Timing Belt: Service and Repair

Toothed Belt, Removing and Installing

Removing

- Remove bumper, Refer to: "Body and Frame : Bumper : Service and Repair" Service and Repair

- Move lock carrier in service position, Refer to: "Body and Frame : Radiator Support : Service and Repair : Lock Carrier, Service Position"

- Remove ribbed belt. Refer to: "Drive Belts, Mounts, Brackets and Accessories : Drive Belt : Service and Repair" Service and Repair

- Remove bolts -arrows- and remove engine cover panel -C-.






- Remove pressure hoses -arrows- between charge air coolers and pressure pipes (left and right sides).








- Remove pressure pipes -1-

Note: Watch position of retaining strips -2-.








- Remove tensioner -1- for ribbed belt.







- Remove left and right toothed belt guards -2-.

- Remove center toothed belt guard -3-.

- Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned.







Note: Turn over the engine at the central bolt on the crankshaft.

- Check position of camshafts: larger holes in securing plates on camshaft sprockets must align opposite one another on inside. If not, turn crankshaft one revolution further.

- Remove sealing plug from cylinder block, left.

- The TDC drilling in the crankshaft must be visible (or able to be felt) in line with the sealing plug hole.

CAUTION! Injury risk - do not turn engine while feeling for TDC drilling






- Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.

- Remove vibration damper on crankshaft.






Note: The central bolt does not have to be loosened to remove the vibration damper.

- Remove idler wheel for ribbed belt -arrows-.






- Remove toothed belt guard behind vibration damper -arrows-.






Note: Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when reinstalled.

The toothed belt tensioning element is oil- damped and can therefore only be compressed slowly by applying constant pressure.

- Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until tensioning lever -2- compresses tensioning element -3- sufficiently to enable special tool T 400 11 to be fitted in drilling and in plunger.

- Insert special tool T 400 11, release toothed belt tensioning roller. Take off toothed belt.


Installing

- Insert camshaft clamp 3391 in securing plates of two camshafts.

- Slacken both camshaft bolts and remove approx. 5 turns.

- Take out camshaft clamp 3391.






- Pull off both camshaft sprockets with special tool T40001.

- Reinstall both camshaft sprockets with securing plates and tighten hand-tight again.

Note: The camshaft sprockets should be just tight enough on the camshaft tapers so that they can still be turned but do not move axially.






- Install toothed belt on all sprockets as illustrated.

- Install camshaft clamp 3391.

- Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until special tool T 400 11 can be removed.






- Pre-tension toothed belt by a turning in direction of arrow with a torque of 15 Nm using a torque wrench.






- Tighten bolts on camshaft sprockets.

- Install idler wheel for ribbed belt -arrows-.

- Install toothed belt guard behind vibration damper -arrows-.







- Install vibration damper. Note positions of locating lugs -arrows- on belt sprocket.







- Install toothed belt guard.

- Install ribbed belt.

Tightening Torque:

1) The central bolt must always be replaced.

2) Turning in two stages of 9O° is also permissible.