Unhook wiring harness -arrows-. Unscrew screws -1, 3- and remove guard -2- for toothed belt of coolant pump.
Remove screws -arrows- and remove cover -1-. Drain coolant.
Unscrew screws -A...D- and press thermostat cover -1- to one side. Remove soundproof cover.
Turn the crankshaft to TDC" in the following way. Unscrew the screw plug of the hole "TDC" on the cylinder block. Screw locking bolt -T10340- into cylinder block as far as it will go and tighten to 30 Nm. Turn the crankshaft to the stop in the direction of engine rotation. The counterweight of the crankshaft is now adjacent to the locking bolt.
Note: The locking bolt -T1C340- only locks the crankshaft in the working direction of rotation.
Carefully! Risk of engine damage! If the locking bolt -T10340- cannot be screwed in completely, the crankshaft is not in the correct position! In this case, proceed as follows. Loosen the lock screw. Rotate crankshaft 90°in direction of engine rotation. Screw locking bolt -T10340- into cylinder block as far as it will go and tighten to 30 Nm. Turn the crankshaft further in the direction of engine rotation until it stops.
For both camshafts, the asymmetrical recesses -arrows- on the gearbox side must be above the middle of the camshafts. On the exhaust camshaft -A- these notches -upper arrows- are accessible through holes in the pulley for driving the coolant pump. On the inlet camshaft -E-, these notches -lower arrows- are located above the middle of the camshaft.
Note: The camshafts have two pairs of recesses, one symmetrical and one asymmetrical. Pregnant "TDC" an asymmetrical pair of notches should be located above an imaginary horizontal center line.
If camshafts are not set as described above: Unscrew locking bolt -T10340-, turn crankshaft one turn further and set again to "TDC"". If camshafts are installed as described above: Insert camshaft clamp -T10494- into camshafts as far as stop and tighten screw -arrow- hand-tight.
Note: The camshaft lock -T10494- must be easy to insert. The camshaft lock must not be installed with an impact tool.
If the camshaft clamp -T10494- does not fit easily.
Carefully! Do not use sharp tools to avoid damage to the toothed belt!
Press tool -T10487- in -direction of arrow- onto toothed belt.
At this time, insert the camshaft clamp -T10494- into the camshaft as far as it will go and tighten by hand using the bolt -arrow-. Remove the crankshaft pulley.
Remove screws -arrows- and remove lower toothed belt guard.
Release hoses from bracket -3-. Remove screw -2-. Unclip clips -arrows- and remove upper toothed belt guard -1-.
Carefully! Risk of damaging the camshaft. Do not use camshaft clamps -T10494- as a stop.
Unscrew plug -1- on inlet camshaft pulley using stop -T10172- with adapter -T10172/1-.
Loosen screws -1, 2- by about one turn. When doing this, use stop -T10172- with adapters -T10172/2- and -T10172/1-.
Loosen screw -1- with key T10500-. Release tensioning roller by turning eccentric -2- with wrench -T10499-.
Carefully! Install used toothed belt only in the same direction of travel. Incorrect installation can lead to the destruction of the belt! Before removing the belt, mark the direction of the belt with chalk or a felt-tip pen for reinstallation.
Remove toothed belt. Remove crankshaft pulley -1- -arrow-.