1 of 8 1/17/2017 8:18 AM

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1 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM Replacing the timing belt Special tools: LIFTING BAR See: Vehicle > Electrical / Mechanical Repair > Lifting Bar LIFT ARM See: Vehicle > Electrical / Mechanical Repair > Lift Arm Lifting hook See: Vehicle > Electrical / Mechanical Repair > Lifting Hook Removing the auxiliaries belt - Turbocharged engines: remove the right hand engine cover and the cover over the right headlamp - Slacken off the auxiliaries belt by turning the screw on the tension pulley clockwise - Remove the auxiliaries belt. Removing the timing covers Remove: - the upper timing cover - the front timing cover. Installing the lifting beam and lifting hook

2 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM Remove the metal bracket for the servo hose from the rotation protection for the auxiliaries belt. Position lifting beam LIFTING BAR See: Vehicle > Electrical / Mechanical Repair > Lifting Bar slightly in front of the front lifting eyelet for the engine. Use lifting arm LIFT ARM See: Vehicle > Electrical / Mechanical Repair > Lift Arm and lifting hook Lifting hook See: Vehicle > Electrical / Mechanical Repair > Lifting Hook to raise the front of the engine a few millimeters. Removing the right-hand engine mounting - the screws for the servo holder - the engine mounting screws - the engine mounting - the lower timing cover.

Timing Belt Service and Repair, Removal and Replacement: Replacing... http://repair.alldata.com/alldata/article/display.action?componentid=64&.

3 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM Position the engine according to the marking Remove the right front wheel. Position the upper timing cover. Turn the crankshaft until the markings on the crankshaft and camshaft pulley correspond. Turn the crankshaft a further 1/4 turn clockwise and then back again until the markings correspond. The markings are illustrated. Remove the upper timing cover. Removing the timing belt Slacken off the center screw for the belt tensioner slightly. Hold the center screw still. Turn the tensioner eccentric clockwise using a 6 mm Allen key to 10 o'clock. Remove the timing belt from the tension pulley, camshaft pulley and water pump. Tensioning the tensioner pulley and the idler pulley Spin the idler pulley and listen for noise. When replacing with a new idler pulley, tighten to 24 Nm. Spin the tension pulley and listen for noise. When replacing, screw the tension pulley into place using the center screw. Screw in the center screw by hand. Ensure that the tensioner fork is centered over the cylinder block rib. Ensure that the Allen hole on the eccentric is at "10 o'clock". Removing the splash guards under the engine

Removing the timing belt (at the bottom) Remove: - the two screws from the lower belt cover - the lower belt guard - the timing belt using a

4 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM Remove: - the front air baffle - the rear air baffle. Removing the timing belt (at the bottom) Remove: - the two screws from the lower belt cover - the lower belt guard - the timing belt using a twisting movement - clean the surrounding area. Installing the timing belt Install the timing belt over the pulley on the crankshaft. Install: - the lower belt guard - the front air baffle - the rear air baffle.

5 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM Install the new belt in the following order: - crankshaft - the idler pulley - intake camshaft - exhaust camshaft - water pump - belt tensioner. Tension the timing belt Note! This adjustment is to be made with a cold engine. Suitable temperature is approximately 20 C/67 F.At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right. The illustration shows the position of the indicator at different engine temperatures.

6 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM - Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft - Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window - Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm. Check that the indicator is in the correct position. Check - Press the belt to check that the indicator on the tensioner moves easily - Install the upper timing cover - Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond. Note! Check that the indicator on the belt tensioner is within the marked area. Installing timing covers

7 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM Install: - the lower timing cover - the front timing cover. Tighten to 12 Nm - the auxiliaries belt. Installing the right engine mounting Screw the engine mounting into place on the engine. Tighten to 67 Nm. Install: - the screws on the bracket for the bodywork. Tighten to 50 Nm - the servo reservoir. Finishing

8 Timing Belt Service and Repair, Removal and Replacement: Replacing of 8 1/17/2017 8:18 AM Remove the lifting beam and lifting hook. Install: - the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt - the front wheel according to Replacing front brake pads See: Brake Pad > Removal and Replacement > Replacing Front Brake Pads - the auxiliaries belt - turbocharged engines: the right hand engine cover and the cover over the right headlamp unit. Checking work Function test: - Test drive the engine ALLDATA, LLC. All Rights Reserved. (Version )

9 Water Pump Service and Repair, Removal and Replacement: Replacing of 6 1/17/2017 8:19 AM Replacing the coolant pump Draining the coolant Remove: - the cap for the expansion tank - the splash guard under the engine. Position a container under the engine drain cock. Drain the engine coolant. Avoid skin contact with the coolant. Transfer the container to the radiator drain cock. Drain off the remaining coolant. Close the nipples. Install the splash guard under the engine. Removing the auxiliaries belt Slacken off the auxiliaries belt by turning the screw on the tension reel clockwise. Remove the auxiliaries belt. Removing the timing covers Remove: - the upper timing cover

Water Pump Service and Repair, Removal and Replacement: Replacing... http://repair.alldata.com/alldata/article/display.action?componentid=74&... 2 of 6 1/17/2017 8:19 AM - the front timing cover.

10 Water Pump Service and Repair, Removal and Replacement: Replacing of 6 1/17/2017 8:19 AM - the front timing cover. Installing the lifting beam and lifting hook Install the lifting beam and the lifting hook according to Replacing the timing belt See: Timing Belt > Removal and Replacement > Replacing The Timing Belt. Removing the right-hand engine mounting Remove the right engine mounting according to Replacing the timing belt See: Timing Belt > Removal and Replacement > Replacing The Timing Belt. Position the engine according to the marking See Replacing the timing belt See: Timing Belt > Removal and Replacement > Replacing The Timing Belt. Removing the timing belt Remove the timing belt according to Replacing the timing belt See: Timing Belt > Removal and Replacement > Replacing The Timing Belt. Removing the coolant pump - Remove the screws - tap the pump wheel using the shaft of a hammer. Remove the pump - clean the gasket faces thoroughly. Installing the coolant pump Install: - a new gasket - a new pump. Tighten the screws. Tighten to 17 Nm. Installing the timing belt

Water Pump Service and Repair, Removal and Replacement: Replacing... http://repair.alldata.com/alldata/article/display.action?componentid=74&.

11 Water Pump Service and Repair, Removal and Replacement: Replacing of 6 1/17/2017 8:19 AM Install the new belt in the following order: - crankshaft - the idler pulley - intake camshaft - exhaust camshaft - water pump - belt tensioner. Tension the timing belt Note! This adjustment is to be made with a cold engine. Suitable temperature is approximately 20 C/67 F.At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right. The illustration shows the position of the indicator at different engine temperatures.

12 Water Pump Service and Repair, Removal and Replacement: Replacing of 6 1/17/2017 8:19 AM - Carefully turn the crankshaft clockwise until the timing belt is tensioned. The belt must be tensioned between the intake camshaft pulley, the idler pulley and the crankshaft - Hold the belt tensioner center screw secure. Turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window - Hold the eccentric securely. Tighten the center screw. Tighten to 20 Nm. Check that the indicator is in the correct position. Check Checking markings - Press the belt to check that the indicator on the tensioner moves easily - Install the upper timing cover - Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond. Note! Check that the indicator on the belt tensioner is within the marked area. Installing timing covers

13 Water Pump Service and Repair, Removal and Replacement: Replacing of 6 1/17/2017 8:19 AM Install: - the lower timing cover - the front timing cover. Tighten to 12 Nm - the auxiliaries belt. Installing the right engine mounting Screw the engine mounting into place on the engine. Tighten to 67 Nm. Install: - the screws on the bracket for the bodywork. Tighten to 50 Nm - the servo reservoir. Finishing

14 Water Pump Service and Repair, Removal and Replacement: Replacing of 6 1/17/2017 8:19 AM Remove the lifting beam and lifting hook. Install: - the metal bracket for the power steering hose on the rotation protection for the auxiliaries belt - the front wheel according to Replacing front brake pads See: Brake Pad > Removal and Replacement > Replacing Front Brake Pads - the auxiliaries belt. Checking work Function test: - runs the engine to normal operating temperature until the thermostat opens - top up the cooling system if necessary. Check for leaks ALLDATA, LLC. All Rights Reserved. (Version )

Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl... http://repair.alldata.com/alldata/article/display.action?componentid=112.

15 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Camshaft seals, replacing Special tools: LIFTING BAR See: Vehicle > Electrical / Mechanical Repair > Lifting Bar LIFT ARM See: Vehicle > Electrical / Mechanical Repair > Lift Arm Lifting hook See: Vehicle > Electrical / Mechanical Repair > Lifting Hook CAMSHAFT ADJUSTMENT TOOL See: Vehicle > Electrical / Mechanical Repair > Camshaft Adjustment Tool Extractor See: Vehicle > Electrical / Mechanical Repair > Extractor ADJUSTMENT TOOL See: Vehicle > Electrical / Mechanical Repair > Adjustment Tool COUNTERHOLD See: Vehicle > Electrical / Mechanical Repair > Counterhold Drift See: Vehicle > Electrical / Mechanical Repair > Drift Drift See: Vehicle > Electrical / Mechanical Repair > Drift Note! As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct. Note! Crankshaft and camshafts must not be turned more than is stated in the method description!if the shafts are turned in any other way, the valves may be damaged. Preparations Remove: - the cable from the battery's negative terminal. First read Note when disconnecting and connecting the battery lead See: Battery > Procedures > Battery Disconnecting. - the inlet hose between air filter and throttle housing. Put it aside. Remove: - the brake servo's vacuum hose from its connection in the throttle housing. Loosen the hose by pressing down the plastic ring at the same time as the hose is pulled upwards. Move the hose aside. - the fuel line and cabling from its clips in the cylinder head's trailing edge.

16 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Remove: - the cable channel's screws. - camshaft's rear cover. - the camshaft position (CMP) sensor housing - the trigger wheel. - right engine protection cover (only turbo). - the auxiliaries belt Removing timing gear covers Remove: - the upper timing cover. - the front timing cover. Installing the lifting beam and the lifting hook

17 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Loosen the servo hose's plate bracket from the auxiliary unit's rotation guard. Place lift tool LIFTING BAR See: Vehicle > Electrical / Mechanical Repair > Lifting Bar slightly in front of the engine's front lifting eye. Use lift arm LIFT ARM See: Vehicle > Electrical / Mechanical Repair > Lift Arm and lift hook Lifting hook See: Vehicle > Electrical / Mechanical Repair > Lifting Hook to lift the engine a few mm at the leading edge. Removing the right-hand engine mounting Remove: - the servo reservoir's screws. - the engine mount's screws.

18 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM - the engine mounting. - the lower timing cover. Position the engine according to the marking Remove the right front wheel. Position the upper timing cover. Turn the crankshaft until the markings on the crankshaft and camshaft gear match. Turn another 1/4 turns clockwise on the crankshaft and then back until the markings match. Markings are shown in figure. Remove the upper timing gear cover. Removing the timing belt Slacken off the center screw for the belt tensioner slightly. Hold and fixate the centre screw. Turn the tensioner's eccentric clockwise using a 6 mm Allen key to 10 o'clock. Remove the timing belt from the camshaft gears. Removing the timing gear pulley

999 5452 Camshaft Adjustment Tool at the rear of the camshafts. Timing gear pulleys with variable valve timing unit: - Remove the plug at the front edge of the variable valve timing unit (TORX 55).

19 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Timing gear pulleys with variable valve timing unit - Install camshaft adjustment tool CAMSHAFT ADJUSTMENT TOOL See: Vehicle > Electrical / Mechanical Repair > Camshaft Adjustment Tool at the rear of the camshafts. Timing gear pulleys with variable valve timing unit: - Remove the plug at the front edge of the variable valve timing unit (TORX 55). - Remove the centre screw in the VVT-unit (TORX 55). Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit. A small amount of oil may run out. Place paper underneath. Timing gear pulleys without variable valve timing units: - Remove the timing gear pulley's screws. Use counterhold COUNTERHOLD See: Vehicle > Electrical / Mechanical Repair

Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl... http://repair.alldata.com/alldata/article/display.action?componentid=112... 6 of 11 1/17/2017 8:21 AM > 999 5199 Counterhold.

- Remove the screw that holds the inner timing gear cover to the cylinder head.

20 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM > Counterhold. - Remove timing gear pulley. - Remove tool CAMSHAFT ADJUSTMENT TOOL See: Vehicle > Electrical / Mechanical Repair > Camshaft Adjustment Tool. - Remove the screw that holds the inner timing gear cover to the cylinder head. Replacing the camshaft seal Carefully press in tool Extractor See: Vehicle > Electrical / Mechanical Repair > Extractor between the sealing ring and the camshaft. Carefully pry out the seal. Oil the new seal. Install the new seal for the camshaft with VVT using drift Drift See: Vehicle > Electrical / Mechanical Repair > Drift. Install the new seal for the camshaft without VVT using drift Drift See: Vehicle > Electrical / Mechanical Repair > Drift. Install the screw holding the inner timing cover to the cylinder head. Secure the crankshaft position Install the adjustment tool. Remove: - front air baffle. - the support between the cylinder block and the intake manifold. - the starter motor mounting screws. Place the starter motor to one side. Remove the blind cover plug and the sealing washer. Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position.

21 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Install gauge ADJUSTMENT TOOL See: Vehicle > Electrical / Mechanical Repair > Adjustment Tool. Make sure that the gauge bottoms against the engine block. Turn the crankshaft back counter-clockwise until it stops against the drift. Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump. Installing camshafts' timing gear pulleys Timing gear pulley without VVT: - install upper timing cover. - install timing gear pulley without VVT on the camshaft. Use two screws positioned so that the markings on the timing belt gears/upper timing gear cover match. Do nottighten.

22 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Timing gear pulley VVT: - Install the timing gear pulley with the centre screw on the camshaft. Make sure that the markings on the timing gear pulleys/upper timing gear cover match, but do not tighten. Installing the timing belt Install the timing belt on the timing gear pulleys. Note! Adjust so that the screws in the timing gear pulley without variable valve timing do not reach the limit position in the oval holes. Tension the timing belt

Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl... http://repair.alldata.com/alldata/article/display.action?componentid=112... 9 of 11 1/17/2017 8:21 AM Note!

23 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Note! This adjustment is to be made with a cold engine. Suitable temperature is approximately 20 C/67 F.At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right. The image shows the indicator position at different engine temperatures. - The belt shall be tight between the inlet camshaft gear, idler gear, and crankshaft. - Fix the belt tensioner centre screw in position and turn the belt tensioner eccentric counter clockwise until the tensioner indicator passes the marked position. Then turn the eccentric back so that the indicator reaches the marked position in the centre of the window - Hold the eccentric secure and tighten the centre screw. Torque tighten to 20 Nm. Tightening timing gear pulley Tighten the centre screw on the timing gear pulley with VVT. Tighten to 90 Nm. Install the plug. Tighten to 35 Nm. Install the third screw on the camshaft without VVT. Tighten to 20 Nm. Remove the adjustment tools. Check - Press the belt to check that the indicator on the tensioner moves easily. - Position the upper timing cover. - Turn the crankshaft two turns. Check that the markings on the crankshaft and camshaft pulley correspond Note! Check that the indicator on the belt tensioner is within the marked area. - Remove the upper timing cover. Installing the timing covers

24 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Install: - lower timing gear cover. - the front timing gear cover. Tightening torque 12 Nm. - the upper timing cover. Installing the right-hand engine mounting Screw down the engine mount against the engine. Tightening torque 67 Nm. Install: - the screws on the body frame's console. Tighten with 50 Nm. Finishing

25 Camshaft Oil Seal Service and Repair, Removal and Replacement: Repl of 11 1/17/2017 8:21 AM Remove lifting beam and lifting hook. Install: - the servo reservoir. - servo hose's metal console on the auxiliary unit belt's rotation guard. - the auxiliaries belt - turbo engines: right engine protection cover as well as the cover over right headlight unit. - rear camshaft cover. - blinder. Tightening torque 17 Nm. - camshaft sensor housing. Tightening torque 5 Nm. - cable channel. - brake servo's vacuum hose. - hose between inlet pipe and air filter housing. - the blind cover plug. - the starter motor mounting screws. - the support between the cylinder block and the intake manifold. - front air baffle. - the cable from the battery's negative terminal. First read Note when disconnecting and connecting the battery lead See: Battery > Procedures > Battery Disconnecting. Checking work Function test: - Carry out a road test ALLDATA, LLC. All Rights Reserved. (Version )

Sized for Print. Timing belt, replacing. Special tools: COUNTERHOLD See: Tools and Equipment\ Counterhold

$Sized for Print. Timing belt, replacing. Special tools: COUNTERHOLD See: Tools and Equipment\ Counterhold$ Timing belt, replacing Special tools: 999 5433 COUNTERHOLD See: Tools and Equipment\999 5433 Counterhold Note! Since the illustrations in this service information are used for different model years and/or