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Timing belt tensioner and toothed pulleys - removal, inspection and refitting
In-car engine repair procedures / Timing belt tensioner and toothed pulleys - removal, inspection and refitting


Tensioner
Note: If the tensioner is being removed for the first time since the vehicle left the factory, a tensioner spring and retaining pin must be obtained for fitting on reassembly.

1 While it is possible to reach the tensioner once the timing belt upper and middle covers only have been removed (see Section 9), the whole procedure outlined below must be followed, to ensure that the valve timing is correctly reset once the belts tension has been disturbed.

2 Release the tension from the timing belt as described in Section 10, paragraphs 1 to 14.

3 Unscrew the tensioner bolt and withdraw the tensioner, unhooking the spring, if fitted (see illustration). Check the tensioner and spring as described in paragraph 16 of Section 10.

11.3 Removing timing belt tensioner
11.3 Removing timing belt tensioner

4 On reassembly, if it is being fitted for the first time, screw the timing belt tensioner spring retaining pin into the cylinder head, tightening it to the specified torque wrench setting. Hook the spring onto the pin and the tensioner backplate, then refit the tensioner, engaging its backplate on the locating peg.

5 Use an Allen key inserted into its centre to rotate the tensioner clockwise as far as possible against spring tension, then tighten the bolt to secure the tensioner.

6 Reassemble, checking the camshaft alignment (valve timing) and setting the timing belt tension, as described in paragraphs 22 to 27 of Section 10.

Camshaft and crankshaft toothed pulleys
7 While it may be possible to remove any of these pulleys once their respective covers have been removed, the complete timing belt removal/refitting procedure (see Section 10) must be followed, to ensure that the valve timing is correctly reset once the belts tension has been disturbed.

8 With the timing belt removed, the camshaft toothed pulleys can be detached once their retaining bolts have been unscrewed as described in paragraphs 18 and 21 of Section 10. The crankshaft toothed pulley can be pulled off the end of the crankshaft once the crankshaft (grooved) pulley and the timing belt have been removed. Note the FRONT marking identifying the pulleys outboard face, and the thrustwasher behind it; note which way round the thrustwasher is fitted (see illustration). Note the pulley-locating Woodruff key; if this is loose, it should be removed for safe storage with the pulley.

11.8 Note FRONT marking on outside face of crankshaft toothed pulley -
11.8 Note FRONT marking on outside face of crankshaft toothed pulley - note which way round thrustwasher behind is fitted

9 Check the pulleys as described in paragraph 16 of Section 10.

10 Refitting is the reverse of the removal procedure.

Timing belt guide pulleys 11 Remove the timing belt covers (see Section 9).

12 Unbolt and withdraw the pulley(s); check their condition as described in paragraph 16 of Section 10.

13 Refitting is the reverse of the removal procedure; tighten the pulley bolts to the specified torque wrench setting (see illustration).

11.13 Tighten timing belt guide pulley bolts to specified torque settings on
11.13 Tighten timing belt guide pulley bolts to specified torque settings on refitting


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