Unlock catches -arrows- with puller -T10527- and remove air duct.
Press release buttons and detach hose -1-. Unscrew screws -arrows- and detach crankcase breather hose.
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-. Release hoses from bracket -3-.
Remove bolt -2-. Unclip clips -arrows- and remove upper toothed belt guard -1-.
Remove screws -arrows- and remove cover from exhaust camshaft adjuster.
Carefully! Collect escaping engine oil! To protect the toothed belt from escaping engine oil, place a rag under the camshaft adjuster. Belt drive parts - camshaft sprockets, crankshaft sprocket, tension and guide rollers must be degreased.
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 -T10340- only locks the crankshaft in the working direction of rotation.
Carefully! Risk of engine damage! If the locking screw -T10340- is not fully screwed in, 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 in the direction of engine rotation until it stops.
For both camshafts, the asymmetrical recesses -arrows- on the gearbox side must now point upwards, as shown in the illustration. 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 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 locking pin -T10494- into camshafts as far as it will go 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-.
Carefully! Risk of damaging the camshaft. Do not use camshaft clamps -T10494- as a stop.
Tighten screw -arrow- hand-tight.
Unscrew plug -1- on inlet camshaft pulley using stop -T10172- with adapter -T10172/1-.
Loosen bolts -1,2- by approx. one turn. To do this, use puller -T10172- with adapters -T10172/2- and -T10172/1-.
Carefully! Reversing the running direction of a used toothed belt can damage it. Before removing the belt, mark the direction of the belt with chalk or a felt-tip pen for reinstallation.
Loosen screw -1- with wrench -T10500-. Release tensioning roller by turning eccentric -2- with wrench -T10499-.
Carefully! Risk of damage to the toothed belt! The toothed belt is made using fiberglass. Therefore, the diameter of its bend should not be less than 50 mm. Otherwise, the service life of the toothed belt will be significantly reduced.
Remove toothed belt from camshaft pulleys.