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Camshaft drive

Camshaft drive

To remove



1. Remove the air cleaner complete with hoses.

2. Slightly loosen the bolts securing the crankshaft pulley. Relieve load from the belt tensioner by turning the belt tensioner pulley locking bolt forward in the car using a 15 mm wrench. Remove the belt from the coolant pump pulley and carefully release the belt tensioner.


3. Remove the belt tensioner and remove the power steering pump pulley.

4. Remove the water pump pulley (to do this you will have to press the engine towards the left in the car - use the engine bracket as a fulcrum).

5. Remove the timing cover.

6. Remove the right-hand front wheel and the cover in the wheel housing. Remove the crankshaft pulley (undo the six bolts but do not remove the centre bolt).


7. Zero the engine. The markings on the camshaft sprockets and timing cover should be in alignment as also should the marking on the crankshaft. Use locking tools 83 95 006 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft.


8. Before removing the toothed belt, mark its direction of rotation . To facilitate refitting, the belt can be marked at both the camshaft marking and the crankshaft marking.

9. Release the belt tension and remove the toothed belt.


To fit



1. Fit the toothed belt according to the marked direction of rotation. Use setting tool 83 95 006 to keep the belt in place and adjust the tensioning roller loosely by hand to prevent the belt from jumping off. Adjust anticlockwise.

Fit a section of the toothed belt and fit tool 83 93 985 to measure the belt tension.

Lightly tighten the centre bolts of the adjusting rollers. Adjust the lower adjusting roller anticlockwise to a belt tension of 275-300 Nm.

Turning torque 40 Nm (30 lbf ft).

Important

The adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.


2. Adjust the tensioning pulley with an allen wrench until the two marks are aligned. Tighten.


Tightening torque 20 Nm (15 lbf ft).

Remove the locking tool for camshaft sprockets 1 and 2.

Adjust the upper adjusting roller counter-clockwise until the No. 2 sprocket moves 1-2 mm clockwise.

Turning torque 40 Nm (30 lbf ft).

Remove the upper locking tool.

3. Turn the engine over two revolutions until just before the zero mark and place the locking tool on the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm rests against the coolant pump's flange and then tighten the arm. Fit setting tool 83 95 006 and check that the markings on the camshaft sprockets are aligned with the markings in the tool.


Important

Check that the A marking is about 2 mm above the B marking, see illustration. If the distance is less than this, readjustment will be necessary.


4. Fit the crankshaft pulley.


Tightening torque 20 Nm (15 lbf ft).

5. Fit the cover and right-hand front wheel.

Tightening torques

110 Nm (81 lbf ft)

6. Fit the timing cover.

7. Refit the water pump pulley (to do this you will have to press the engine towards the left in the car - use the engine bracket as a fulcrum).

8. Refit the power steering pump pulley.

Turning torque 8 Nm (6 lbf ft).

9. Refit the belt tensioner.


Turning torque 40 Nm (30 lbf ft).

10. Relieve the load from the belt tensioner by turning the belt tensioner pulley locking bolt forwards in the car using a 15 mm wrench. Fit the belt on the coolant pump pulley and check the other pulleys. Carefully release the belt tensioner.

11. Refit the air cleaner complete with hoses.