Toothed belt, removing and installing
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- Jasmin Wheeler
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1 Toothed belt, removing and installing Special Tools and Equipment ^ 3212 spanner wrench ^ 3387 pin wrench ^ T40011 pin ^ T40026 locking pin ^ T40028 socket ^ T40030 camshaft adjuster gauge Removing Lock carrier in service position, Refer to Body and Frame. Ribbed belt removed, Refer to Drive Belt, Service and Repair. 1/17
2 Unscrew bolts (arrows) and remove ribbed belt tensioner. Remove ribbed belt gear of vane pump (arrows) using 3212 spanner wrench as retainer. 2/17
3 Remove 8 bolts 1. Remove harmonic balancer 2 and thrust washer 3. Note: Thrust washer 3 is only installed on toothed belt gear with part number 06C No thrust washer must be installed for toothed belt gear with part number 06C B. 3/17
4 Unscrew bolts 1 to 12 and remove toothed belt guards. Remove rear engine cover (arrows). 4/17
5 Remove coolant reservoir (arrows). Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch F66 at bottom of expansion tank. Tie coolant expansion tank with connected coolant hoses 1 to 3 to side. Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 1 at air filter housing. Disconnect electrical harness connector 2 at Mass Air Flow (MAP)sensor. Remove air guide hose 3 together with Mass Air Flow (MAF)sensor. Remove air filter housing (arrows). 5/17
6 Remove bolts 1 and 3. Disconnect hose 4 from line of secondary air injection. Pull out guide tube for oil dipstick 2 from the oil pan (upper part) toward top and swing it forward for removal. Remove bolts 5 and 6 at right cylinder head cover. Disconnect electrical harness connectors 1 to 4. Remove ignition coils (arrows). 6/17
7 Remove hose of crankshaft housing ventilation (arrow). Unscrew bolts for right cylinder head cover in the sequence 12 to 1. Remove cylinder head cover. Unscrew bolts 4 and 5 at left cylinder head cover. Disconnect electrical harness connectors 1 to 3 and 6. Remove ignition coils (arrows). 7/17
8 Remove hose of crankshaft housing ventilation (arrow). Unscrew bolts for left cylinder head cover in the sequence 12 to 1. Remove cylinder head cover. WARNING: Turning of the engine must only occur in direction of engine rotation (clockwise) at the crankshaft Turn engine until the cams (arrows) at intake and exhaust camshaft of cylinder 3 (right cylinder bank) point upward uniformly. Note: Turn engine at crankshaft central bolt. 8/17
9 Insert T40030 camshaft adjuster gauge at camshafts of right cylinder head. Note: Slightly turn crankshaft back and forth so that the claw of T40030 camshaft adjuster gauge can properly grab the camshafts. Spread T40030 camshaft adjuster gauge with threaded shaft (tightening torque 10 Nm) until it is seated without axial play. Insert T40030 camshaft adjuster gauge at left cylinder head in the same manner. If installed, disconnect electrical harness connector at after run coolant pump. Unscrew sealing plug of TDC mark at cylinder block. 9/17
10 Thread T40026 locking pin into the hole of the removed sealing plug and tighten. Note: Slightly turn crankshaft back and forth to do so. Note: Catch escaping oil using a rag. Pry off securing rings 1 for caps 2 at all camshaft gears. 10/17
11 Remove bolts 1 to 4 for crankshaft gears. Note: The bolts remain loosely threaded in. Using an 8 mm hex socket wrench, turn toothed belt tensioner in direction of arrow until the tensioning lever pushes the tensioner together far enough so that the T40011 pin can be inserted into the bore of the pistons and housing. Notes: ^ The toothed belt tensioner is oil dampened. Compress it by slowly applying constant pressure. ^ Mark rotational direction of toothed belt. Reversing the direction in which it runs can ruin it. 11/17
12 Loosen bolt (arrow) of eccentric pulley. Remove toothed belt. Installing (adjusting valve timing) Camshafts aligned using T40030 camshaft adjuster gauge Crankshaft aligned using T40026 locking pin Camshaft gears loosened. Notes: ^ Replace gaskets, O rings and self locking bolts. ^ When fuming camshaft, crankshaft must not be at TDC for any cylinder. Valves and/or pistons may be damaged. Bolt in camshaft gears 1 to 4 far enough so they can still just be turned without canting. Install toothed belt as depicted in illustration. ^ For exact valve timing adjustment, the toothed belt must make exact contact with front edge of all toothed belt gears. 12/17
13 Using 3387 pin wrench, turn eccentric pulley 1 in clockwise direction until the handle of the pin wrench is exactly above the center axle of coolant pump gear 2. Hold pin wrench in this position and tighten bolt 3 to 45 Nm. Place torque wrench horizontally on socket head of tensioning lever. Turn with 45 Nm in direction of arrow to pretension toothed belt. 13/17
14 Using 8 mm socket head wrench, turn toothed belt tensioning roller in direction of arrow until T40011 pin can pulled out. Place torque wrench horizontally on socket head of tensioning lever. Turn with 25 Nm in direction of arrow to tension toothed belt. 14/17
15 Insert T40028 socket at camshaft adjuster of exhaust camshaft on left cylinder bank. Turn rotor of camshaft adjuster clockwise to 10 Nm up to stop (arrow). Turn rotor of camshaft adjuster at right cylinder bank clockwise to 10 Nm up to stop (arrow). Tighten camshaft adjuster to 100 Nm. 15/17
16 Insert caps 2 with new O rings 1 at camshaft gears and secure them with the securing ring. Remove T40030 camshaft adjuster gauge. Remove T10026 alignment bolt and thread sealing plug of TDC marking with new O ring into cylinder block. Installation is reverse of removal, noting the following: Install cylinder head covers, Refer to Valve Cover, Service and Repair.. Install toothed belt guards, Refer to Timing Belt, Service and Repair. Install harmonic balancer, Refer to Harmonic Balancer Crankshaft Pulley, Service and Repair. Install ribbed belt, Refer to Drive Belt, Service and Repair. 16/17
17 Component Tightening Torques (Part 12 Of 17) Tightening torques 2018 ALLDATA, LLC. All Rights Reserved. (Version ) 17/17
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