Note: Replace screws that are tightened to the specified angle. If the o-ring of the screw plug is damaged, replace the o-ring.
Check position "TDC" camshaft and crankshaft. The camshaft lock -T10494- is mounted on the camshaft housing.
Carefully! Risk of damage to camshafts. The camshaft clamp -T10494- must not be used as a stop.
The locking bolt -T10340- is screwed into the cylinder block until it stops and tightened to a torque of 30 Nm. Crankshaft turned forward until it touches locking screw -T10340- ="TDC" position". Screw in new screws -1, 2- for camshaft pulleys by hand. The camshaft pulleys should still turn on the camshafts, but should not oscillate.
The protrusion of the tensioning roller -arrow- must engage in the molded recess in the cylinder head.
Install the crankshaft sprocket to the crankshaft. The mating surfaces between the V-ribbed belt pulley and the crankshaft toothed pulley must be free of grease. The milled flat part -arrow- of the crankshaft pulley must sit on the milled flat on the crankshaft toe.
When installing/reserving the toothed belt, observe the correct sequence. Raise the toothed belt and place it on the guide pulley -1- and tensioning pulley -2- and then on the camshaft pulleys -3- and -4-.
Turn eccentric -2- of tensioning pulley with spanner -TW499- in -direction of arrow- until arrow -3- is approx. 10 mm to the right beyond the recess. Turn the eccentric back so that the arrow is exactly opposite the notch.
Carefully! Use torque wrench -VAS 6583- for tightening! When setting the tightening torque on the torque wrench -VAS 6583-, the length specified on the socket -T10500- must be entered!
While holding the eccentric in this position, tighten bolt -1- to 25 Nm using socket -T10500- with torque wrench -VAS 6583-.
Note: Later on, after turning the crankshaft or starting the engine, the arrow -3- may slightly deviate from the position opposite the notch. This is normal and will not adversely affect the timing belt tension.
Tighten screws -1, 2- with a preliminary torque of 50 Nm; while using stopper -T10172- with adapters -T10172/2- and -T10172/1-.
Unscrew locking bolt -T10340-. Unscrew bolt -arrow- and remove camshaft clamp -T10494-. Install lower belt guard -arrows-. Install the crankshaft pulley.
Checking the installation of the timing phases
Rotate crankshaft 2 turns 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. The counterweight of the crankshaft is now adjacent to the locking bolt.
Note: The locking bolt -T10340- only locks the crankshaft in the working direction of rotation. Camshaft lock -T10494- must be easy to insert. The camshaft lock must not be installed with an impact tool.
Insert locking pin -T10494- into camshafts as far as stop and hand-tighten screw -arrow-. If the camshaft clamp -T10494- cannot be inserted, the valve timing is incorrect: repeat the valve timing adjustment. If the camshaft lock -T10494- is inserted, the valve timing is correct. Unscrew locking bolt -T10340-. Unscrew bolt -arrow- and remove camshaft clamp -T10494-. Tighten bolts -1, 2- to final torque using stop -T10172- with adapters -T10172/2- and -T10172/1-.
Tighten screw plug -1- to 20 Nm using stop -T10172- with adapter -110172/1-.
Carefully. Risk of engine damage. After completing the work, make sure that the locking pin -T10340- and the camshaft lock -T10494- are not left on the engine.
Installation in reverse order.