Withdrawal
Remove the engine hood. Remove poly V-belt.
Remove top toothed belt cover by opening buckles -arrows-. Position crankshaft in direction of engine rotation "TDC". The notch on the poly V-belt pulley for the crankshaft must line up with the edge of the -0- mark.
The locating holes in the inlet camshaft sprocket with camshaft adjuster and in the exhaust camshaft sprocket must be aligned with the calibration holes in the camshaft bearing housing -arrows-.
Instruction. If the fixing holes are on opposite sides, then the crankshaft must be rotated one more turn.
Secure camshafts with locating pins -T10074-: locating pin -A- must be inserted through the locating hole of the inlet camshaft gear into the calibration hole on the camshaft bearing housing. locking pin "IN" must be inserted through the locating hole of the exhaust camshaft gear into the gauge hole on the camshaft bearing housing. Remove engine mount.
Remove poly V-belt pulley for crankshaft. Remove bottom cover for toothed belt by unscrewing bolts -arrows-.
Remove bolts -arrows- and remove engine mount -1-.
Check position "TDC" Camshaft: The flattened tooth on the toothed belt sprocket -1- for the crankshaft must align with the mark -arrow- on the oil pump housing. Pos. -2- ignore.
Carefully! Risk of damage to a previously used V-ribbed belt when changing its course. For refitting, before removing the V-ribbed belt, mark the direction of its travel with chalk or a felt-tip pen.
Remove bolt -1- for main drive belt tensioner. Turn tensioning pulley counterclockwise -arrow- with a hexagon socket wrench and remove toothed belt.
Installation
Install in reverse order; note the following: Inlet camshaft sprocket with camshaft adjuster and exhaust camshaft are secured with locating pins -T10074-.
If removed, fit toothed belt tensioner for main drive and turn anti-clockwise to the indicated position -arrow- with an hexagon socket wrench.
Finger-tighten the bolt for the toothed belt tensioner for the main drive. The bolt -2- for the oil pump housing must be seated in the recess in the base plate.
Instruction. Position -3- and -arrows- are disregarded. Observe the designation of the running direction of the previously used belt.
Fit toothed belt for main drive -B- in sequence, coolant pump. tensioner pulley, crankshaft and intake camshaft.
A. Toothed belt for mating drive.
Tension the toothed belt, to do this turn the tensioning pulley clockwise -arrow A- until the pointer -3- is above the mark -arrow B- in the base plate -1-. Tighten bolt for toothed belt tensioner for main drive. Remove locking pin -T10074-. Turn the crankshaft in the direction of engine rotation 2 turns and set it back to "TDC".
Check position "TDC" Camshaft: The flattened tooth on the toothed belt sprocket -1- for the crankshaft must align with the mark -arrow- on the oil pump housing. Pos. -2- ignore. The locating holes in the inlet camshaft sprocket with variable valve timing and in the exhaust camshaft sprocket must be aligned with the gauge holes in the camshaft bearing housing -arrows-.
Secure camshafts with locating pins -T10074-: The locating pin -A- must be inserted through the locating hole in the inlet camshaft gear into the calibration hole on the camshaft bearing housing. The locking pin -3- must be inserted through the fixing hole of the exhaust camshaft gear into the calibration hole in the camshaft bearing housing.
Position locating flange -T10110- on gearbox side on camshaft bearing housing for inlet camshaft as follows: pin -arrow- of locating flange -T10110- must engage in small hole in thrust bearing of inlet camshaft. The lugs -1- of the inlet camshaft must engage in the recess -2- of the retaining flange -T10110-.
Turn inlet camshaft to stop against direction of engine rotation at hexagon of retaining flange -T10110- and hold.
If the valve timing is correctly set, the holes -arrows- in the retaining flange -T10110- must be aligned with the threaded holes in the camshaft bearing housing. If the holes are not aligned, then repeat the setting.
Installation is in the reverse order, while it is necessary to install the support bracket and engine mounts, install the poly-V-belt pulley for the crankshaft.
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