Toothed Belt, Removing From Camshaft Sprockets

4.9 Toothed Belt, Removing From Camshaft Gears

Special Tools and Workshop Equipment Required
- Locking Pin -T40001-
- Drift -3204-
- Spanner Wrench -3212-
- Crankshaft Holder -3242-
- Open End Wrench -3312-
- Puller -T40001-
- Camshaft Adjustments -T40005-

Removing

- Remove intake air duct to air filter

- Remove the bumper.

- Bring lock carrier into service position.






- Remove engine cover -arrows-






- Remove fan ring for viscous fan -arrows-.

Note:
The fan has left threads.






- Counterhold pulley for viscous fan using -3212- and remove viscous fan using -3312- (left thread).

- Remove viscous fan together with fan ring.

- Remove ribbed belt gear for viscous fan.

Note:
^ Before removing toothed belt, mark the running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.
^ Note previously marked direction of belt rotation and be sure that it is seated correctly on pulley.






- To loosen ribbed belt, turn tensioner clockwise in direction of -arrow- using 17mm box wrench until two holes are aligned; counterhold in position using -3204-.

- Remove ribbed belt.






- Turn the engine to the TDC position by hand. Markings -A- and -B- must align.






- Check the camshaft position: Large holes of securing plates on camshaft sprockets must face toward inside and align, otherwise turn crankshaft one further rotation.






- Remove sealing plug -arrow- from cylinder block on left side.

- Top Dead Center (TDC) mark on crankshaft must be behinds bore (can be touched) of removing sealing plug.






- Install -3242- in hole of the removed sealing plug and tighten.

Note:
The toothed belt tensioner is oil-dampened. Compress it by slowly applying constant pressure.






- Turn toothed belt tensioning lever -1- towards left in direction of -arrow- using 8mm hex socket wrench until tensioner -2- is compressed far enough so that -T40011- fits in hole and plunger.

- Insert -T40011- and release toothed belt tensioning lever.






- Install -T40005- in locking plates of camshafts.

- Loosen both bolts for camshafts approximately 5 turns.

- Remove -T40005-.






- Remove both camshaft gears using -T40001-.

- Remove toothed belt gear cyl. banks 1 to 4 together with toothed belt.

Caution!
Check gears after removing. If dents are visible, replace camshaft gears.

Placing









^ Tightening specifications.

- Remove toothed belt gear of camshaft cyl. banks 1 to 4, place toothed belt and bolt onto camshaft.

- Hand-tighten both camshaft gears with securing plates.

Note:
The camshaft sprockets should be loose enough on the cone to be turned but not so loose as to be tipped.

- Insert -T40005-.






- Turn toothed belt tensioning lever -1- far enough towards left in directoin of -arrow- using 8mm hex socket wrench until -T40011- can be removed.

- Tighten camshaft gears.

Note:
The -T40005- serves as a retainer.

- Remove camshaft adjustment -T40005-.
- Remove -3242- and seal bore using sealing plug.
- Rotate engine 2 crankshaft rotations.
- Install the viscous fan.