Tech Tips

Timing belt installation

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the work is undertaken when the engine is cold, so ideally, the vehicle will not have been run for at least four hours.
tart by removing the plastic guard from Insert, and fully screw into place, the crankshaft
underneath the engine and then, after taking off timing tool (T10340) and rotate the crankshaft until
the front offside wheel, the lower part of the plastic the shaft rests on the tool. Then fit the camshaft tool
cowling from inside the wheel arch. This will reveal the (T10494) and after making sure it is in the correct
auxiliary belt system and by relaxing the tension on the position, lock it with a screw.
belt with a spanner on the tensioner, the belt can be Using special tool (T102475), remove the

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removed. Before disconnecting the tensioner, lock it by crankshaft pulley, followed by the lower timing belt
inserting a pin as shown (fig 1). cover and the two alternator retaining screws to
Remove the cap in the engine block used to detach it. Then take off the plate shown (fig 3), their screws to 50Nm before removing the camshaft
close the hole in which the crankshaft timing tool will support the engine appropriately from above and timing tools and temporarily refitting the crankshaft
be inserted. Disconnect the air intake to the filter box, remove the top engine mount adjacent to the timing pulley to enable the engine to be turned through a
take out the filter box and detach the pipes between belt and take off the central timing belt cover to access few clockwise revolutions.
the throttle and turbo, and the filter box and turbo, as the tensioner and idler. After removing the cover of Check the belt tensioner needle remains in the
well as the oil vapour recirculation pipe and the turbo the left (exhaust) and the central cap of the right right position, and using the crankshaft and camshaft
air intake connector. (intake) variable valve timing units, take off the tools, that the timing is still correct. If so, appropriately
Remove the water pump belt cover and the tensioner and timing belt. Appropriately lock the valve lock the valve timing units and tighten their screws
cover on the gearbox side of the intake camshaft, timing units, remove the centre screws and the units another 135°.
drain the cooling system and take off the upper cover themselves. Remove the water pump with the belt drive and
of the water pump and the expansion tank, as the after flushing out the cooling system, to remove any
debris and cleaning the water pump facing, reposition
the replacement pump, with the new belt, Dayco
941094, at the same time.
It is extremely important to follow the correct
tightening procedure when reattaching the water
pump cover, so first tighten the screws to 10Nm in the
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sequence shown (fig 6) and then loosen by one turn.
1 Put a hex screw in ‘A’, torque to 30Nm and hold the
Attach the new idler, Dayco ATB2637 and torque wrench in position while retightening screws 2,
pump and belt should be changed at the same time. torque to 45Nm, and tensioner, Dayco ATB2636, 1 and 5 to 10Nm and then 3, 4, 5, 1 and 2 to 12Nm.
Detach the upper timing belt cover, which will ensuring it is fitted as shown (fig 4), and then fit the
expose the variable exhaust valve timing unit on the valve timing units on the corresponding camshafts, but
left and intake on the right, and rotate the central do not fully tighten their screws.
crankshaft pulley screw clockwise and position the
intake camshaft as viewed from the gearbox side as
shown (fig 2).
After disconnecting the ignition coil and

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removing the spark plugs, insert a screwdriver, which is
long enough to touch the top of the number one
piston at BDC and rotate the crankshaft to its TDC (the Refit the components in reverse order of their

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screwdriver will rise by 35mm). removal, tension the crankshaft pulley screw to 150Nm
+ 180° and the crankshaft timing tool cap to 30Nm. To
Fit the new timing belt, Dayco 941060, installing follow best practice, Dayco also recommends the
it clockwise from the crankshaft pulley via the replacement of the auxiliary tensioner Dayco APV3270
tensioner, exhaust and then intake camshaft pulleys and the auxiliary belt Dayco 6PK1000.
and the idler. Use the special tool (T10499) to move Refill the cooling system, start the engine and
the needle of the tensioner to the right, about 10mm carefully check for leaks and ensure the radiator fan is
beyond the fixed reference and then back to the operating correctly. Then, once the engine is cold,

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middle of the fixed reference as shown (fig 5). Tighten check the level of the fluid again.
the tensioner fixing screw to 25Nm.
Suitably lock the valve timing units and tighten

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