your mechanic should know how to set and lock the pulleys with the correct tool, lol if your having to tell him what to do, go somewhere who knows what there doing.
Timing Belt fitting procedure for BKD:
NOTE: Engine must be COLD.
- Ensure camshaft sprockets locked with tools Fig.19404.9 & Fig.19404.10.
- Ensure crankshaft sprocket locking tool located correctly Fig.19404.11.
- Ensure timing marks aligned Fig.19404.12.
- Ensure tensioner pulley locking pin inserted Fig.19404.18. Tool No.T10115.
- Ensure tensioner retaining lug is properly engaged Fig.19404.20.
- Turn camshaft sprockets fully clockwise in slotted holes.NOTE: Sprockets should turn freely without tilting.
- Fit timing belt in clockwise direction, starting at crankshaft sprocket.NOTE: If reusing old belt, observe direction of rotation marks on belt. Ensure belt is taut between sprockets on non-tensioned side.
- Remove locking pin from tensioner pulley Fig.19404.18. Tool No.T10115.
- Slacken tensioner pulley nut Fig.19404.15.
- Turn tensioner pulley slowly clockwise until pointer aligned with notch Fig.19404.21. Use tool No.T10020 Fig.19404.17.NOTE: Ensure tensioner pulley nut does not turn Fig.19404.15.
- Hold tensioner pulley. Use tool No.T10020 Fig.19404.17.
- Tighten tensioner pulley nut Fig.19404.15. Tightening torque: 20 Nm + 45°.NOTE: As tensioner pulley nut is tightened, the pointer may move clockwise 5 mm maximum. DO NOT adjust position of tensioner pulley. Timing belt will settle once run in.
- Hold camshaft sprocket (CA1). Use tool No.T10172.NOTE: Ensure belt is taut between sprockets on non-tensioned side.
- Tighten bolts of each camshaft sprocket Fig.19404.13 & Fig.19404.14. Tightening torque: 25 Nm.
- Remove:
- Camshaft sprocket holding tool.
- Camshaft sprocket locking tools Fig.19404.9 & Fig.19404.10.
- Crankshaft sprocket locking tool Fig.19404.A or Fig.19404.B.
- Check valve timing as follows:
- Turn crankshaft slowly two turns clockwise until just before TDC on No.1 cylinder.
- Fit camshaft sprocket (CA1) locking tool while slowly turning crankshaft to TDC Fig.19404.9. Tool No.3359.
- Ensure camshaft sprocket (CA2) locking tool can be inserted Fig.19404.10. Tool No.3359.
- Ensure crankshaft sprocket locking tool can be inserted easily Fig.19404.A or Fig.19404.B.
- Ensure timing marks aligned Fig.19404.12.
- Ensure tensioner pulley pointer aligned with notch or 5 mm maximum to the right of notch Fig.19404.21.
- If camshaft sprocket (CA2) locking tool cannot be inserted Fig.19404.10:
- Slacken camshaft sprocket (CA2) bolts Fig.19404.14.
- Turn camshaft sprocket (CA2) hub until locking tool can be inserted Fig.19404.10. Tool No.3359.
- Hold camshaft sprocket (CA2). Use tool No.T10172.
- Tighten camshaft sprocket (CA2) bolts Fig.19404.14. Tightening torque: 25 Nm.
- Remove camshaft sprocket holding tool.
- Remove locking tools Fig.19404.9, Fig.19404.10, Fig.19404.A or Fig.19404.B.
- If crankshaft sprocket locking tool cannot be inserted Fig.19404.A or Fig.19404.B:
- Slacken bolts of each camshaft sprocket Fig.19404.13 & Fig.19404.14.
- Turn crankshaft sprocket until locking tool can be inserted Fig.19404.A or Fig.19404.B.
- Hold camshaft sprocket (CA1). Use tool No.T10172.
- NOTE: Ensure belt is taut between sprockets on non-tensioned side.
- Tighten bolts of each camshaft sprocket Fig.19404.13 & Fig.19404.14. Tightening torque: 25 Nm.
- Remove camshaft sprocket holding tool.
- Remove locking tools Fig.19404.9, Fig.19404.10 & Fig.19404.A or Fig.19404.B.
- Install RH engine mounting bracket Fig.19404.7.NOTE: Engine may need to be raised/lowered slightly.
- Tighten RH engine mounting bracket bolts Fig.19404.6. Tightening torque: 45 Nm + 90°. Use new bolts.
- Install components in reverse order of removal.
- Tighten crankshaft pulley bolts Fig.19404.2. Tightening torque: 10 Nm + 90°. Use new bolts.
- Fit and align RH engine mounting:
- Engine mounting clearance: 13,5 mm Fig.19404.22.
- Ensure engine mounting aligned parallel with engine mounting bracket Fig.19404.23.
- Tighten:
- Engine mounting bolts Fig.19404.24. Tightening torque: 50 Nm.
- Engine mounting bolts Fig.19404.25. Tightening torque: 20 Nm + 90°. Use new bolts.
- Engine mounting bolts Fig.19404.26. Tightening torque: 60 Nm + 90°. Use new bolts.
- Tighten bolt securing lower torque reaction link to subframe. Tightening torque: 100 Nm + 90°. Use new bolt.
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