Timing Belt: Service and Repair

Replacing the Timing Belt/Idler Pulley/Belt Tensioner

Special Tools
- Belt Tension Gauge No. 998 8500, or equivalent
- Press Tool No. 999 5456, or equivalent

NOTE: For additional information on special tools and equipment used in this procedure, refer to Service and Repair. Tools For Engine Service and Repair

Procedure




1. Remove:
- spark plug cover
- fuel line clips
- lift expansion tank and place it on engine
- front timing cover
- auxiliaries belt




2. Align camshaft/crankshaft timing marks:
- Remove right front wheel and slacken wing liner.
- Remove vibration damper guard.
- Turn camshaft pulleys until all marks are aligned.




3. Check belt tension:
- Wait 5 minutes after adjusting timing belt.
- Locate gauge 998 8500 between the exhaust camshaft pulley and water pump.
- Read off gauge using a mirror, the gauge must not removed before taking reading.
- For 21 mm belts, the tension should be between 3.5-4.6 units.
- For 23 mm belts, the tension should be:
B5204/B5254/B5234: 2.5-4.0 units
B5252: 2.7-4.2 units
- If the tension is incorrect tensioner must be replaced.




4. Timing belt removal:
- Remove upper tensioner screw.
- Undo the lower screw.
- Turn tensioner to free pulley.
- Remove:
lower screw
tensioner
upper timing cover
timing belt




5. Check tensioner and idler pulleys:
- Spin the pulleys and listen for noise in the bearings.
- Check that the tensioner pulley actuator arm has not seized in its bearing. Check the idler pulley and tensioner pulley are tightened correctly.
- Tensioner pulley, tighten to: 30 Nm (22 ft lb)
- Idler pulley, tighten to: 24 Nm (18 ft lb)




6. Lock tensioner:
- Inspect for signs of leakage.
- Compress tensioner with tool 939 5456, or equivalent. Place tensioner and tighten center nut fully. Wait until the tensioner is compressed and install lock pin (0 2 mm) in the piston.

NOTE: Replace tensioner if leaks are observed, if there is no resistance to compression or if the tensioner cannot be compressed.




7. Replace timing belt:
- Install tensioner, torque 25 Nm (18 ft lbs).
- Place belt around the crankshaft arid right idler pulley.
- Place belt over camshaft pulley.
- Place belt around water pump and grass belt over the tensioner pulley.




8. Turn engine crankshaft two revolutions:
- Pull locking pin from tensioner.
- Install upper timing cover.
- Turn the crankshaft two revolutions and check that the timing markings on the crankshaft and camshaft pulleys are aligned.




9. Reinstall:
- the two fuel pipe clips
- front timing cover
- accessory belt
- spark plug cover
- expansion tank
- vibration damper guard
- wing liner, wheel

Carry out function test:
- Test run engine.