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Tooth belt, removing and fitting

Tooth belt, removing and fitting

Change


1. Open the bonnet

2. Disconnect the battery and remove the ground cable

3. Remove the engine cover.

Unscrew the lid on the oil filler connection

2x Unscrew

Screw on the lid on the oil filler connection

4. Remove Air filter housing, air control

Remove the mass air flow sensor connector.

remove the cable clip from the air filter housing.

Remove the crankcase ventilation hose and the intake manifold.

5. Undo the front right wheel

5x Undo bolt

6. Raise the car

7. Remove the right front wheel.

5x Undo bolt

8. Raise the car

9. Remove the wing liner.


10. Remove the multi-belt

Turn the multi-belt tension device in the direction of the arrow - use a 15 mm flexi-head spanner (2)

Insert KM-6130 (1) or a 4.5mm drift.

Mark the direction of rotation


11. Remove the multi-belt tension device

Tighten the multi-belt tension device. Remove KM-6130 or the drift (2)

Undo the multi-belt tension device

Undo the bolt (1)


12. Remove the crankshaft multi-belt pulley

Prise loose the front screw plug from the oil pan

Use KM-911 ( 83 96 327 Holder tool, fixing of flywheel )

Undo the bolt

Remove KM-911


13. Fit KM-6313 ( 83 96 145 Centring fixture, subframe - engine with 83 96 368 Additional kit for centring fixture ) (1)

Place 83 96 145 Centring fixture, subframe - engine to the left of the front axle member (arrows, picture I) Instruction: The guide bolt must be in the hole in the front axle member

Put both right-hand holders onto the front axle member (arrows, picture II) Instruction: The guide bolt must be in the hole in the front axle member (arrow, picture III)

2x Tighten bolt


14. Fit the support. Adjust the support bracket.

Screw on the nut


15. 3x Adjust the support

Gearbox end, Instruction: Turn the spindle until the brackets (1) are firmly against the guide pins

Engine control end, Instruction: Insert the support pin firmly into the engine block hole (arrow). Tighten the bolts, nut and support

16. Lower the car

17. Remove the right-hand engine pad

Undo the engine holder adapter - 3x Unscrew bolt (1)

Undo the engine pad - 2x Unscrew bolt - Unscrew nut (2)


18. Remove the top part of the tooth belt cover

3x Unscrew the bolt (arrows)

Detach from the rear tooth belt cover

19. Remove the bottom of the tooth belt cover

Undo the bolt (arrow)

Detach from the rear tooth belt cover


20. Remove the camshaft sensor (1)

2x Unscrew bolt (2) Instruction: Place the camshaft sensor to one side


21. Set ignition TDC cylinder 1

Screw tight the bolt for the crankshaft multi-belt pulley

Put the crankshaft on the mark - Turn the crankshaft at an even rate Instruction: The marks on the tooth belt sprocket and the rear tooth belt cover must agree (III)

Fix the camshaft sprocket. Instruction: The marks must be in front of each other and correspond with the top of the cylinder head (I) - use KM-852 83 96 319 Holder tool, fixing of camshaft sprocket Z18XE ) (ll)


22. Remove the tooth belt

Undo the tooth belt tensioning pulley (IV) - Undo the bolt - Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer(1) on the tooth belt tensioning pulley is just short of the left-hand end position.

23. Put in the tooth belt, Instruction: Check the fitting position.

24. Fit the right-hand engine pad

Fasten the engine holder adapter - 3x Tighten bolt - Tightening torque 55 Nm - Fasten the engine pad - 2x Tighten bolt - Tightening torque 55 Nm - Tighten nut - Tightening torque 55 Nm

25. Put on the tooth belt Instruction: The pulling side must be taut (I)


26. Tension the tooth belt

Tension the tooth belt tensioning pulley - Turn the setting eccenter in the direction of the arrow (anticlockwise) until the pointer on the tooth belt tension roller is just short of the right-hand end position

Fasten the bolt for the tooth belt tensioning pulley (1)


27. Remove KM-852 (83 96 319 Holder tool, fixing of camshaft sprocket Z18XE)

28. Valve timing, check: Turn the crankshaft (720°) in the direction of engine rotation with the bolt for the crankshaft multi-belt sprocket

Put the crankshaft on the mark Instruction: The marks on the tooth belt sprocket and the rear tooth belt cover must agree (III)

Put in KM-852 (II) Instruction: The marks must be in front of each other and correspond with the top of the cylinder head (I)


29. Remove KM-852

30. Tooth belt tension, setting

Undo the tooth belt tensioning pulley - Undo the bolt

Turn the setting eccenter in the direction of the arrow (clockwise) until the pointer (1) on the tooth belt tensioning pulley corresponds with the groove (2) - Adjust a used tooth belt to the USED mark - Adjust a new tooth belt to the NEW mark

Tighten the bolt for the tooth belt tensioning pulley - Tightening torque 20 Nm


31. Tooth belt tension, check

Turn the crankshaft (720°) Instruction: The pointer on the tooth belt tensioning pulley and the groove must agree - Adjust a used tooth belt to the USED mark - Adjust a new tooth belt to the NEW mark

32. Clean the threads.

2x Clean threads - For camshaft sensor

33. Fit the camshaft sensor Instruction: Fit the bolts with locking compound (red)

2x Tighten bolt - Tightening torque 8 Nm

34. Fit the bottom of the tooth belt cover

Tighten the bolt - Tightening torque 4 Nm

35. Fit the top of the tooth belt cover

Fasten the rear tooth belt cover

3x Tighten bolt - Tightening torque 4 Nm

36. Raise the car

37. Remove the support for the engine

38. Remove 83 96 145 Centring fixture, subframe - engine .

39. Fit the multi-belt tensioning device

Tighten the bolt - Tightening torque 35 Nm

Tension the multi-belt tensioning device - Use KM-913-A or a flex-head spanner

Insert KM-6130 or a 4.5mm drift.

40. Fit the crankshaft multi-belt pulley

Put in KM-911 ( 83 96 327 Holder tool, fixing of flywheel )

Change the bolt

Tighten the bolt - Tightening torque 95 Nm + 30° + 15°

Remove KM-911

Fit the front screw plug

41. Fit the multi-belt

Instruction: Observe the rotation direction and fitting position

Undo the multi-belt tensioning device - Use KM-913-A

Remove KM-6130


42. Fit the wing liner.

43. Lower the car

44. Fit the front right wheel

45. Fit the air filter housing

Fit the intake hose

Fit the engine vent hose

Connect cable set connector

Fasten the cable set

46. Fit the engine cover

Unscrew the lid on the oil filler connection

2x Tighten bolt - Tightening torque 8 Nm

Screw on the lid on the oil filler connection

47. Connect the battery.

48. Close the bonnet

49. Program erased memories