FITTING & TENSIONING THE NEW CAMBELT

The main steps for fitting and tensioning the cambelt are detailed in our photographs/captions, but there are some extra points that need to be observed.

When fitting the new cambelt and guiding it onto the drive sprockets/pulleys, ensure the belt is kept taut as you proceed. With the timing pin/bolt inserted in the flywheel, the belt sprocket timing marks must align as intended before and after fitting the new belt.

With the timing pin/bolt removed from the flywheel and the tensioner lock nut slackened, use a 6mm Allen key to rotate the tensioner pulley anticlockwise, so that the tensioner assembly’s pointer and prongs sit in the position indicated in Step 32. Now fully tighten the tensioner assembly’s locknut to 24Nm (18lb ft).

With the crankshaft pulley and securing bolt refitted and torqued to 15Nm (11lb ft), rotate the engine clockwise through six full revolutions, then reinsert the flywheel’s timing pin/bolt (rotate the engine back and forth a little to ensure that the pin/bolt is fully engaged). Reaffirm that the belt sprocket timing marks still align as intended.

If all is well at this stage, remove the timing pin/bolt again, and release the tensioner assembly lock nut while holding the Allen key. Now rotate the tensioner assembly until the pointer is in its central position relative to the two prongs, then retighten the tensioner’s lock nut to 24Nm (18lb ft). You must ensure that the tensioner assembly is NOT in contact with the cylinderhead; if it is, repeat the tensioning procedure.

Reassemble the various components in reverse order to dismantling. Avoid starting the engine until the auxiliary drivebelt is fitted, to prevent possible damage to the crankshaft pulley.

On completion fit a new crankshaft pulley bolt and torque it to 40Nm (30lb ft) plus 70° plus 5°.