|
Timing, Adjust
 Remove
| 2. |
Remove engine cover (2)
| • |
Detach oil filler port closure cap (1)
|
| • |
Pull off engine cover
Note: Rubber retainers
(3) must remain on engine cover
|
| • |
Attach oil filler port closure cap
|
|
|
|
| 3. |
Remove air cleaner housing (5) with air intake hose
| • |
Detach wiring harness plug (2) from hot film mass air flow
meter
|
| • |
Detach air intake hose from air intake pipe
|
| • |
Detach air cleaner housing from wheel housing
|
| • |
Detach water drain hose (3) from air cleaner housing
|
|
|
|
| 4. |
Remove ribbed V-belt
| • |
Mark direction of rotation
|
| • |
Apply tension to ribbed V-belt tensioner via bolt (1) in the
direction of the arrow
|
| • |
Fix ribbed V-belt tensioner to bore (2)
|
|
|
|
| 5. |
Detach wiring trough (4) from front toothed belt cover
(top)
| • |
Detach wiring harness (3)
| – |
Disconnect camshaft sensor wiring harness plug
|
|
| • |
Unclip wiring trough in direction of arrow
|
|
|
|
| 6. |
Detach front toothed belt cover (top) (4)
| • |
Unscrew 8x bolts
Note: Note different
bolt lengths
|
| • |
Remove camshaft sensor bracket (1)
|
|
|
|
| 7. |
Raise vehicle by its full height
|
| 8. |
Detach the lower engine cover and right engine splash guard
|
| 9. |
Insert KM-6173 (3)
| • |
Align support bearing (1)
|
| • |
Raise support bearing until journal (2) sits flush in mount
(4)
|
|
|
|
| 10. |
Attach KM-6001-A (1)
Note: Attaching
KM-6001-A guarantees perfect alignment of the drive unit with the
front axle body
| • |
Slacken 4x bolts (arrows) in adjusting rails
|
| • |
Insert KM-6001-A
| – |
Insert journals (2) and (5) in guide holes in front axle
body
|
|
| • |
Tighten 4x bolts in adjusting rails
|
| • |
Adjust support bearings, front (4) and rear (3)
| – |
Raise support bearings up to the stop on the guide journals
Note: The guide
journals must be seated free from play in the support bearings
|
|
|
|
|
| 11. |
Detach torsional vibration damper (1)
| • |
Unscrew 4x bolts
Note: Counterhold at
bolt (2)
|
|
|
|
| 12. |
Lower vehicle by its full height
|
| 13. |
Remove engine damping block support
| • |
Detach from engine damping block bracket
|
| • |
Detach from cylinder block
|
| • |
Remove engine damping block adapter (1)
|
|
|
|
| 14. |
Remove coolant pump drive gear (1)
|
|
|
| 15. |
Remove front toothed belt cover (lower) (1)
|
|
|
| 16. |
Move crankshaft in direction of engine rotation to "Cylinder
no.1 combustion stroke TDC"
Note: Marking on
toothed belt drive gear must align with projection on oil pump
cover (arrows)
| • |
Fix with TDC fixing bolt (M6) (1) camshaft drive gear
|
| • |
Fix with TDC fixing bolt (M8) (2) high pressure pump gear
|
|
|
|
| 17. |
Remove toothed belt
| • |
Mark direction of rotation
|
| • |
Slacken the toothed belt tension roller
|
| • |
Apply preliminary tension to toothed belt tension roller with
hexagon (2) in direction of arrow
|
| • |
Fix toothed belt tension roller in pre-tensioned position
|
|
|
|
Install
| 18. |
Install toothed belt
Note: TDC fixing bolts
must be installed in the high pressure drive gear and camshaft
drive gear and markings (6) and (7) must align
| • |
Position toothed belt
| – |
Toothed belt must be tensioned in the direction of the arrow
from the toothed belt drive gear (5) via the oil pump drive gear
(4) and high pressure pump drive gear (2) to the camshaft sprocket
(1)
|
| – |
Observe direction of rotation
|
|
| • |
Slacken the toothed belt tension roller (3)
|
| • |
Remove 2x TDC fixing bolt
|
| • |
Turn crankshaft 60° against the direction of engine
rotation
|
| • |
Tighten toothed belt tension roller 38.2 Nm
|
|
|
|
| 19. |
Timing, Check
| • |
Turn crankshaft 6 revolutions in direction of engine rotation
to the adjustment position
|
| • |
The following factors must be present at the adjustment
position
Note: If one of these
factors is not present, the timing must be adjusted
| 1. |
TDC fixing bolt M6 (1) must be able to be inserted
in the camshaft drive gear |
| 2. |
TDC fixing bolt M8 (2) must be able to be inserted
in the high pressure pump drive gear |
| 3. |
Marking (4) on the toothed belt drive gear must
align with the marking (3) on the oil pump housing cover |
|
| • |
Remove 2x TDC fixing bolt
|
|
|
|
| 20. |
Install front toothed belt cover (lower)
|
| 21. |
Install coolant pump drive gear
| • |
Tighten 3x bolt 12.3 Nm
|
|
| 22. |
Install engine damping block bracket
| • |
Insert engine damping block adapter
|
| • |
Attach engine damping block support to cylinder block
|
| • |
Engine damping block support to engine damping block
bracket
|
|
| 23. |
Raise vehicle by its full height
|
Important: Journal (1) of toothed
belt drive gear must engage in the bore (2) of the torsional
vibration damper
|
| 24. |
Install torsional vibration damper
| • |
Tighten 4x bolt 19.6 Nm
Note: Counterhold
against bolt, toothed belt drive gear
|
|
|
|
| 25. |
Remove engine mount KM-6173
|
| 26. |
Remove engine mount KM-6001-A
|
| 27. |
Install lower engine cover and right engine splash guard
|
| 28. |
Lower vehicle by its full height
|
| 29. |
Install front toothed belt cover (top)
| • |
Tighten 8x bolt 9.8 Nm
Note: Note different
bolt lengths
|
| • |
Install camshaft sensor bracket
|
| • |
Attach vacuum line to toothed belt cover
|
|
| 30. |
Attach wiring trough to front toothed belt cover (top)
| • |
Attach wiring harness
| – |
Connect camshaft sensor wiring harness plug
|
|
|
| 31. |
Insert ribbed V-belt
Note: Note running
direction of ribbed V-belt
| • |
Position ribbed V-belt
| – |
I. Ribbed V-belt without air conditioning
|
| – |
II. Ribbed V-belt with air conditioning
|
|
| • |
Apply tension to ribbed V-belt tensioner via bolt (1) in the
direction of the arrow
|
| • |
Release ribbed V-belt tensioner
|
|
|
|
| 32. |
Install air cleaner housing with air intake hose
| • |
Attach water drain hose to air cleaner housing
|
| • |
Attach air intake hose to air intake pipe
|
| • |
Connect wiring harness plug to air mass flow meter
|
|
| 33. |
Install engine cover
| • |
Detach oil filler port closure cap
|
| • |
Attach oil filler port closure cap
|
|
|
