Installing The Crankshaft Adjustment Tool
Remove the starter motor mounting screws. Pull out the starter motor and put it aside.
Remove the blind cover plug from the hole for the adjustment tool.
Turn the crankshaft clockwise slightly.
Install: 9995451 . Ensure that the tool bottoms out against the cylinder block.
Scheme 137
Note. Oil the center screw before installation
Push on the variable valve timing unit/timing gear pulley on the camshaft.
Install the center screw (1) which secures the variable valve timing unit to the camshaft.
Tighten the screw slightly.
Slacken off, but do not remove the screws (2) which secure the timing gear pulley to the variable valve timing unit.
Turn the timing gear pulley until the screws at the oval holes are in the center position. Tighten the screws (2) slightly.
Turn the variable valve timing unit clockwise to its limit position so that the unit is in its end position. Install the upper timing cover.
Slacken off the center screw and continue turning clockwise until the timing gear pulley marking aligns with the marking on the upper timing cover.
Tighten the center screw in the variable valve timing unit. Tighten. See: Summary of tightening torques for specific components .
Scheme 138
Install
- the timing gear pulley on the exhaust camshaft. Turn until the timing gear pulley marking aligns with the marking on the upper timing cover.
- the 3 screws. Do not tighten.
Scheme 139
Spin the pulleys and listen for noise from the bearings.
Check that the pulley surfaces to the belt are clean and smooth.
Check the tension pulley lever and mounting.
The tension pulley lever, torque 30 Nm . The idler pulley, torque 25 Nm .
Scheme 140
Check that there is no visible leakage.
Press the tensioner/damping unit together using: 9995456 .
Position the tensioner/damping unit in the tool. Screw the tool center nut to the bottom.
Wait until it is compressed and then install a lock pin in the piston.
Note. The tensioner damping unit must be replaced if there is leakage or there is no resistance when pushed in or if it cannot be pushed in.
Install the tensioner/damping unit. Tighten to 25 Nm .
Scheme 141
Note. Variable valve timing units do not have return springs and are easily thrown out of position when the camshaft belt is installed. Check that the markings align.
Install the belt in the following order
- the idler pulley
- intake cam
- exhaust cam
- water pump
- tension pulley.
Scheme 142
Pull the lock pin out of the tensioner/damping unit.
| CAUTION | Optimize the timing belt tension. Press it between the camshaft timing gear pulleys and between the water pump and exhaust camshaft. |
Scheme 143
Slacken off the 3 timing gear pulley screws slightly (applies to both timing gear pulleys).
Install the center plug in the variable valve timing unit.
Tighten, see: Summary of tightening torques for specific components .
Hold the center plug at 35 Nm at the same time as tightening the 3 x screws on the camshaft timing gear pulley to: Summary of tightening torques for specific components .
This is to ensure that the variable valve timing unit is in its end position when the timing gear pulley is tightened.
Tighten the 3 x screws on the exhaust camshaft timing gear pulley. Tighten to: Summary of tightening torques for specific components
Remove
- «9995452»(ref-403953-S02369714572011061000000) from the rear of the camshafts
- «9995451»(ref-403953-S26663901482011061000000) . Install new plugs with new sealing washers. Tighten. See: «Summary of tightening torques for specific components»(ref-406890-S18127190462011070100000) .
Install the deflection limiter washer on the piston rod for the tensioner/damping unit.
Scheme 144
Position the upper timing cover.
Turn the crankshaft 2 rotations. Check that the markings on the crankshaft and timing gear pulleys correspond.
Remove the upper timing cover.
Remove the starter motor mounting screws. Pull out the starter motor and put it aside. Remove the plug of the gauge hole. Rotate the crankshaft slightly clockwise. Install: 9995451 . Make sure that it bottoms against the engine block.
Scheme 145
Turn the crankshaft counterclockwise to its stop against the crankshaft adjustment tool. Check that the marking on the crankshaft timing gear pulley aligns with the marking on the oil pump.
Scheme 146
Note. Some engines have double VVT units/belt pulleys. If this is the case, the method is to be performed on both.
Note. Oil the center screw before installation.
Press the variable valve timing unit/timing gear pulley onto the camshaft. Install the center screw (1) that holds the variable valve timing unit to the camshaft. Do not tighten yet .
Slacken off, but do not remove the screws (2) which secure the timing gear pulley to the variable valve timing unit.
Position the upper timing cover.
Scheme 147
Turn the timing gear pulley so that the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley's marking is 1 tooth before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw (1) in the VVT unit to 120 Nm .
Check that the variable valve timing unit does not rotate when tightening. Install the center plug and tighten to 35 Nm .
Install the belt pulley on the intake camshaft : Install the belt pulley on the intake camshaft with three screws; do not tighten yet .
Turn the timing gear pulley to the marking. Check that the markings on the timing gear pulley/intake camshaft and upper timing cover correspond.
Adjust The Belt Tensioner
Note. This adjustment is done on a cold engine. A suitable temperature is approximately 20° C/68° F.
At higher temperatures (with the engine at operating temperature or a high outside temperatures for example) the indicator is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different engine temperatures.
Scheme 148
Fix the belt tensioner center screw in position and turn the belt tensioner eccentric counterclockwise until the tensioner indicator passes the marked position.
Then turn the eccentric back so that the indicator reaches the marked position in relation to actual temperature.
At the same time, ensure that the center screw remains fixed. At 20° C/68° F, the indicator should be centered in the window.
If the indicator is not in the right position, the adjustment must be repeated.
Note. The variable valve timing unit must not be released from the limit position until after the timing gear pulleys have been tightened.
Tighten the screws (2) on the timing gear pulley for the exhaust camshaft to 10 Nm .
Tighten the screws on the timing gear pulley for the intake camshaft to 20 Nm .
Remove
- the camshaft adjustment tools «9995452»(ref-403953-S02369714572011061000000)
- the crankshaft stop «9995451»(ref-403953-S26663901482011061000000) .
Install the plug with a new sealing washer. Tighten to 40 Nm .
Scheme 149
- press the belt to check that the indicator on the tensioner moves easily
- install the upper timing belt cover
- turn the crankshaft 2 rotations; check that the markings on the crankshaft and timing gear pulleys align
- check that the indicator on the belt tensioner is within the marked area.
Removing The Camshaft Adjustment Tool
Remove the camshaft adjustment tool 9995452 and the crankshaft adjustment tool 9995451 .
Install the plug to the starter motor with a new washer and tighten. See Tightening torque .
Scheme 150
Turn the engine 2 revolutions.
Then check that the belt tensioner indicator is in the center position. If not, it must be adjusted so that the indicator is in the correct position described in a previous work element.
Remove the starter motor mounting screws. Pull out the starter motor and put it aside.
Remove the blind cover plug for the adjustment tool hole. Turn the crankshaft clockwise slightly. Install the adjustment tool 9995451 . Ensure the adjustment tool bottoms against the engine block.