Aftermarket October 2022

OCTOBER 2022 AFTERMARKET 37 www.aftermarketonline.net the manufacturer’s recommended replacement interval of 100,000 miles or 72 months, a repair time of 1.6 hours and the workshop repair instructions available on Schaeffler’s REPXPERT workshop information system, belt replacement is a great repair for any independent garage. “Always remember to disconnect the battery earth lead before starting the repair and to only turn the engine in the direction of rotation during belt removal and replacement. In addition, if fitted with a timing belt driven water pump, it is also recommended that the water pump is replaced at the same time. However, in this instance, the customer declined the recommendation. The following workshop equipment is required for this repair: Vehicle lift (two post is ideal) Engine support Engine timing/locking tool set Schaeffler’s 4T rule Reminding readers on Schaeffler’s 4T rule, Alistair noted: Temperature – “Always carry out timing belt replacement on an engine that is at ambient temperature, as this can affect belt tension.” Tools – “Timing/locking tools are essential for the correct and accurate timing on today’s engines.” Torque – “Ensure all bolts are torqued to the manufacturer’s specifications.” Tension – “Always tension the belt correctly, ensure the tensioner is tensioned in the correct rotation, tension marks align and pulley movement is available, where required.” Timing belt removal Alistair began: “With the INA timing belt kit ordered and service information checked, place the vehicle on the ramp, open the bonnet and disconnect the battery earth lead, then remove the plastic engine cover followed by the air filter assembly (Fig.1). Slacken the O/S/F wheel, then raise the vehicle lift to gain access to the underside and remove the engine undertray, lower the ramp to waist height and remove the O/S/F wheel, disconnect the front section of the wheel arch liner and then remove the lower splash guard to expose the auxiliary drive belt area.It is always advised to replace this auxiliary belt when replacing the timing belt, so with the auxiliary belt still installed, slacken the four front pulley bolts and then remove it to inspect for wear. Also check the over-running alternator pulley for its correct function and the idlers for smooth operation. The next part of the removal process is to support the engine. In this instance a subframe attached engine support was used under the vehicle, but an engine brace works equally well. With the engine supported, lower the vehicle lift to gain access to the engine bay. Remove the upper timing belt cover (Fig.2) and then the engine mounting and engine bracket assembly (Fig.3), to make the timing belt fully visible and accessible. Rotate the engine in a clockwise direction until the notch on the camshaft pulley is aligned with the pointer on the cam cover (Fig. 4), then raise the vehicle lift to gain access to the crankshaft pulley, remove the pulley and inspect it for any cracking on the rubber damper area and replace if necessary. With the pulley removed, unscrew the bolt from the oil pump housing and insert and tighten the locating pin (Fig.5), then fit the crankshaft locking plate (Fig.6). With the crankshaft locked, slacken the timing belt tensioner bolt, ease the timing belt off the upper pulleys, remove the crankshaft locking plate and then the timing belt. Timing belt replacement Alistair continued: “With the timing belt removed, check for any leaks that may contaminate the new timing belt kit and rectify as required. Remove and replace the timing belt tensioner and idlers and secure them using the new bolts supplied in the INA timing belt kit. Before installation of the new timing belt, ensure the camshaft pulley and high-pressure fuel pump are aligned. “Locate the new timing belt onto the crankshaft pulley and refit the crankshaft locking plate. Working in a clockwise direction ensure that the white lines on the new timing belt align with the marks on the high-pressure fuel pump and camshaft pulley. With the belt installed, check all timing marks align, set the tensioner so the pointer aligns with the hole/reference point on the base plate (Fig.7), tighten and torque the tensioner bolt. Remove the crankshaft locking plate, rotate the engine two complete revolutions, refit the crankshaft locking tool and check that the camshaft and high-pressure fuel pump timing marks align to ensure the timing is correct and check the pointer is still aligned correctly on the tensioner.” Alistair added: “Installation is in reverse order of removal, in this instance the multi ribbed auxiliary belt and tensioner were also replaced.” For more information, visit: www.repxpert.co.uk Fig. 7 Fig. 6 Fig. 5