Toothed Belt, With Divided Toothed Belt Guard
Toothed Belt, with Divided Toothed Belt Guard
• Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have cover => [ (Item 25) Cover for Toothed Belt Guard ] Toothed Belt Drive, Without Divided Toothed Belt Guard Overview and guard is divided in engine bracket area. Toothed belt, vehicles without divided toothed belt guard, removing and installing. Refer to => [ Toothed Belt, without Divided Toothed Belt Guard ] Toothed Belt, Without Divided Toothed Belt Guard.
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Shackle (1 Set=2 Pieces) (10 - 222 A /12)
• Toothed Belt Tensioner (T10020)
• Locking Pin (T10060A)
Removing
- Remove the engine cover and air filter.
Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opened.
- Open cap of coolant expansion tank.
- Remove noise insulation.
- Remove right noise insulation fasteners - 1 to 3 -.
- Remove the bolts - 1 to 3 - and the pendulum support.
- Drain the coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection.
- Mark the fuel line - 1 - and the EVAP line - 2 -.
- Disconnect fuel line - 1 -.
- Disconnect the EVAP line - 2 -.
- Disconnect the EVAP line to fuel tank - 3 -.
- Remove EVAP canister upward in direction of - arrow -.
- Loosen the coolant hose from the retainer - 1 -.
- Remove bracket for EVAP filter - arrows -.
- Remove the filler tube bolt for the windshield washer fluid reservoir - 1 -.
- Remove the retaining clip, by removing bolts - 2 and 3 -.
- Disconnect the electrical connector - 1 - from coolant level indicator.
- Remove coolant expansion tank - arrows -.
- Disconnect coolant pipe - arrow -.
- Remove the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Remove ribbed belt tensioner - arrows -.
- Loosen coolant pipe - arrows -.
- Remove the bolts - arrows - and the toothed belt guard.
- Install the (10 - 222 A) onto fender bolting edge. The spindles are positioned forward.
- Hook the carabiner hooks of the spindles with the (10 - 222 A /12) into the lifting eyes.
- Remove bolts from assembly mount/engine support - arrows - remove assembly mount completely.
When lifting the engine with the (10-222A) , make sure that no components/hoses are damaged, overstressed or torn off.
- Raise the engine with the (10-222A) until both engine support upper bolts - 1 and 2 - can be loosened and removed.
- Remove the bolts - arrows - and disconnect charge air pipe with hoses.
- Loosen the lower bolts - 3 - and remove the engine support downward and out.
- Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must align with arrow on toothed belt guard.
- Remove vibration damper/belt pulley.
• The TDC markings must align before removing vibration damper.
• Crankshaft must not be rotated any more until TDC position is marked with an assisting mark.
- Remove lower bolts from lower section of toothed belt guard - arrows -.
- Identify TDC position - arrow -.
- Remove both upper bolts from toothed belt guard - arrows - and remove guard downward from engine.
- Now remove engine bracket upward from engine.
- Mark rotational direction of toothed belt.
- Loosen tensioning roller and remove toothed belt.
- Then, turn the crankshaft back slightly.
Installing
• For the correct tightening specifications, refer to => [ Toothed Belt Drive, with Divided Toothed Belt Guard Overview ] Toothed Belt Drive, With Divided Toothed Belt Guard Overview.
• When turning camshaft, crankshaft must not be at TDC. Valves and/or pistons may be damaged.
• The engine must be no more than warm to the touch.
- Position camshaft and crankshaft on TDC marking.
- Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).
- Route toothed belt in the sequence: Tensioning roller, camshaft gear, coolant pump and last over the relay pulley - arrow -.
• Be sure tensioning roller is properly seated in cylinder head.
- Tension toothed belt. To do so, turn socket head wrench on eccentric clockwise in direction of - arrow - until notch stands above the tab (toothed belt excessively tensioned).
- Release tension on toothed belt again.
- Now tension toothed belt until notch and tab align.
- Tighten mounting nut.
- Turn the crankshaft 2 revolutions further in direction of engine rotation until the engine is positioned at TDC again. For this it is necessary that the last 45° (1/8 rotation) is turned without interruption.
- Check toothed belt tension. Specified value: Tab and notch align.
- Check valve timing. The markings must align - arrows -.
If the markings do not match:
- Repeat valve timing adjustment.
If the markings match:
- Install engine bracket on cylinder block and tighten bolts hand-tight.
• Note different length of bolts. Bolt - 3 - is approximately 25 mm shorter than bolts - 1 and 2 -.
- Lower the engine using the (10-222A) until lower bolt- 3 - can be tightened.
- Tighten all bolts.
- Install engine mounting.
- Tighten engine subframe mount and engine bracket bolts hand-tight - arrows -, by bringing the contact surfaces into contact using (10 - 222 A).
- Remove the (10 - 222 A).
- Reconnect fuel and ventilation lines. Make sure connector couplings are securely fastened.
- Install coolant expansion tank.
- Install the crankshaft belt pulley. Refer to => [ Vibration Damper ] Service and Repair.
- Adjust the engine mounts. Refer to => [ Subframe Mount, Adjusting ] Adjustments.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install air guide pipes and connector. Refer to => [ Hose Connections with Connector Couplings ] Service and Repair.
- Install fuel system.
- Install noise insulation.
- Install engine cover/air filter.