43.1 Accessory Drive Belt Installation Details
1 Crankshaft pulley
2 Bolt, to be replaced, 10 Nm, then tighten to an angle of 90°
3 Belt tensioner 13
4, 7 Bolt, 23 Nm
5 Auxiliary units bracket
6, 10 Centering bushings
8 Generator
9 Bolt, 45 Nm, tightened with D000 600A2 locking sealant
11 Bolt, 25 Nm
12 Air conditioning compressor
13 Auxiliary drive belt
2. Timing belt installation details are shown in the accompanying illustration.
43.2 Timing Belt Installation Details
1 Bolt, subject to replacement, 10 Nm, then tighten to an angle of 90
2 Crankshaft pulley
3 Rear lower timing belt cover
4, 14, 25 Bolt, 10 Nm, tightened with fixing sealant D000 600A2
5 Central timing belt cover, to remove remove cover 6 and the auxiliary drive belt tensioner
6 Upper timing belt cover, to remove remove the right air pressure tube
7 Timing belt
8 Nut, 20 Nm, then tighten to an angle of 45°
9 Tension roller
10 Bolt, 20 Nm, then tighten to an angle of 45°
11 Camshaft gear wheel
12 Bolt, 100 Nm
13 Wheel hub 11, with SMR sensor rotor
14 Bolt, 10 Nm
15 Rear timing belt cover, remove water pump to remove
16 Rubber stopper
17 Bolt, 25 Nm
18 Sealing ring
19 Water pump
20 Bolt, 13 Nm
21 Intermediate roller
22 Crankshaft gear, there should be no grease between the shaft and the gear
23 Bolt, to be replaced, 120 Nm, then tighten to an angle of 90°, do not lubricate
24 Nut, 22 Nm
Removal the timing belt
3. Remove the accessory drive belt.
4. Remove the air pressure hose.
5. Remove the expansion tank fastener and set it aside, without disconnecting the coolant hoses, on the cylinder head.
6. Press the latches and disconnect the feed line (2 on the accompanying illustration) and return (1) fuel lines.
43.6 Fuel lines
7. Press the clamps (see accompanying illustration) and remove the upper timing belt cover.
43.7 Timing Belt Upper Cover Fasteners
8. Remove the accessory drive belt tensioner.
9. Remove the right front wheel arch liner.
10. Remove the crankshaft pulley. Remove the lower and middle timing belt covers.
11. Install the MP9-200 beam (No. 10-222A) and unload the engine support using the MP9-200/10 hook (No. 10-222A/1 0) hooked onto the right lifting eye.
43.11 Unloading the power unit supports
12. Remove the bolts (1-2 on the accompanying illustration) and remove the connecting stud. Loosen the bolts (3-6) and remove the engine console.
43.12 Removing the engine console
13. Remove the bolts (1-3 on the accompanying illustration) and remove the engine support. If necessary, slightly lower/raise the engine while unscrewing the bolts.
43.13 Engine support fasteners
14. Turn the crankshaft clockwise by its front central bolt to the TDC position. In this case, the slot with teeth (1 on the accompanying illustration) should be located on top, and the tab (1) of the timing belt sensor rotor should be opposite the mark (2) on the rear timing belt cover.
43.14 TDC marks on the camshaft gear
Note: For clarity, the timing belt is not shown in the illustration.
15. Lock the hub with pin No.3359 and also lock the crankshaft gear by sliding the T10100 tool onto it from the front. The pin of the T10100 tool must enter the hole in the front sealing flange, and the arrow on the T10100 tool must be located opposite the mark on the crankshaft gear (see accompanying illustration).
43.15 Fixation at TDC
16. If the timing belt is to be reused, mark the direction of its rotation on it. Loosen the camshaft gear mounting bolts by one turn (see accompanying illustration).
43.16 Camshaft gear mounting bolts
17. Loosen the nut (1 on the accompanying illustration) timing belt tensioner, carefully turn the tensioner eccentric counterclockwise with the T10264 Allen key and lock it by inserting the T10265 device.
43.17 Timing belt tension loosening
18. Turn the timing belt tensioner clockwise until it stops and tighten the nut (1 on the accompanying illustration) by hand. Remove the timing belt idler roller and remove the belt, starting from the crankshaft.
43.18 Fixing the timing belt tensioner
Timing belt installation, timing phase adjustment
Note: Timing adjustment should only be performed on a cold engine. Do not rotate the camshaft when any of the pistons is at TDC - there is a risk of damaging the pistons and valves.
19. Make sure that the shafts are secured with tools No.3359 and T10100, and that the timing belt tensioner is secured with a nut in the loose position.
20. Make sure the tensioner roller is correctly positioned in the hole in the rear timing belt cover (see accompanying illustration).
43.20 Position of the tensioner in the rear cover
21. Tighten the camshaft gear bolts slightly so that there is no wobble but the gear can still be turned on the hub. Turn the gear clockwise in the elongated holes until it stops.
22. Place the timing belt on the crankshaft sprocket, tensioner roller, camshaft sprocket and finally on the water pump sprocket.
23. Install the timing belt idler roller.
24. Remove the T10265 tool from the tension roller. Loosen the nut (1 on the accompanying illustration) tension roller and turn its eccentric with the T1 0264 Allen key clockwise until the pointer (2) is in the center of the base plate gap. Make sure that the tensioner nut does not turn. Holding the tensioner eccentric in this position, tighten the tensioner nut with a force of 20 Nm, and then tighten it to an angle of 45°. When tightening the nut, the pointer turns no more than 5 mm to the right from the gap in the base plate. This position should not be adjusted, since the timing belt will still settle.
43.24 Tensioning the timing belt
25. Install the T10172 counter support and press it in the direction of the arrow (see accompanying illustration). While holding the camshaft gear pulled out, tighten the bolts (1) to 20 Nm, then tighten them to an angle of 45°. Remove locking pins No.3359 and T10100.
26. Turn the crankshaft clockwise two revolutions until it is just before the TDC position. In this position, lock the camshaft hub again with locking pin #3359 (see illustration 43.14) and make sure that the crankshaft can be locked with the T10100 tool (see illustration 43.15), and the timing belt tensioner pointer is no more than 5 mm to the right of the base plate gap. If these conditions are met, proceed to paragraph 28.
27. If the crankshaft cannot be locked, loosen the camshaft gear mounting bolts and turn the crankshaft in the TDC area so that the T10100 tool can be installed. Lock the crankshaft, pull the camshaft gear again and tighten its bolts (20 Nm + 45° angle). Remove locks No.3359 and T10100 again and check the timing adjustment (return to paragraph 26).
28. Install the remaining parts in the reverse order of removal. Tighten the engine mount bolts in the following order: (2-1-3 in illustration 43.13) with a force of 40 Nm, and then pull them to an angle of 180°.