starts opening at: 87°C (187°F)
Wide open at: 102°C (216°F)
Other engines:
Markings: 90
Starts opening at: 90°C (194°F)
Wide open at: 105°C (221 °F)