Replace toothed belt
Remove
2. |
Disconnect battery
• |
Detach negative clamp from earth terminal
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3. |
Remove air cleaner housing
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4. |
Remove air intake pipe (1) together with air mass flow
meter
• |
Disconnect wiring harness plug of air-flow meter
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6. |
Remove engine damping block (2)
• |
Detach from side member
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• |
Detach from engine damping block bracket
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7. |
Raise engine on timing side using engine bridge
• |
Raise the engine until the lower screw of the engine damping
block bracket is at the same height as the recess in the side
member
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8. |
Release right engine damping block bracket (1)
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9. |
Remove injector wiring harness retaining plate (1)
• |
Lay retaining plate aside.
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10. |
Remove camshaft sensor (1)
• |
Disconnect wiring harness connector.
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11. |
Release upper toothed belt cover (2)
• |
Unscrew 6 bolts (arrows)
Note: Observe different
bolt lengths
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• |
Unclip 4x fuel return line (1)
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12. |
Raise vehicle by its full height
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13. |
Remove engine cover and right engine splash guard
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14. |
Remove ribbed V-belt
Note: Mark direction of
rotation
• |
Apply tension to ribbed V-belt tensioner via bolt (1) in the
direction of the arrow
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• |
Fix ribbed V-belt tensioner at bore (2) with KM-6130
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15. |
Remove right engine damping block bracket (1)
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16. |
Remove upper toothed belt cover (1)
• |
Unscrew 2 bolts (arrows)
Note: Observe different
bolt lengths
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17. |
Remove torsional vibration damper (1)
• |
Unscrew 4x bolts
Note: Counterhold at
bolt (2)
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18. |
Remove lower toothed belt cover (1)
• |
Remove engine damping block adapter
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19. |
Set cylinder 1 to TDC of combustion stroke
• |
Fix camshaft sprocket in position using TDC locking bolt
(M6x25) (1)
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• |
Turn crankshaft evenly in direction of engine rotation, until
mark (3) of toothed belt drive gear is in line with mark (2) on oil
pump cover
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20. |
Release toothed belt tension roller (1)
• |
Slacken bolt of toothed belt tension roller (2)
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• |
Turn toothed belt tension roller approx. 90°
anticlockwise
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• |
Tighten bolt, toothed belt tension roller
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21. |
Remove toothed belt
• |
Mark direction of rotation
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Install
22. |
Install toothed belt
Note: TDC locking bolt
must be installed in camshaft sprocket (9) and high-pressure pump
gear (8) and marks (6) and (7) must align
• |
Position toothed belt
Note: Observe direction
of rotation
– |
Toothed belt must be tensioned in the direction of the arrow
from the toothed belt drive gear (5), through the oil pump drive
gear (4) and the high-pressure pump drive gear (2) to the camshaft
sprocket (1)
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• |
Slacken the toothed belt tension roller (3)
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• |
Tighten toothed belt tension roller 49
Nm
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23. |
Timing, Check
• |
Remove 2x TDC fixing bolt
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• |
Turn crankshaft approx. 720° in the direction of rotation
of the engine
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To toothed belt drive gear
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• |
Mark on toothed belt drive gear must be in line with the lug on
the oil pump cover
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• |
Screw in 2x TDC locking bolts
Note: If it is not
possible to screw in a TDC locking bolt, the basic setting must be
carried out again.
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• |
Unscrew 2x TDC fixing bolt
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24. |
Install lower toothed belt cover
• |
Insert engine damping block adapter
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25. |
Install torsional vibration damper
• |
Tighten 4x bolt 20 Nm
Note: Counterhold at
toothed belt drive gear bolt
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26. |
Install upper toothed belt cover
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27. |
Install right engine damping block bracket
• |
Tighten lower bolt 60 Nm
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28. |
Insert ribbed V-belt
Note: Observe direction
of rotation
• |
Position ribbed V-belt
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I. Ribbed V-belt without air conditioning
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II. Ribbed V-belt with air conditioning
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• |
Apply tension to ribbed V-belt tensioner via bolt (1) in the
direction of the arrow
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• |
Release ribbed V-belt tensioner
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29. |
Remove engine cover and right engine splash guard
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30. |
Lower vehicle by its full height
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31. |
Fasten top of toothed belt cover
• |
Tighten 6x bolt 10 Nm
Note: Observe different
bolt lengths
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• |
Clip in 4x fuel return line
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32. |
Install camshaft sensor
• |
Fix wiring harness plug
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33. |
Fasten right engine damping block bracket
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34. |
Install injector wiring harness retaining plate
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35. |
Lower engine on timing side using engine bridge
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36. |
Install engine damping block
• |
Attach engine damping block to mount
– |
Tighten 3 new bolts 80 Nm +
45°
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38. |
Install air intake pipe together with air mass flow meter
• |
Connect mass air flow meter wiring harness plug
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39. |
Install air cleaner housing
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40. |
Connect battery
• |
Attach earth clamp to earth terminal
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41. |
Program volatile memories
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