Replace rear toothed belt cover (Y 17 DTL, with
air conditioning, LDH)
Note: KM-6394 must be used from model year 04 instead of
KM-6169-1 .
Important: On vehicles from model
year 04 with ESP - the steering angle sensor loses its basic
adjustment each time the battery is disconnected. It must be
recalibrated.
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2. |
Disconnect battery
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3. |
Detach front right wheel
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5. |
Remove front right wheel
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7. |
Remove ribbed V-belt cover
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8. |
Detach alternator wiring harness
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Disconnect wiring harness plug (1)
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9. |
Attach KM-6169 (1)
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Attach KM-6169 at left side of front
axle unit (arrows, fig.I)
Note: Guide pin must be
seated in bore in front axle body
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Attach both right holders on the front axle body (arrows,
Illus. II).
Note: Guide pin must be
seated in bore in front axle body (arrow, Fig. III)
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10. |
Install support
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Adjust bracket (2) for support
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11. |
Adjust supports
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Transmission side
Note: Turn spindles
until mounts are positioned at guide journals free of play
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Engine timing side
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Insert journal of the support in the bore of the cylinder block
without play (arrow)
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12. |
Loosen coolant pump ribbed V-belt pulley (1)
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13. |
Remove ribbed V-belt
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Tension ribbed V-belt tensioner in direction of arrow
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With KM-913-A
Note: Mark direction of
rotation
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14. |
Detach coolant pump ribbed V-belt pulley
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16. |
Remove air cleaner housing (1)
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Remove wiring harness plug for hot film mass air flow meter
(3)
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Release in direction of arrow
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Remove air intake hose (4)
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17. |
Remove right engine damping block
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18. |
Remove wiring trough (1)
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Unclip vacuum lines (2)
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19. |
Loosen upper part of toothed belt cover
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Remove 8 bolts
Note: Note dissimilar
bolt lengths
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20. |
Detach right engine bracket (1)
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Remove right engine bracket, right engine bracket adapter,
upper part of toothed belt cover
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22. |
Remove torsional vibration damper (1)
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23. |
Detach lower part of toothed belt cover
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24. |
Set no.1 cylinder to TDC
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Turn crankshaft evenly until TDC-fixing bolts can be
inserted
Note: The mark on
toothed belt drive gear must align with lug on oil pump cover
(arrows)
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Injection pump gear (M8) (2)
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26. |
For toothed belt tension roller with leaf spring:
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loosen toothed belt tensioner
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Remove tension spring (1)
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27. |
For toothed belt tension roller with spiral spring:
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Remove toothed belt tension roller (1)
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28. |
Remove toothed belt
Note: Mark direction of
rotation
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29. |
Remove toothed belt tensioner
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For toothed belt tensioner with leaf spring: remove toothed
belt tensioner spring retainer
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30. |
Detach camshaft pulley
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Unscrew TDC-fixing bolt (2)
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Counterhold camshaft pulley with KM-6156 and KM-956-1
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31. |
Remove injection pump gear
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Unscrew TDC-fixing bolt
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Pull off injection pump gear
Note: Note woodruff
key
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32. |
Remove toothed belt guide roller
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33. |
Remove rear toothed belt cover
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34. |
Attach rear toothed belt cover
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Tighten bolts ( 9.8 Nm )
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Clip in wiring harness, vacuum line
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35. |
Attach toothed belt clamping roller spring retainer
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Tighten bolts ( 9.8 Nm )
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36. |
Install toothed belt guide roller
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Tighten bolt ( 80.4 Nm )
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37. |
Install injection pump drive gear
Important: Observe tightening
sequence
1. |
Tighten nut 60 Nm
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2. |
Loosen nut |
3. |
Waiting time: 60 sec |
4. |
Tighten nut 60 Nm
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38. |
Attach camshaft pulley
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Block using KM-6156 and KM-956-1
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Tighten bolt ( 63.7 Nm )
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Install TDC-fixing bolt
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39. |
For toothed belt tension roller with leaf spring: remove
toothed belt tension roller
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Attach toothed belt clamping roller spring retainer
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Screw in bolt (M10) in lower bore of toothed belt tensioner
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Install fastening bolt of the toothed belt tension roller
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40. |
For toothed belt tension roller with leaf spring: install
toothed belt tension roller
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Install fastening bolt of the toothed belt tension roller
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41. |
Check crankshaft position
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Mark on toothed belt drive gear must align with lug on oil pump
cover (no.1 cylinder TDC)
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42. |
Install toothed belt
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Position toothed belt
Note: Toothed belt must
be taut from toothed belt drive gear via oil pump drive gear and
injection pump drive gear
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For toothed belt tension roller with leaf spring:
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Unscrew TDC-fixing bolt
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Rotate crankshaft 60° against direction of engine
rotation
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Tighten bolt of toothed belt tension roller
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For toothed belt tension roller with spiral spring 49 Nm
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For toothed belt tension roller with leaf spring 38.2 Nm
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For toothed belt tension roller with leaf spring: unscrew bolt
(M10) from lower bore of toothed belt tensioner
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43. |
Timing, Check
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Turn crankshaft approx. 780° in direction of engine
rotation
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The mark on toothed belt drive gear must align with lug on oil
pump cover (arrows)
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Screw in TDC-fixing bolts (1, 2)
Note: If the TDC fixing
bolts cannot be screwed in, basic adjustment must be repeated
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Unscrew TDC-fixing bolts
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44. |
Attach lower part of toothed belt cover
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Tighten bolts ( 9.8 Nm )
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45. |
Attach right engine bracket
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Insert lower bolt
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Into right engine bracket and right engine bracket adapter
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Insert right engine bracket, right engine bracket adapter,
upper part of toothed belt cover
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Tighten 3 bolts( 40 Nm )
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46. |
Fasten upper part of toothed belt cover
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Tighten bolts ( 9.8 Nm )
Note: Note dissimilar
bolt lengths
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48. |
Install right engine damping block
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To side member
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Tighten bolts ( 40 Nm )
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On engine bracket
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Tighten bolts ( 60 Nm + 30°
+ 15°)
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50. |
Attach coolant pump ribbed V-belt pulley
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51. |
Install torsional vibration damper
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Tighten bolts ( 19.6 Nm )
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52. |
Install ribbed V-belt
Note: Pay attention to
running direction and installation position
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Release ribbed V-belt tensioner
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53. |
Fasten coolant pump ribbed V-belt pulley
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Tighten bolts ( 9.8 Nm )
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56. |
Attach alternator wiring harness
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Connect wiring harness plug.
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57. |
Attach ribbed V-belt cover
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59. |
Install right front wheel
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61. |
Fasten right front wheel
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Tighten bolts ( 110 Nm )
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62. |
Install air cleaner housing
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Fasten air intake hose.
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Connect wiring harness plug to hot film mass air flow meter
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64. |
Calibrate steering angle sensor
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Switch on ignition
Note: Rotate the
steering wheel one time from its right-hand to its left-hand
stop.
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65. |
Program volatile memories
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