Service Manual Section 2, D8-D12. 1991
Contents
1. Check the basic setting Fit the new timing gear belt Important Do not rotate the crankshaft or camshaft or else the pistons may strike the valves Align the tooth belt pulley with the marking e Thread the belt around the crankshaft and intermedia te shaft The two markings on the belt should be oppo site the crankshaft marking e Tension the belt and thread it over the camshaft and belt tensioner e Check that the belt is properly in place and that the pulley markings are aligned with the engine markings Tension the timing belt e Undo the belt tensioner nut approx 1 revolution e The belt tensioner s spring will tension the belt e Retighten the nut Refit the lower timing gear casing the vibration damper Check that the guide plate is correctly positioned Important The vibration damper only fits in one position There is a lug on the crankshaft gear which fits into the vibration damper Refit the crankshaft bolt and washer Tighten the vibration damper Remove the nut and washer from the belt tensioner Use counterhold 999 5284 Fix it in position with the nut Tighten the crankshaft bolt Stage 1 60 Nm 6 kpm Stage 2 angle tighten 60 use protractor 999 5098 Use counterhold 999 5284 Fit the washer and nut on the belt tensioner Tighten the nut 10 Refit the upper timing gear casing coolant pump pulley drive belts loose fan shroud pre heating hose2. Remove the timing belt Rotate the crankshaft clockwise until cyl no 1 flywheel side is above the TDC injection point so that the follo wing markings match flywheel bell housing rear protecting plate camshaft gear Etch a mark on the injection pump s mounting bracket opposite the mark on the injection pump s drive gear Remove the plug from the threaded hole to the right of the oil dipstick Insert an 8 mm thick drill bit through the hole Check that the drill locks the crankshaft Remove the crankshaft pulley Undo the tensioner pulley Remove the drive belt Clean and check the drive gears Fit the timing belt Check that the drill bit in the crankshaft has not shifted Fit the timing belt The markings on the belt should match the marks on the crankshaft injection pump gear Note Observe the following when fitting the belt the belt s direction of rotation arrows on the belt the sequence in which the belt is to be fitted over the various gears follow the numbers in the figure the tension pulley must be completely non tensioned so as to avoid damaging the belt Adjusting the timing belt Tighten an M6 screw to adjust the position of the ten sion pulley Apply special tool 999 5506 to the belt and the tension pulley Slide the O ring on gauge 999 5434 below the graded scale 1 Place gauge 999 5434 in the hole in 999 5506 and press the tool as in the illustration 2 The depth of
3. 131 25 Adjust the camshaft crankshaft acc to the markings Rotate the crankshaft clockwise with the centre screw Position the camshaft so that the marking on the pulley is opposite the marking on the inner tooth belt cover and the crankshaft marking is opposite 0 on the cover Engines with the distributor at the front edge of the engine block remove the distributor cap and check that the rotor is aligned with the marking Remove the vibration damper Remove the nut and washer from the belt tensioner Use counterhold 999 5284 Secure it with the nut Remove the vibration damper screw Remove counter hold 999 5284 Check adjust the 0 marking Remove the vibration damper Remove the lower timing gear casing Remove the camshaft belt Undo the belt tensioner s nut about 1 revolution Pull out the pulley so that the pulley tensioner is comp ressed Tighten the nut once again Note The pistons may strike the valves if the cranks haft or camshaft are rotated when the timing gear belt is removed Remove the camshaft belt Check the belt tensioner Rotate the tension pulley and listen for abnormal noise from the bearing Check that the contact surface with the belt is free from scratches and rubber residue Check that the belt tensioner slides smoothly around its guide pin that the contact surface against the block is clean After cleaning lubricate with P N 11 61 246 50g or 11 61 247 500g
4. 8 socket 1 in the belt tensioner to loosen the belt On the 1995 model use tool 999 5547 in the belt tensioner s centre 2 Lock the belt tensioner in its service setting with a lock pin in the holes 3 when they are above one another Remove the belt Remove the belt tensioner Undo the belt tensioner s two screws and remove the tensioner Grease the automatic tensioner pulley not M Y 1995 Undo the pulley s centre screw and dismantle as in the figure Apply grease P N 11 61 246 2 50 g or 11 61 247 0 500 g between the friction plate and cover and in the four holes used for the spring marked by arrows Reassemble the belt tensioner Torque tighten the cen tre screw to 20 Nm Refit the belt tensioner Torque tighten to 20 Nm 5 Fit the belt New A new belt every 90 000 km Loop the belt around the crankshaft Then loop it around the A C compressor idler pulley alternator and servo pump the dotted line shows the belt path if no A C is fitted ioe Tighten the belt tensioner using the articulated wrench A and fit the belt into place IO Check its operation D11 Camshaft belt replace B 200 230 Special tool 5284 1 Remove e fan e clamp for pre heating hose under fan shroud variant e fan shroud Remove the drive belts and coolant pump pul ley e undo the adjustment screws e remove all the drive belts e remove the pulley Remove the upper timing gear casing
5. Use special tools 999 5434 and 5435 to check the tension 7 5 mm Remove the tensioner screw Fit e camshaft belt cover e crankshaft pulley e auxiliary unit drive belt e drive belt for power steering and air conditioning whe re fitted Check adjust the auxiliary unit belts see inspection point D9 Fit a new timing gear belt and Poly V belt Special tools 999 5006 999 5115 999 5383 999 5434 999 5506 Remove the lower cover plate for the Poly V belt Poly V belt from the alternator coolant pump Fit the lifting eyelet and its lift hooks Place a flannel under the fuel return pipe Remove fuel return pipe at the fuel pump s pipe and remove it from the lifting eyelet beside the timing gear end Remove the rubber gaiter Remove the screw at the left front wing A Place lifting eyelet 999 5006 above the engine and insert hook 999 5115 into the eyelet Place support unit 999 5383 and lifting eyelet 999 5115 in the eyelet Lower the engine mounting at the timing gear Remove the three screws 1 and nut 2 and remove the mounting Remove the fuel filter from the housing bracket Remove the two nuts Remove the timing gear housings Remove the three screws 3 and dismantle the timing cover from the fuel pump s gear Remove the four screws 5 and dismantle the upper timing gear cover
6. pressure can be felt with the thumb The correct pressure is obtained when the measuring needle is at the same height as the top of the gauge Carefully withdraw gauge 999 5506 and read the belt tension in mm Adjust belt tension correctly using the M6 screw Refe rence value for checking and adjusting cold engine 7 5 mm Tighten the tension pulley s lock nut to 50 Nm Check that the marks on the timing belt match the marks on crankshaft injection pump gear crankshaft gear 1700014A Fit the crankshaft pulley Fit the crankshaft pulley Clean the centre screw Apply locking fluid and tighten the screw to 95 Nm Check that the crankshaft pulley is correctly fit ted Remove tool 999 5434 Remove the drill bit Rotate the crankshaft two full revolutions clockwise Stop in the TDC position and reinsert the drill bit Check that the marks on the timing gear cover and injection pump mounting bracket match the marks on the camshaft injection pump s gears Check belt tension Remove the M6 screw Check tighten belt tension and adjust if necessary see the section on adjusting the timing belt on the previous page 999 5382 1700019A 1700022A Check adjust injection pump Fit the gauge to the injection pump If necessary remove 6 mm of material from the gauge 999 5382 see the figure Remove the drill bit and rotate the crankshaft 3 4 revo lution clockwise Fit
7. with tool 999 5456 Place the tension unit in the tool and screw the tool s centre nut to the end Wait until compression is complete and insert a lock pin 0 2 mm in the piston Note If there is any visible leakage or if no resistance is felt during compression or if compression is impos sible the tensioner must be replaced 12 Fit the camshaft belt Thread the belt around the crankshaft and right idler pulley Thread the belt over the camshaft pulleys Thread the belt around the coolant pump and press it over the tensioning pulley Fit the tensioner Fit the tensioner s screws torque 25 Nm Pull out the lock pin from the tensioner Press firmly or hit the belt with a rubber mallet twice in the direction of arrow 1 and twice in the direction of arrow 2 Fit the upper timing gear cover Fit the upper timing gear cover Rotate the crankshaft two revolutions and check that the markings on the crankshaft and camshaft pulleys match Fit ignition cable cover front timing gear casing vibration damper shield splash guard under the engine Perform a function test Test run the engine Fit the auxiliary unit belt Note New belt every 90 000 km Thread the belt around the crankshaft Then around the A C compressor idler pulley alterna tor and servo pump Tighten the belt tensioner with the articulated wrench and position the belt Check its operation
8. 1 is at TDC and the markings on the flywheel bell housing and camshaft belt cover cam gear are opposite each other Remove the plug at the bottom right beside the oil dipstick and insert an 8 mm lock pin in the hole in the crankcase Check that the crankshaft cannot be rotated Remove the crankshaft pulley and vibration damper Remove the belt cover and make a mark on the edge opposite the mark on the camshaft gear Undo the belt tensioner Remove the belt Begin at the tensioner Fit the camshaft belt Check that the lock pin is in place Place the belt so that the mark is opposite the marks on the crankshaft and camshaft gear Observe the following when fitting the belt s direction of movement see the arrow the sequence in which the belt is to be fitted to the gears see fig Adjust the camshaft belt Tension the belt with the help of an M6 screw Use special tools 999 5434 and 5435 Correct tension 7 5 mm cold belt Tighten the tensioner s lock nut Tightening torque 50 Nm 999 5434 999 5435 Check that the belt is correctly fitted Remove the special tool Remove the lock pin Turn the crankshaft two full revolutions in the correct direction of rotation Rotate the crankshaft to the TDC position insert the lock pin and check that the mark on the camshaft gear is opposite the mark on the edge of the belt cover Remove the lock pin and refit the plug Check camshaft belt tension
9. D8 Distributor lubricate B 200 230 E in the 240 Lubricate the distributor shaft sparingly 1 2 drops of oil D9 Auxiliary unit belts check adjust Applies to engines which do not have multi tooth belts Check belt tension It should be possible to press the middle of the belt about 5 10 mm If necessary adjust by changing the position of the alternator B 16 B 18 B 20 D 19 T 3 track belt Check belt tension with gauge 115 9660 Measure at A 6 track belt Check belt tension with special tools 999 5434 and 999 5436 Measure at B Remove the right hand protecting cover for measuring under B ee Engine type Check Adjustment Adjustment min value run in belt new belt__ track belt Tool 115 9660 20 kg 30 35 kg 45 50 kg 6 track belt Tool 999 5434 999 5436 Basic version 4 5 mm 4mm 3 4 mm Single option 3 5 mm 3mm 2 3 mm Double option 3 5 mm 3mm qi 2 3mm_ D19T 4 5 mm 3mm 2 3 mm If belt tension has dropped below the control value the tension shall be adjusted to the nominal value for a run in belt D10 Auxiliary drive belt grease the belt tensioner replace belt As of model year 1995 the belt tensioner is a maintenance free unit Grease the belt tensioner every 45 000 km fit a new belt every 90 000 km B 5202 5204 5234 5252 5254 Remove the auxiliary drive belt Use an articulated wrench with a 3
10. ary Connect the fuel pump s return pipe Fit the rubber ring in the lifting eyelet the return pipe through the lifting eyelet a new clamp on the return pipe Connect the return pipe to the fuel pump s pipe and tighten the clamp 1700021A Bleed the fuel system Place a container under the pump Connect a hose to the bleeder screw 3 and let it hang down into the container Open the bleeder screw Use the filter s manual pump build up pressure until clean fuel appears via the bleeder screw Shut the bleeder screw and remove the hose Pump a few more times until a slight resistance is felt Fit the Poly V belt on the alternator coolant pump Check adjust the drive belt Poly V belt Fit tools 999 5434 and 999 5436 to the belt Thread the gauge s 0 ring below the graded scale 4 Fit the gauge and press it as far in as shown in the figure 5 The depth of this pressure can be felt with the thumb The correct length is obtained when the needle is flush with the top of the gauge Carefully remove the gauge and read the belt tension 6 Inspection Adjustment Adjustment max value run in belt new belt 4 5 mm 4mm 3 4mm Fit the lower cover plate and tighten to 9 Nm side protector Fit fuel filter the two nuts and tighten them Start and check 2100272A B 6244 6254 6304 Special tool 998 8500 Rem
11. ck belt tension Belt tension should now be within the prescribed range 4 9 0 2 27 Install idler pulley Ensure the pulley is properly seated 28 Install the lower timing gear casing 2 the upper timing gear casing 1 29 Test operation Test run the engine B 5202 5204 5234 5252 5254 Special tool 998 8500 999 5456 Including greasing the tension pulley 1 Remove the spark plug cover the two fuel pipe clamps lift up the expansion tank and place it above the eng ine the front timing gear cover the auxiliary unit belt the lower belt casing N Align the camshafts crankshaft according to the marking Remove the right front wheel and undo the wheel arch liner somewhat Remove the vibration damper protecting plate Turn the crankshaft clockwise until the markings cams haft gear and inner timing gear cover and the cranks haft pulley oil pump housing match wo Check the belt tension Wait 5 minutes after adjustment of the timing gear belt Place gauge 998 8500 between the output axle pulley and the coolant pump Read the value with the help of a mirror the gauge may not be removed before the reading is completed Belt tension should be within 21 mm belt 3 5 4 6 units 23 mm belt 4 valve 2 5 4 0 units 23 mm belt 2 valve 2 7 4 2 units If the recommended value is not obtained the tensio ner must replaced A Remove the camshaft belt Remove the tensioner s uppe
12. gauge 999 5382 remove the plug B and insert the pin 2 which be longs to the special tool fit and tighten the holder 3 fit the dial gauge 4 and insert it at least 0 2 mm Tighten the gauge and reset it to zero Check adjust injection Rotate the crankshaft clockwise until the needle on the gauge shows 5 00 Press the drill bit in and rotate the crankshaft clockwise until the drill slips into the recess in the crankshaft Read the gauge The reference value is found on the pump s inspection arm Tolerance 0 02 mm If the correct value is not obtained undo the pump gear s three screws 5 the pump s drive shaft 6 is rotated until the correct value is appears on the dial Tighten the three screws to 20 Nm Check the setting once more Remove the gauge Remove tool 999 5382 together with the dial and pin Refit the plug with a new gasket Tighten to 20 Nm Fit the oil filler cap EZ l K A Dd Ws SS Ye SUF RAK NE 5 7 Fit the timing covers Fit the upper timing cover and the four screws Fit the fuel pump s gear casing and the three screws Tighten all the screws Tightening torque 9 Nm Refit the engine mounting Fit the mounting Fit and tighten the three screws Tightening torque 50 Nm Fit and tighten the nut Tightening torque 50 Nm Remove lifting eyelet 999 5006 and 999 5383 together with the hooks 999 5115 Check the fitting and adjust if necess
13. haft seals Check the balance shaft and crankshaft mar kings Check the balance shaft markings to ensure that they are opposite the marking on the inner timing gear ca sing Check that the crankshaft is opposite the TDC marking on the engine block Fitting of balance shaft belt The balance shaft belt s three markings A Balance shaft right side white dot B Crankshaft lower marking blue dot C Balance shaft left side white dot A B 18 teeth B C 34 teeth Fit the balance shaft belt Carefully insert the belt under the crankshaft gear Check that the belt s blue dot marking B is opposite the TDC marking on the guide plate on the lower section of the crankshaft Thread the belt around the left upper balance shaft so that the C mark is opposite the balance shaft gear marking Thread the belt on the right lower balance shaft so that the A mark is opposite the balance shaft gear marking Thread the belt around the tensioner pulley 14 Check the balance shaft and crankshaft mar kings Check that they are still correct 15 Tighten the tensioner pulley Tension the belt using a hexagonal key in the adjust ment hole 1 of the pulley Rotate the crankshaft a few degrees to each side of the TDC marking Position the crankshaft at TDC The pulley s adjustment hole should be just under the 3 o clock position when the lock screw is tightened Tighten the lock screw 2 to 40 Nm Use a hexagonal
14. he crankshaft and right idler pulley Thread the belt over the camshaft gears Thread the belt around the coolant pump and press the belt over the tension pulley Rotate the crankshaft through two revolutions Pull out the lock pin from the tensioner Press hard or hit the belt with a plastic mallet twice in the direction of arrow 1 and twice in the direction of arrow 2 Fit a new plastic washer on the piston Make sure that the washer is centred on the piston and tensioner housing Note Check that the correct side of the washer faces upwards See the illustration The recessed side should face up Fit the upper timing gear casing Rotate the crankshaft two revolutions and check that the markings on the crankshaft and camshaft pulleys match Refit the two clamps for the fuel pipes the front timing gear cover the auxiliary unit belt the spark plug cover the expansion tank the lower belt casing the inner wheel arch liner the wheel Check operation Test run the engine D12 Camshaft belt auxiliary unit belt replace B 16 B 18 B 20 Special tools 999 5434 999 5435 999 5436 115 9660 1 Remove e right side protecting plate e power steering pump cover e auxiliary unit drive belts after the power steering and or alternator has have been loosened e Remove the camshaft belt cover Remove the camshaft belt Rotate the crankshaft so that cylinder no
15. holder fan Tension the drive belts When correctly tensioned the belt should be able to be pressed down 5 10 mm using normal thumb pressure 11 Start the engine and run it until the thermostat opens Switch off the engine 12 Tension the camshaft belt Remove the rubber plug in the timing gear casing Turn the engine over to TDC Undo the belt tensioner nut approx 1 revolution The belt tensioner spring will tension the belt Tighten the nut once again Refit the plug in the timing gear casing Retighten belt tension after 15 000 km see op D12 B 204 234 l Special tool 5416 998 8500 Including replacement of balance shaft pulley and greasing of tension pulley 1 Remove alternator drive belt drive belts for servo pump and A C if fitted the three timing gear casings splash guard under the engine Adjust camshafts crankshaft according to marking Adjust engine to TDC for cylinder 1 Check that the marking on the camshaft pulley is oppo site the marking on the inner timing gear casing Check that the marking on the crankshaft s belt guidan ce pulley is opposite the TDC marking on the engine block Measure the belt tension Wait 5 minutes after adjustment of the camshaft belt Place measurement instrument 998 8500 between the output axle s belt pulley and the tensioner pulley Read the value Belt tension should be between 3 5 4 6 units If the correct va
16. key to counterhold the adjustment hole 1 456 16 Check the belt tension Use measuring instrument 998 8500 Measure at the belt above the position of the removed idler pulley Belt tension should now be between 1 4 units Note If belt tension is outside the above range the tension pulley should be loosened and step 15 should be repeated Fitting the camshaft belt 17 Lock the tensioner element Check that there is no visible leakage Press together the tensioner with tool 999 5456 Place the tensioner in the tool and tighten the tool s centre nut Wait unit compression is completed and then insert a lock pin diam 2 mm in the piston 18 Fit the camshaft belt Place the belt s twin stripe marking opposite the mark ing on the guide plate on the upper side of the crank shaft Place the belt around the crankshaft gear and over the tension pulley and then over the right idler pulley Place the belt over the camshaft gears The belt s two single markings must match the camshaft gear mark ings Thread the belt around the left idler pulley and press the belt over the tension pulley 19 Fit the tensioner Insert the tensioner screws Torque M8 20 Nm M 10 50 Nm Pull the lock pun out of the tensioner Remove holder 999 5416 Rotate the crankshaft 2 revolutions and check that the markings on the crankshaft and camshaft gears still match 20 Check adjust balance shaft tension Use ga
17. lt tension Wait for 5 minutes after adjustment of the camshaft belt Place gauge 998 8500 between the output shaft pulley and the coolant pump Read the value Belt tension should be between 21 mm belt 3 5 4 6 units 23 mm belt 3 0 4 0 units 28 mm belt 2 5 3 5 units If the specified value is not obtained the tensioner unit must be replaced Remove the camshaft belt Loosen and remove the tension unit s upper screw Undo the lower screw Rotate the tension unit so that the screw is released Remove the lower screw Remove the tension unit Remove the camshaft belt Do not rotate the camshafts or crankshaft when the timing gear belt has been removed Check the tensioner and idler pulleys Rotate the pulleys and listen for abnormal noise from the bearings Check that the pulley surfaces facing the belt are clean and smooth Check the tension pulley lever and the idler pulley s attachment Tension pulley lever torque 40 Nm Idler pulley torque 25 Nm Grease the bushing Remove the tension pulley lever s screw the tension pulley the socket behind the screw Grease the surfaces of the lever s bushing screw and socket with grease P N 11 61 246 2 50 g or 11 61 247 0 500 g Fit the socket the tension pulley the tension pulley lever s screw torque tighten to 3945 Nm Lock the tensioner Check that there is no visible leakage Compress the tensioner
18. lue is not obtained the tensioner must be replaced Secure the camshaft gear Use holder 999 5416 Removing the camshaft belt Remove the camshaft belt Remove the tensioner s upper screw M8 Undo the lower screw M10 Rotate the tensioner until the screw is freed Remove the lower screw Remove the camshaft belt Check the tension and idler pulleys Rotate the idler pulleys and listen for abnormal noise in the bearings Check that the pulley surfaces against the belt are clean and smooth Check the tension pulley lever and the idler pulley attachment Tension pulley lever torque 40 Nm Idler pulleys torque 25 Nm Greasing the bushing Remove the tension pulley s lever screw the tension pulley the socket behind the screw Grease the surfaces of the lever s bushing the screw and socket with grease P N 11 61 246 2 50 g or 11 61 247 0 500 g Refit the socket the tension pulley the screw for the tension pulley torque tighten to 39 5 Nm Removal of the balance shaft belt Remove the balance shaft belt s idler pulley Check that the pulley surfaces and bearings are fault free Undo the balance shaft belt tension pulley Undo the lock screw 10 Remove the balance shaft belt Pull the belt off the tensioner pulley and balance shaft pulley Pull the belt out under the crankshaft gear Check the tensioner pulley bearings and look for signs of oil leakage at the s
19. oval of auxiliary unit belt incl greasing of belt tensioner As of model year 1994 the belt tensioner is maintenan ce free Remove the auxiliary unit belt Remove the belt Use an articulated wrench with a 3 8 socket 1 to loosen the belt As of M Y 1994 use tool 999 5547 in the belt tensioner s centre 2 Lock the belt tensioner in the service setting by inser ting a lock pin in the holes 3 when they are above each other Remove the belt Remove the belt tensioner Undo the belt tensioner s two screws and remove the tensioner Grease the automatic tensioner pulley Undo the tensioner s centre screw and dismantle as in the figure Apply grease P N 11 61 246 2 50 g or 11 61 247 0 500 g between the friction plate and cover and in the four holes used for the spring marked by arrows Reassemble the belt tensioner Torque tighten the belt tensioner Torque tighten the centre screw to 20 Nm Refit the belt tensioner Torque tighten to 20 Nm Replacing the camshaft felt incl greasing the tension pulley 5 Remove the front timing gear casing the splash guard under the engine the vibration damper shield ignition cable cover 6 Set the camshaft crankshaft acc to the markings Rotate the crankshaft clockwise until the markings on the camshaft pulley and inner timing gear cover and the markings on the crankshaft pulley oil pump housing match Remove the upper timing gear cover Measure be
20. r screw Undo the lower screw Turn the tensioner so that the pulley rotates freely Remove the lower screw the tensioner the upper timing gear casing the camshaft belt Check the tensioner and idler pulleys Rotate the pulleys and listen for abnormal noise from the bearings Check that the pulley contact surfaces with the belts are clean and smooth Check that the tensioner pulley lever has not seized in its bearing Check the idler pulley attachment Tension pulley lever torque 40 Nm Idler pulley torque 25 Nm Greasing the bushing Remove the tension pulley lever s screw the tension pulley the socket behind the screw Grease the surfaces of the lever s bushing screw and socket with grease P N 11 61 246 2 50 g or 11 61 247 0 500 g Refit the socket the tension pulley the tension pulley lever s screw torque tighten to 40 Nm Lock the tensioner Check that there is no visible leakage Remove the plastic washer on the piston Compress the tensioner with tool 999 5456 Place the tensioner in the tool and tighten the centre nut Wait until compression is complete and then insert a lock pin diam 2 mm in the piston Note If there is any visible leakage or if there is no resistance upon compression or if compression is im possible the tensioner must be replaced Fit the new camshaft belt Insert the tensioner screws Tighten to 25 Nm Thread the belt around t
21. uge 998 8500 Measure on the belt above the location of the removed idler pulley Belt tension shall be 3 8 0 2 units at 20 C If tension is too low Adjust by turning the tensioner pulley clockwise Note The tensioner pulley may only be turned clockwise Only small movements are required If tension is too high Carry out steps 15 16 Turn the crankshaft one revolution Check adjust the newly set values 21 Install guide plate check that it is in place middle timing gear casing fan shroud tie strips for the heater hose radiator fan and pulley all the drive belts 22 Run the engine to operating temperature Run the engine until the thermostat opens Switch off the engine Caution Remember that timing gear casings 1 and 2 have not yet been fitted at this point Check adjust balance shaft belt tension after thermostat opens 23 Check belt tension Use gauge 999 8500 Place the gauge above the location of the removed idler pulley Tension should be between 4 9 0 2 units If belt tension is correct proceed to steps 27 29 If belt tension is too low proceed to steps 24 26 If belt tension is too high repeat steps 15 16 and adjust as per steps 24 26 24 Turn the crankshaft clockwise and read the gau ge Note The tensioner pulley may only be rotated clockwi se Only small movements are required 25 Turn the crankshaft clockwise one revolution 26 Che
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