|
Replace toothed belt
 Remove
| 2. |
Disconnect earth cable from battery
|
| 3. |
Remove air cleaner housing
|
| 4. |
Detach front toothed belt cover (top) (1)
| • |
Release upper catch (3)
|
| • |
Pull front toothed belt cover (top) upwards by cast projection
(arrow), applying slight tension
|
|
|
|
| 5. |
Detach ribbed V-belt (1)
| • |
Mark direction of rotation
|
| • |
Apply tension to ribbed V-belt tensioner (2) in the direction
of the arrow and fix with KM-6130 (3)
|
|
|
|
| 7. |
Detach lower engine compartment cover / splashguard
|
| 8. |
Possibility 1: Lock flywheel
|
|
|
| 9. |
Possibility 2: Lock crankshaft
| • |
Attach KM-6625
| – |
Detach screwed connection (1)
|
| – |
Tighten screwed connection (3)
|
|
|
|
|
| 10. |
Detach torsional vibration damper (3)
|
| 11. |
Detach ribbed V-belt tensioner (1)
| • |
Unscrew bolt (2)
| – |
Ribbed V-belt tensioner remains locked with KM-6130
|
|
|
|
|
| 12. |
Detach front toothed belt cover (bottom) (2)
|
|
|
|
| 13. |
Set engine to TDC
| • |
Remove KM-911 or KM-6625
|
| • |
Screw in bolt, torsional vibration damper
|
| • |
Move crankshaft in direction of engine rotation to "cylinder 1
TDC of combustion stroke" (III)
|
|
| 15. |
Lock camshaft sprockets in position with KM-6340
| • |
Position camshaft sprockets in such a way that the markings
(arrows) are opposite each other
|
| • |
Attach KM-6340-Left to intake
camshaft sprocket (I)
|
| • |
Insert KM-6340-Right (II)
|
|
| 16. |
Remove toothed belt
| • |
Mark direction of rotation
|
| • |
Apply tension to toothed belt tension roller clockwise, using
an Allen key and fix using KM-6333
(IV)
|
|
|
Install
|
| 17. |
Insert toothed belt
Note: Threading the
toothed belt through the engine damping block support is only
permissible in conjunction with the assembly tool supplied with new
toothed belts as otherwise it is possible to damage the toothed
belt at this stage by kinking it
| • |
Insert toothed belt (1) in enclosed assembly tool (2)
| – |
If the toothed belt has been used, observe direction of
rotation
|
|
| • |
Guide toothed belt through engine damping block support with
assembly tool
|
|
|
| 18. |
Position toothed belt
Note: Observe direction
of rotation
| • |
Place toothed belt on exhaust camshaft sprocket
|
| • |
Place toothed belt on intake camshaft sprocket
|
| • |
Guide toothed belt past the tensioning and guide rollers and
place on toothed belt drive gear
|
| • |
Apply tension to the toothed belt tension roller and remove
KM-6333
| – |
Toothed belt tension roller automatically moves to the correct
position
|
|
|
| 21. |
Turn crankshaft through 720°
| • |
2 revolutions in direction of engine rotation
|
| • |
Place toothed belt drive gear on the marking, cylinder 1 TDC of
combustion stroke (arrows)
|
|
|
|
| 23. |
Lock camshaft sprockets in position with KM-6340
| • |
Insert KM-6340-Left (1)
|
| • |
Insert KM-6340-Right (2)
Note: Markings (3) on
KM-6340 must align - otherwise dismantle
toothed belt and place in position again
|
|
|
|
| 26. |
Attach front toothed belt cover (bottom)
|
| 27. |
Unscrew torsional vibration damper bolt
| • |
Lock flywheel with KM-911 or KM-6625
|
|
| 28. |
Fit torsional vibration damper
Important: Use new bolt
|
| • |
Tighten bolt 95 Nm + 45° +
15°
|
|
| 29. |
Possibility 1: Remove KM-911
|
| 30. |
Possibility 2: Detach KM-6625
| • |
Detach screwed connection
|
| • |
Tighten bolted connection
|
|
| 31. |
Attach ribbed V-belt tensioner
|
| 32. |
Insert ribbed V-belt
Note: Observe direction
of rotation
| • |
Apply tension to ribbed V-belt tensioner anti-clockwise and
place ribbed V-belt in position
|
|
| 33. |
Attach lower engine compartment cover / splashguard
|
| 35. |
Attach front toothed belt cover (top)
Important: Ensure that it is
latched correctly
|
| • |
Tighten 2x bolt 6 Nm
|
|
| 36. |
Install air cleaner housing
|
| 37. |
Connect earth cable to battery
|
| 38. |
Program volatile memories
|
|
