Table of contents: Take off ↓ Installation (timing phase… ↓
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. 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. Roller; 18. Hub, with sensor crown; 19. Nut, 100 Nm; 20. High pressure pump toothed belt pulley; 21. Upper part of the toothed belt protective cover; 22. Bolt; 23. Coolant pump; 24. Bolt, 15 Nm; 25. Crankshaft toothed pulley; 26. Bolt, 120 Nm + 90°, replace, do not additionally lubricate the thread and flange, tightening can be done in several stages; 27. Lower part of the toothed belt protective cover; 28. Middle part of the toothed belt protective cover; 29. Bolt, 10 Nm; 30. Belt pulley/vibration damper, installation possible in only one position - holes offset; 31. Bolt, 10 Nm + 90°, replace
Take off
The toothed belt may only be installed when the engine is cold, as the position of the tensioner mark depends on the engine temperature. Remove the torsional vibration damper. Release the "arrow" clamps, remove the toothed belt protective cover. Turn the tensioner in the "direction of the arrow", remove the poly V-belt from the generator pulley and relieve tension on the tensioner. Remove the poly V-belt.
Remove the middle and lower toothed belt covers "arrows". "Pos. 1" is not taken into account.
Turn the crankshaft by the toothed belt bolt so that the camshaft is at "TDC". The toothed segment "arrow" should be directed upwards. Fix the camshaft hub using the locking pin of the direct injection pump of the diesel engine "3359".
For the sake of clarity, the camshaft timing belt pinion is shown without the timing belt. Secure the crankshaft timing belt pinion with the crankshaft stopper "T10050". The marks on the timing belt pulley "2" and the crankshaft stopper "1" should be opposite each other "arrow". The crankshaft stopper journal should enter the hole in the sealing flange. The stopper can be pushed onto the sprocket only from the end face of the splines.
Loosen bolts "1" of the camshaft timing belt gear by approximately 90°. Ignore the "arrow". Loosen bolts "1" of the high-pressure pump timing belt gear by approximately 90° using the XZN 10 "T10385" attachment.
Loosen the nut "1" of the tension roller. Turn the eccentric of the tension roller with the angle screwdriver "T10264" counterclockwise "arrow" so that the tension roller can be fixed with the lock "T10265".
Then turn the tension roller eccentric clockwise "arrow" with the "T10264" angle screwdriver until it stops and tighten the nut "1" by hand. Risk of damaging the previously used poly V-belt when changing its running direction. For reinstallation, before removing the poly V-belt, mark its running direction with chalk or a felt-tip pen.
Remove the toothed belt first from the idler pulley, then from the remaining pulleys.
Installation (timing phase adjustment)
Installation is in the reverse order. In doing so, observe the following: The engine must be cold for adjustment work on the toothed belts. Conditions: The tension roller is secured with the "T10265" lock and the nut turned to the right as far as it will go. Secure the camshaft hub with the "3359" locking pin of the diesel direct injection system pump. Bolts "1" remain loosely screwed in. The camshaft toothed belt gear should still rotate, but should not wobble. Ignore the "arrow". The crankshaft is secured with the "T1 0050" crankshaft lock. Secure the high-pressure fuel pump hub with the "3359" locking pin of the diesel direct injection system pump. Bolts "1" remain loosely screwed in. The high-pressure pump toothed belt gear should still rotate, but should not wobble.
If necessary, rotate the high pressure pump toothed belt gear with a screwdriver using the heads of bolts "1" so that the hub can be secured with a locking pin.
Rotate the camshaft and high-pressure pump toothed belt gears in their longitudinal holes clockwise until they stop. Install the toothed belt in the following sequence:
- 1. Crankshaft toothed pulley
- 2. Tension roller
- 3. Timing belt gear of the camshaft
- 4. gear of the toothed belt of the coolant pump
- 5. High pressure pump toothed belt pulley
- 6. Roller
Loosen nut "1" of the tension roller and remove the lock "T10265". Ignore the "arrow".
Pay attention to the correct fit of the tension roller in the rear cover of the toothed belt "arrow".
Install the counter support "T10172" on the camshaft timing belt gear as shown in the figure. Turn the counter support counterclockwise "arrow" and hold in pretension. In this position, tighten bolts "1" of the camshaft timing belt gear and bolts "2" of the high-pressure pump timing belt gear. Tightening torque 20 Nm.
Now carefully rotate the tension roller eccentric with the angle screwdriver "T10264" in a clockwise direction until the pointer "2" is in the middle of the gap of the support plate. Nut "1" must not be turned. Hold the tension roller in this position and tighten the nut. Remove the locking pin "3359" and the crankshaft stopper "T10050".
