Tensioner Index Page I Tensioner Adjustment

Mechanical V6 Cambelt Tensioner

Installation

MECHANICAL CAMBELT TENSIONER KIT

To fit the mechanical tensioner, you must plug off the old style tensioner's drain-back hole in the engine block with a special plug (supplied) and replace the hollow stud which previously fed oil to the old style tensioner with a special adapter stud (supplied).

1. To gain access:

ON MILANO & GTV 6 MODELS:

Access the old style timing belt tensioner by removing the radiator, auxiliary drive belts and the timing belt covers.

ON 164 MODELS:

1. Remove the RH side front wheel.

2. Remove the strut assembly (four bolts on the

bottom and three nuts on top of the shock tower).

3. Remove the front inner fender panel.

4. Remove the water pump-a/c belt and the power

steering pump belt.

5. Remove the radiator hoses from the thermostat

housing/water pump.

6. Remove the two lower timing belt covers.

7. Remove the top engine "dog bone brace" and the two

top timing belt covers.

2. Using a 41mm socket on the crankshaft nut, turn the engine clockwise and line up the top dead centre marks at the crankshaft pulley.

3. Very carefully and clearly mark the relative position of the camshaft drive pulleys in relation to the cylinder heads. On Milano and GTV6 models, you will also need to mark the auxiliary drive pulley, as it drives the ignition distributor. Be sure to make your marks clear and accurate. If you do not mark the cam pulleys you will have to remove the valve covers in order to reference the factory marks. If you mis-time the cams you could bend valves - so be very careful.

4. Remove the old style timing belt tensioner. Do not lose the retaining nuts and washers as you will reuse them later to mount the new style tensioner (except do not re-use any nuts which have been used in "double-nut" removal of studs, see #6 below).

5. Remove the old timing belt (if the vehicle is a 164 you must remove the Motronic crank sensor).

6. Remove the long hollow oil-feed stud. The stud can be easily removed if you double-nut it and you shock it lose by striking it sharply, two or three times on the end, with a brass hammer. Wear eye protection and do not use a steel hammer - brass only.

7. Clean the area around the hole for the stud and clean all traces of oil from the threads in the block.

8. Apply several drops of threadlocker to the 10 mm end of the special conversion stud (part number 60897506).

9. Double-nut the 8mm end of the special conversion stud and thread it into the block until the 10mm portion of the stud is flush with the surface. Remove the double nuts.

10. Drill, tap and plug the drain-back hole. Start by drilling it out with a 1/4" drill bit. Put tape on the bit 12mm (1/2") from the end so that you can gauge your drilling depth. Next, enlarge the hole using a 17/64" bit. Also put tape on this bit 12mm (1/2") from the end to gauge drilling depth. You may notice that the passage you are drilling out goes into the block at an angle and is not a straight passage. This is normal because the passage is cast and not machined. Let your drill bit follow the passage. When the hole is plugged, the thread locker will compensate for any irregularities and since the passage is not under any pressure, it will provide a positive seal. Use an 8X1.25mm tap and thread the hole 12mm maximum. (Do the first half, remove the tap and clear away any shavings, then tap the hole the rest of the way. Again, clear away any shavings.)

11. Apply threadlocker to the plug and thread it into the hole until it is flush. Clean away any excessive threadlocker.

12. Install the new style belt tensioner. Mount it using the same nuts (but not any used for removing studs) and washers which retained the old tensioner.

13. Install a new timing belt. Pay close attention to the timing reference marks made earlier. Double check that you did not disturb the TDC (top dead centre) position of the crank shaft and that you engaged the appropriate teeth of the cam drive pulleys. Use great care so as to maintain proper cam timing. On Milano and GTV6 models you must properly index the auxiliary drive so as to maintain the proper ignition timing.

Note: This installation is reversible: If in the future you should wish to return to using an oil-fed tensioner, remove the plug and replace the special stud with the original oil-fed long stud.