Removal and installation of the timing belt for the K9K engine

Fitting the Timing Belt of the K9K Engine

In this article we explain how to fit the timing belt of the K9K engine correctly.

Removing the upper timing cover
Fig. 1. Removing the upper timing cover: 1 — cover fasteners
  1. Having disconnected the two fasteners, we remove the upper timing cover.
  2. We set the No. 1 cylinder piston to top dead centre (TDC) of the compression stroke. To do this:
    • Turning the crankshaft clockwise by the accessory drive pulley retaining bolt, we align the hole in the cylinder head with the hole in the camshaft pulley.
    • There are holes in the camshaft pulley and in the cylinder block which must be aligned.
    • We insert a suitable 8 mm stud into the hole in the pulley and the cylinder block.
Locking the camshaft pulley
Fig. 2. Locking the camshaft pulley with a stud
  1. Using a TORX E14 socket, we unscrew the plug of the hole for fitting the TDC locking pin. The plug is located to the left of the flywheel in the cylinder block at the level of the No. 1 cylinder.
Unscrewing the plug of the TDC locking pin hole
Fig. 3. Unscrewing the plug of the hole for fitting the TDC locking pin
  1. We screw the TDC locking pin into the hole.
Fitting the TDC locking pin
Fig. 4. Fitting the TDC locking pin
  1. We unscrew the accessory drive pulley retaining bolt.
Unscrewing the pulley retaining bolt
Fig. 5. Unscrewing the accessory drive pulley retaining bolt
  1. We remove the pulley.
Removing the lower timing cover
Fig. 6. Removing the lower timing cover: 2 — fasteners; 3 — plastic bolt
  1. Having unclipped the fasteners and removed the plastic bolt, we remove the lower timing belt cover.
Position of the keyway on the crankshaft
Fig. 7. Position of the keyway on the crankshaft (TDC of the No. 1 cylinder)

In this position (TDC of the No. 1 cylinder), the keyway on the crankshaft must be at the top.

Slackening the tensioner roller nut
Fig. 8. Slackening the tensioner roller retaining nut
  1. Holding with a 6 mm hex key, we slacken the tensioner roller retaining nut and remove the timing belt.

Fitting the timing belt

  1. We fit the timing belt in the reverse order of removal.
Fitting the timing belt
Fig. 9. Fitting the timing belt
Checking that the marks align
Fig. 10. Checking that the marks on the pulleys align

During fitting, the mark on the camshaft pulley and the mark on the high-pressure fuel pump pulley must align with the marks on the belt.

Timing belt fitting diagram with marks
Fig. 11. Fitting the timing belt: A — mark on the camshaft pulley; B — mark on the fuel pump pulley; C — mark on the cylinder block

Mark “B” on the high-pressure fuel pump pulley must align with mark “C” on the cylinder block.

Tensioning the timing belt
Fig. 12. Tensioning the timing belt: A — arrow on the tensioner; B — slot
  1. We tension the belt: arrow “A” on the tensioner must align with slot “B”.
  2. We tighten the roller nut to a torque of 27 N·m.
  3. We fit the accessory drive pulley in the reverse order of removal.
  4. We remove the camshaft pulley locks and the TDC locking pin.
  5. We turn the crankshaft by the accessory drive pulley bolt six revolutions.
  6. We check that the marks align. If the marks do not align, we repeat the belt fitting.
  7. We fit all parts in the reverse order of their removal.