Early Model
Replacing toothed (timing) beltSpecial tools: 951 2661, 999 5433, 5006, 5383, 5460
General
Note! Service interval for timing belt and tensioner pulley: 165,000 km/105,000 miles.
Remove auxiliaries belt
- Remove the right engine compartment cover and the cover above the right headlight unit
- Release the auxiliaries belt by turning the pulley screw clockwise
- Remove the auxiliaries belt
- Release the belt tensioner (counterclockwise).
Remove upper timing gear covers
- Remove two screws and remove upper cover by undoing the two clips at the side
- Remove the screw and take the cover off.
Install lifting beam and lifting lug
Note! Remove the nut from the body support.
- Position the lifting beam 999 5006 centrally above the engine and install the lifting lugs 999 5460 in the lifting eyes.
- Install the extra support 999 5383 (if necessary). Lift the engine up a few mm at the front.
Remove engine mounting on timing gear side
- Remove three bolts and the screw from the mounting at body side and pull out the mounting with the rubber.
Remove lower timing gear cover
- Undo bottom cover and move backwards.
Remove engine bracket
- Remove the four bolts and pull bracket from engine. Lift engine if necessary.
- Turn wheel to the right.
- Open lid in side cover.
Align timing gear and crankshaft according to the markings
- Place the upper cover in position.
- Turn the crankshaft clockwise until the markings, camshaft gear, inner timing gear cover and the crankshaft/gear wheel align with the oil pump housing.
- Remove upper rear timing cover.
Remove timing belt at the top side
- Remove bolt (A) and take tensioner off
- Remove timing belt and move it downwards
- Clean and check the gears.
Check idler pulley
- Rotate the pulley rapidly and listen for abnormal noise from the bearing.
- When replacing: torque setting idler pulley 25 Nm.
- Check that all pulley contact surfaces for the belt are clean and smooth.
Remove the engine splashguards
Remove:
- rear
- front.
Remove timing belt at lower side
- Remove the two bolts from the snow cap
- Remove the timing belt and take it out with a turning movement
- Clean surrounding.
Note: For additional Variable Valve Timing adjustment info see Variable Valve Timing, Adjustments Adjustments
Install timing belt at lower side
- Place the timing belt between damper and engine block.
- Route belt upwards.
Install cover plates
- Place the lower snow cover and fit the two bolts
- Place the front and rear engine splashguards.
Install new timing belt and tensioner pulley
- Check timing marks
- Position the new tensioner, and finger tighten bolt (A)
- Turn excenter from tensioner in lowest position, see picture
- Route the belt around the crankshaft (1) and the idler pulley (2)
- Route the belt over both timing gears (3.4)
- Route the belt over the water pump (5) and around the tension pulley (6)
- Install upper rear timing cover on engine (do not tighten)
- Check alignment.
Adjusting timing belt tension
- Tighten bolt (B) to 3 Nm
- Place a 6 mm hex tool in the tensioner and turn tensioner anti clockwise until the toothed belt is tensioned
- Move the adjuster until the indicator pin is in the middle (A)
- Tighten the bolt (B) to 20 Nm without moving the tensioner
- Re-adjust if necessary
- Press pin (A) clockwise and anti-clockwise to check.
Check timing belt tension
- Rotate the crankshaft two revolutions and check that the markings on the crankshaft pulley and timing gears align with the marks on the timing gear cover
- Check the adjustment of the tensioner (indicator pin (A) in the middle)
- Adjust again if necessary
Note! After adjustment always turn crankshaft twice.
- Remove upper timing cover.
Install engine bracket
- Clean mounting pin, position bracket and install bolts. Tightening torque 35 Nm + 75°
Install timing gear covers
Install:
- lower timing gear cover. Check lower cover and water hose fittings
- the top cover (1x screw) (B), torque setting 10 Nm
- the top timing cover and tighten.
Note! Close lid in side cover move front wheels straight.
Install auxiliaries belt
- Clean the pulley grooves
- Turn the tensioning device clockwise
- Install the auxiliaries belt as illustrated
- Release the belt tensioner (counterclockwise)
- Tighten the bracket. Torque to 10 Nm
- Install power steering hose. Torque 10 Nm.
Install engine suspension on timing gear side
- Position the support on the engine and tighten the bolts (A) to 67 Nm
- Loosely install the bolts in the body support
- Remove the lifting beam 999 5006
- Tighten the body support (13) nut to 98 Nm.
Test drive engine
- Start the engine and check function.
- Install the right engine compartment cover and headlight unit cover.