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J Engine and Engine Aggregates > Diesel Engine > Timing Gear Case > Repair Instructions > Toothed Belt, Remove and Install (17 DR, X 17 DTL)

 

Toothed Belt, Remove and Install (17 DR and X 17 DTL)  

Object Number: 616191  Size: DEFAULT  Remove, Disconnect   

Remove alternator V-belt - see operation "V-belt - Alternator, Remove and Install".  

Remove upper part of front toothed belt cover.  

Remove lower wheel housing panel.  

Remove crankshaft pulley (1) - counterhold on fastening bolt (2) of toothed belt drive pulley.  

For vehicles with air conditioning: Release power steering pump V-belt tension - see operation "V-Belt for Power Steering Pump, Replace (X 17 DTL, RHD/India Version)" in group "M".  

Remove lower part of front toothed belt cover.  

Object Number: 2415361  Size: DEFAULT

 

 

Object Number: 616191  Size: DEFAULT  Remove, Disconnect   

Remove engine vent hose from camshaft housing cover.  

Remove camshaft housing cover from camshaft housing.  

Object Number: 616198  Size: DEFAULT  Adjust   

Turn the crankshaft in the direction of engine rotation to approx. 90 ° (dimension I) before "1st Cylinder TDC" using the fastening bolt (1) for the toothed belt drive pulley.  

Object Number: 616196  Size: DEFAULT  Inspect   

1st cylinder exhaust cam (2) must point vertically upwards.  

Object Number: 2414919  Size: DEFAULT

 

 

Object Number: 616191  Size: DEFAULT  Remove, Disconnect   

Release injection pump pulley fastening bolts (3) and hand tighten - must be possible to turn injection pump pulley on injection pump flange.  

Release fastening bolt (5) for toothed belt tension roller and turn adjusting eccentric (6) in direction of arrow (clockwise) until pointer (4) is positioned just before left stop.  

Mark direction of travel of toothed belt and remove toothed belt (1).  

Remove fastening bolt (2) for camshaft pulley - counterhold with open-ended spanner at camshaft hex. Install new camshaft pulley fastening bolt and hand tighten - camshaft pulley on camshaft must still be rotatable. Observe installation position of washer.  

Object Number: 2415325  Size: DEFAULT

 

 

Object Number: 616192  Size: DEFAULT  Install, Connect   

Insert Dial gauge MKM-571-B (1) in Tool KM-661-1 (2) - arrow on KM-661-1 points towards engine timing side. Attach base (3) Ø 10 mm to dial gauge. To adjust dial gauge, left positioning pins of tool (I+II) must be seated in bores of camshaft housing. Set probe of dial gauge onto basic circle of 2nd cam (intake, 1st cylinder). Set dial gauge MKM-571-B to "0" - ensure that the probe is not seated on the cam oil bore!  

Object Number: 616201  Size: DEFAULT  Important!   

The Dial Gauge MKM-571 may be pre-tensioned by max. 0.5 mm, otherwise the resulting measurement will be incorrect.  

Object Number: 616192  Size: DEFAULT  Install, Connect   

Offset Tool KM-661-1 with dial gauge to the left. Right positioning pins (III+IV) must be seated in the bores of the camshaft housing.  

Object Number: 2398738  Size: DEFAULT

 

 

Object Number: 616192  Size: DEFAULT  Install, Connect   

Install Holder KM-661-2 (3) over 4th cylinder.  

Object Number: 616198  Size: DEFAULT  Adjust   

Rough adjustment: Carefully turn camshaft with open-ended spanner (1) at hex of camshaft in direction of arrow until elevation of approx. 0.80 mm (indicator on Gauge MKM-571-B) is attained.  

Fine adjustment: Adjust elevation of 0.60 to 0.64 mm (indicator of Gauge MKM-571-B) with adjustment screw (2) at Holder KM-661-2.  

Object Number: 616201  Size: DEFAULT  Important!   

Elevation of 0.60 to 0.64 mm is not a nominal value.  

Object Number: 2414922  Size: DEFAULT

 

 

Object Number: 616198  Size: DEFAULT  Adjust   

Turn crankshaft and injection pump pulley in direction of engine rotation to "1st Cylinder TDC" - see operation "1st Cylinder TDC, Adjust".  

Object Number: 616196  Size: DEFAULT  Inspect   

Check toothed belt and replace if necessary.  

Notice: 

Document the replacement of the toothed belt on the provided sticker.  

Object Number: 616192  Size: DEFAULT  Install, Connect   

Note direction of travel of toothed belt and position toothed belt.  

 

 

Object Number: 616198  Size: DEFAULT  Adjust   

Tension toothed belt:  

Turn adjusting eccentric (1) in direction of arrow (anti-clockwise) until pointer is located just before right stop - tighten fastening bolt (2).  

Object Number: 616192  Size: DEFAULT  Install, Connect   

Tighten camshaft pulley on camshaft. The tightening torque of 75 Nm + 60 ° + 5 ° must be observed as this has an impact on the camshaft elevation.  

Tighten fuel injection pump pulley - tightening torque 25 Nm.  

Object Number: 616201  Size: DEFAULT  Important!   

Remove Tool KM-661-1 and set aside carefully - ensure that Dial Gauge MKM-571-B is not displaced.  

Object Number: 616191  Size: DEFAULT  Remove, Disconnect   

Remove all retaining and adjusting tools.  

Object Number: 2414915  Size: DEFAULT

 

 

Object Number: 616198  Size: DEFAULT  Adjust   

New Toothed Belt, Adjust:  

At fastening bolt of toothed belt drive pulley, turn crankshaft two turns (720 ° ) in engine rotational direction to TDC - mark (1) on toothed belt drive pulley must align with mark (2) on the oil pump.  

Release fastening bolt (6) and turn adjuster eccentric (5) in direction of arrow (clockwise) until pointer (3) on tooth belt tension roller aligns with the notch mark (4).  

Tighten fastening bolt (6) of toothed belt tension roller - tightening torque 25 Nm.  

Object Number: 616196  Size: DEFAULT  Inspect   

At fastening bolt of toothed belt drive pulley, turn crankshaft two turns (720 ° ) in engine rotational direction to TDC - mark (1) on toothed belt drive pulley must align with mark (2) on the oil pump. Check adjustment of toothed belt tension roller. If the pointer (3) does not align with the notch mark (4), repeat the adjustment procedure.  

Object Number: 2414916  Size: DEFAULT

 

 

Object Number: 616198  Size: DEFAULT  Adjust   

Run-in Toothed Belt, Adjust:  

At fastening bolt of toothed belt drive pulley, turn crankshaft two turns (720 ° ) in engine rotational direction to TDC - mark (1) on toothed belt drive pulley must align with mark (2) on the oil pump.  

Release fastening bolt (6) and turn adjuster eccentric (5) in direction of arrow (clockwise) until pointer (3) on toothed belt tension roller is approx. 4 mm/0.16 in to the left of the notch mark (4).  

Tighten fastening bolt (6) of toothed belt tension roller - tightening torque 25 Nm.  

Object Number: 616196  Size: DEFAULT  Inspect   

At fastening bolt of toothed belt drive pulley, turn crankshaft two turns (720 ° ) in engine rotational direction to TDC - mark (1) on toothed belt drive pulley must align with mark (2) on the oil pump. Check adjustment of toothed belt tension roller. If the pointer (3) is not approx. 4 mm to the left of the notch marks (4), repeat the adjustment procedure.  

Object Number: 2414917  Size: DEFAULT

 

 

Object Number: 616198  Size: DEFAULT  Adjust   

Turn crankshaft in direction of engine rotation to "1st Cylinder TDC" - see operation "1st Cylinder TDC, Adjust".  

Object Number: 616201  Size: DEFAULT  Important!   

Carefully position Tool KM-661-1 (2). The right positioning pins must be seated in the bores of the camshaft housing - ensure that Dial Gauge MKM-571-B (1) is not altered. Base (3) rests on inlet cam of the 1st cylinder.  

Object Number: 616197  Size: DEFAULT  Measure   

Read off value on Dial Gauge MKM-571-B.  

Nominal value: 0.55 mm ± 0.03 mm.  

If the measured result does not match the nominal value, repeat adjustment.  

Object Number: 2399468  Size: DEFAULT

 

 

Object Number: 616201  Size: DEFAULT  Important!   

After adjustment of timing, the start of feed of the fuel injection pump must be checked and if necessary corrected - see operation "Feed Start, Check and Adjust".  

Object Number: 616191  Size: DEFAULT  Remove, Disconnect   

Remove all retaining and adjusting tools.  

Object Number: 616192  Size: DEFAULT  Install, Connect   

Attach camshaft housing cover to camshaft housing - tightening torque 8 Nm/6 lbf. ft. Attach engine vent hoses to camshaft housing cover.  

Attach lower part of front toothed belt cover to rear toothed belt cover - tightening torque 4 Nm/ 3 lbf. ft.  

For vehicles with air conditioning: Adjust power steering pump V-belt tension - see operation "V-belt for Power Steering Pump, Replace (X 17 DTL, RHD/India Version)" in group "M".  

Attach crankshaft pulley to toothed belt drive pulley - counterhold on fastening bolt of toothed belt drive pulley - tightening torque 20 Nm/ 15 lbf. ft.  

Install lower wheel housing panelling. Attach upper part of front toothed belt cover to rear toothed belt cover - tightening torque 4 Nm/ 3 lbf. ft. Install alternator V-belt - see operation "V-belt - Alternator, Remove and Install".  

 

 


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J Engine and Engine Aggregates > Diesel Engine > Timing Gear Case > Repair Instructions > Toothed Belt, Remove and Install (17 DR, X 17 DTL)

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