hOW DO I REMOVE THE CAM BELT TO REFIT WITH NEW

MICHAEL LANG, December 2005

In workshop conditions they would allow 3.4 hours non air con and 3.9 hours with air con to do this job.
You will require locking pin set available from Partco or similar.
Removal
1 raise and support front of car
2 engine undershield if fitted
3 R.H wheel arch liner
4 auxilliary drive belts
5 upper timing belt covers
6 air intake pipe XUD 7TE models
(retain rubber spacer)
7 Turn crankshaft to TDC on number 1 cylinder
then insert flywheel timing pin.
Insert a bolt of suitable size in camshaft sprocket to lock and then insert 2 bolts in injector spocket to lock.
8 Slacken tensioner nut and bolt
9 move tensioner away from belt using square drive extension and ratchet then re-tighten tensioner nut and bolt.
10 remove clutch housing cover plate
11 fit flywheel locking tool
12 remove crankshaft pulley you will probably need a puller
13 remove timing belt lower cover
14 support engine with jack or crane
15 remove upper engine mounting
16 remove timing belt
17 slacken tensioner nut and bolt
18 operate tensioner several times to ensure freedom of movement ( it is good practise really to replace tensioner could save you hundreds in the long run)
19 push tensioner back and lightly tighten nut and bolt.
Installation
1 As you have locked everything up it can't have moved but double check everything is in place all locking bolts and pins
2 fit belt anti-clockwise direction starting at crank.
3 slacken tensioner nut and bolt allow tensioner to operate then re-tighten nut and bolt.
4 remove locking pins and locking bolts
5 turn crankshaft on pulley bolt two complete revolutions in clockwise direction.
6 Go back to TDC on number 1 and ensure that all locking pins and bolts can be re-inserted.
7 slacken tensioner bolt and nut
8 then re-tighten to 17 to 20 Nm
9 remove all locking pins and bolts
10 Re-install everything else in reverse order to removal from here.
11 coat threads of crank pulley bolt in thread lock the tighten to 40Nm then a further 60 degrees.
There job done that was nice and easy wasn't it?

chris, December 2005