ENGINE CODE: ARZ RECOMMENDED LABOUR TIME: 2.2 HOURS
Fitters need the following special tools for this procedure:
1. OE locking tool (T40011)
2. OE tensioning bolt (T10092)
3. OE engine support bridge (10-222A)
Significant errors are frequently committed when changing the timing belt on this model of vehicle. To ensure that the belt change operation goes smoothly, the ContiTech Power Transmission Group has created a step-by-step guide of how to change the belt correctly.
Firstly, the manufacturer recommends changing the belt and the tensioning pulley at around 110,000 miles, or after five years.
Preparatory work
Identify the vehicle using the engine code and then disconnect the vehicle battery. Do not turn the crankshaft and camshaft once the timing belt has been removed. Turn the engine in the normal direction of rotation (clockwise) unless otherwise specified. You should turn the engine only at the crankshaft pulley and not at other sprockets and make sure you comply with all of the VM’s recommended tightening torques. Raise the vehicle and support the engine, or fit the engine support bridge so that the front engine mount is not under strain.
Remove the engine cover, power steering reservoir (do not detach the hoses), ancillary unit belt and belt tensioner, coolant expansion reservoir (the hoses do not need to be detached), and upper, middle and lower timing belt guards. Disconnect the fuel lines and remove the plug from the Hall-effect sensor as well as the hose between the charge-air line and charge-air cooler, engine compartment underpanel, crankshaft belt pulley and front engine mount. Make sure the engine is sufficiently supported or that you use an engine support bridge to lift it.
Camshaft belt removal
Set the valve timings to the TDC mark of cylinder 1; the mark (notch) on the camshaft pulley must align with the mark (notch) on the rear timing belt guard.
Check the crankshaft mark; to do so, remove the rubber plug from the torque converter housing.
The mark (notch) on the flywheel must align with the mark (projection) of opening.
Screw the OE tensioning bolt (T10092) into the hydraulic damper and slowly release the tension on the timing belt/tensioning pulley by turning the OE tensioning bolt (T10092), until the OE locking tool (T40011) can be inserted into the small bore of the hydraulic damper.
The timing belt can now be removed.
Camshaft belt installation
Screw the OE tensioning bolt (T10092) into the new hydraulic damper.
Then fit the new tensioning pulley (27Nm) and new hydraulic damper (15Nm) and tighten the OE tensioning bolt (T10092) so that the locking tool will be easy to remove from the new hydraulic damper later.
Do not withdraw the locking pin until the timing belt and tensioning pulley are correctly installed. The hydraulic damper may only be actuated with the tensioning bolt and pressing this together with a vice or pliers could damage the hydraulic damper.
Fit the timing belt on the crankshaft pulley, starting clockwise. Take care to ensure that the timing belt is not kinked during fitting – it must be tight between the sprockets on the tight side. Tension the timing belt by withdrawing the locking pin of the hydraulic damper and removing the OE tensioning bolt (T10092). The tension is set by the hydraulic damper and there are no other marks on the tensioning pulley.
Turn the engine through two revolutions in the direction of engine travel then set the engine to TDC of cylinder 1. Check and, if necessary, correct the timings. You should then refit the crankshaft belt pulley; to do so, hold the crankshaft central bolt using a box-end wrench or counterhold before tightening to the appropriate torque. Finally, fit the components in the reverse order of removal.
You should now fit the upper and lower timing belt guard (10Nm) using a threadlocker, before moving on to the ancillary unit belt and belt tensioner (23Nm). The engine mount bolts and engine mount are next, followed by the hose between the charge-air pipe and charge-air cooler, power steering reservoir and coolant expansion reservoir. Reconnect the fuel lines and plug the Hall-effect sensor back in before refitting the engine cover and engine compartment underpanel.
Record the changing of the original ContiTech timing belt on the sticker supplied and place this in the engine compartment.
Before finishing the job, make sure you carry out a test run or test drive.
