Toothed belt drive 1. Toothed belt, before removing, mark the direction of travel, check the degree of wear, do not bend; 2. Nut, 20 Nm; 3. Rolling roller; 4. Bolt, 50 Nm + 90°, replace; 5. Nut, 20 Nm + 45°, replace; 6. Tension roller; 7. Bolt, 20 Nm + 45°, replace; 8. Camshaft drive sprocket; 9. Roller; 10. Bolt, 20 Nm; 11. Bolt, 100 Nm; 12. Hub; 13. Bolt, 5 Nm; 14. Rear timing belt cover; 15. Bolt, 20 Nm; 16. Bolt, 10 Nm; 17. Rolling roller; 18. Hub, with sensor crown; 19. Nut, 100 Nm; 20. High pressure pump timing belt pulley; 21. Upper part of the toothed belt guard; 22. Bolt; 23. Coolant pump; 24. Bolt, 15 Nm; 25. Crankshaft timing pulley; 26. Bolt, 120 Nm + 90°, replace, do not lubricate the threads and collar additionally, tightening can be done in several steps; 27. Lower part of the toothed belt guard; 28. Middle part of the toothed belt guard; 29. Bolt, 10 Nm; 30. Belt pulley / vibration damper, installation possible in only one position - the holes are offset; 31. Bolt, 10 Nm + 90°, replace
Take off
Installation of the timing belt may only be carried out when the engine is cold, since the position of the tension element mark depends on the engine temperature. Remove the vibration damper. Release the brackets -arrows- and remove the toothed belt protective cover. Turn the tension element in the -direction of the arrow-, remove the poly V-belt from the generator pulley and relieve the tension on the tension element. Remove the poly V-belt.
Remove middle and lower toothed belt covers -arrows-. -Pos. 1- do not take into account.
Rotate the crankshaft by the timing belt bolt so that the camshaft is at TDC". The toothed segment -arrow- must point upward. Secure the camshaft hub using the diesel direct injection pump locking pin. engine -3359-.
For clarity, the camshaft timing belt gear is shown without a timing belt. Secure crankshaft timing belt gear using crankshaft stopper -T10050-. The marks on the toothed belt pulley -2- and the crankshaft stopper -1- must be opposite each other -arrow-. In this case, the crankshaft lock pin should fit into the seal hole. flange. The stopper can be pushed onto the sprocket only from the end side of the splines.
Loosen the bolts -1- of the camshaft timing belt gear by approximately 90°. -Arrow- ignore. Loosen the bolts -1 - of the high-pressure pump toothed belt gear using a socket XZN 10 -T10385- by approximately 90°.
Loosen the nut -1- of the tension roller. Using an angle screwdriver -T10264-, turn the tension roller eccentric counterclockwise -arrow- until the tension roller can be secured with the locking pin -T10265-.
Then turn the tension roller eccentric using an angle screwdriver -T10264- clockwise -arrow- until it stops and tighten the nut -1- by hand. There is a risk of damage to a previously used poly V-belt when its travel is changed. For reinstallation, before removing the poly V-belt, mark the direction of its movement with chalk or a felt-tip pen.
Remove the toothed belt first from the take-off roller, then from the remaining pulleys.
Installation (timing adjustment)
Install in reverse order. Please note the following: To carry out adjustment work on the timing belts, the engine must be cold. Requirements: The tension roller is secured with a clamp -T10265- and a nut to the right until it stops. Secure the camshaft hub using the diesel direct injection pump locking pin. engine -3359-. Bolts -1- remain loosely screwed in. The camshaft timing belt gear should still rotate, but should not swing. -Arrow- ignore. The crankshaft is secured with the crankshaft stop -T1 0050-. Secure the fuel injection pump hub using the diesel direct injection pump locking pin. engine -3359-. Bolts -1- remain loosely screwed in. The high pressure pump timing belt gear should still rotate, but should not swing.
If necessary, rotate the high-pressure pump toothed belt gear using a screwdriver using the bolt heads -1 so that the hub can be secured with a locking pin.
Rotate the camshaft timing belt and high-pressure pump gears in their longitudinal holes clockwise until they stop. Install the timing belt in the following sequence:
- 1. Crankshaft timing pulley
- 2. Tension roller
- 3. Camshaft timing belt gear
- 4. coolant pump timing belt gear
- 5. High pressure pump timing belt pulley
- 6. Roller
Loosen the nut -1- of the tension roller and remove the lock -T10265-. -Arrow- ignore.
Ensure that the tension roller is seated correctly in the rear toothed belt cover -arrow-.
Install counter support -T10172- onto camshaft timing belt sprocket as shown in the illustration. Turn the counter-support counterclockwise -arrow- and hold it in pretension. In this position, tighten the bolts -1- of the camshaft timing belt gear and the bolts -2- of the high-pressure pump timing belt gear. Tightening torque 20 Nm.
Now carefully turn the tension roller eccentric using an angle screwdriver -T10264- in a clockwise direction until the pointer -2- is in the middle of the gap in the support plate. The nut -1- cannot be turned. Hold the tension roller in this position and tighten the nut. Remove the locking pin -3359- and the crankshaft lock -T10050-.
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