Installation
All Vehicles
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NOTE: Rotate the crankshaft clockwise.
Rotate the crankshaft to TDC on cylinder No. 1.
NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key points straight up.
Remove the blanking plug, completely screw in the special tool and auto-align the crankshaft to TDC.
- Position cylinder No. 4 to valves overlap" and install the special tool.
- Hold the camshafts by the hexagon using an open-ended wrench and turn them in the direction of engine rotation.
- Slide the special tool onto the ends of both camshafts.
CAUTION: Do not kink the timing belt (do not bend the timing belt less than a diameter of 35 mm).
CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the timing pin.
NOTE: Design with lower idler pulley shown (built up to 06/1999).
NOTE: The lug of the belt tensioner should not be hooked in the sheet metal cover during timing belt installation.
Position a new timing belt in place.
- Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
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CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the timing pin.
NOTE: Design without lower idler pulley shown (built 06/1999 onwards).
NOTE: The lug of the belt tensioner should not be hooked in the sheet metal cover during timing belt installation.
Position a new timing belt in place.
- Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.
- NOTE: Incorrect timing belt tension will cause incorrect valve timing.
- Pre tension the timing belt.
- Rotate the tensioner locating tab counterclockwise and insert the locating tab into the slot in the rear timing cover.
- Position the hex key slot in the tensioner adjusting washer to the 4 o'clock position.
- Tighten the attaching bold enough to seat the tensioner firmly against the rear timing cover, but still allow the tensioner adjusting washer to be rotated using a 6mm hex key.
CAUTION: Tension the timing belt, working counterclockwise. Using the hex key, rotate the adjusting washer counterclockwise until the notch in the pointer is centered over the index line on the locating tab (the pointer will move clockwise during adjustment).
While holding the adjusting washer in position, tighten the bolt
NOTE: Hold the intake timing belt pulley with special tool to stop it from turning.
Tighten the timing belt pulleys.
- Tighten the intake camshaft timing belt pulley bolt.
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NOTE: Hold the exhaust camshaft by the hexagon with an open-ended wrench to stop it from turning.
Tighten the exhaust camshaft timing belt pulley bolt.
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Remove the special tool.
- Install the blanking plug.
- Remove the special tool.
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NOTE: Hold the camshaft by the hexagon with an open-ended wrench to stop it from turning.
Tighten the exhaust camshaft to stage 2.
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NOTE: Turn the crankshaft two revolutions in the normal direction of rotation.
Check the valve timing by inserting the special tool. Correct it, if necessary.
- Screw in special tool 303-574 and make sure that the crankshaft is touching it.
- Insert special tool 303-465 into the camshafts; if necessary loosen the timing pulleys and correct the camshaft alignment.
- Detach the special tools.
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NOTE: Use a new blanking plug.
Install the blanking plug on the exhaust camshaft pulley.
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