Toothed Belt, without Divided Toothed Belt Guard
Toothed Belt, without Divided Toothed Belt Guard
• Vehicles from 01/2006 have a new toothed belt guard. Identification: The upper toothed belt guard does not have a 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 with divided toothed belt guard, removing and installing => [ Toothed Belt, with Divided Toothed Belt Guard ] Toothed Belt, With Divided Toothed Belt Guard.
Special tools, testers and auxiliary items required
• Engine Support Bridge (10 - 222 A)
• Spindle (10 - 222 A /11) ; quantity: 2
• Special Hook (10 - 222 A /20) ; quantity: 2
• Additional Hooks (2) (10 - 222 A /2)
• Engine Support Basic Set (T40091)
• Engine Support Supplement Set (T40093) with Engine Supplement Left and Right (T40093/3-2) and Engine Supplement Left and Right (T40093/3-3)
• Toothed Belt Tensioner (T10020)
• Locking Pin (T10060A)
Removing
- Disconnect the electrical connector on the mass airflow (MAF) sensor (G70) - 3 -.
- Open clips - 1 and 2 - and remove air guide hose from MAF sensor.
- Remove front air intake connector on lock carrier - 4 -.
- Remove engine cover.
Cover cap of expansion tank with a rag and open carefully, as hot steam or hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove center noise insulation fasteners - 1 to 4 -.
- Remove the right noise insulation - arrows -.
- Remove noise insulation frame - arrow -.
- Remove the bolts - arrows - and disconnect charge air pipe with hoses.
- 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 Evaporative Emission (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 -.
- Unbolt the filler tube 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 -.
- Remove EVAP canister bracket.
- Loosen coolant pipe - arrows -.
- Disengage shift cable - arrow -.
- Position the (10 - 222 A) on fender bolting edge with the following tool parts:
• Engine brackets (10 - 222 A /1) , quantity: 2
• Engine support bridge (10 - 222 A)
• Spindle (10 - 222 A /11) (spindle faces forward)
• Additional hooks (10 - 222 A /2)
• Adapter (10 - 222 A /20)
• Connectors (T40091/3) qty. 2
- Engage spindle (10 - 222 A /11) with (10 - 222 A /2) and special hook (10 - 222 A /20) on transmission lifting eye.
- Tension engine/transmission subframe with spindle.
- Install adapter (T40093/3-2) (left) and (T40093/3-3) (right) on supports (T40093/3).
- Remove ground (GND) line from left longitudinal member.
- Remove left and right connecting bolt for front section of the long member.
- Secure adapter to the long members with bolts - arrow - removed earlier.
• The illustration shows the left side of the vehicle.
- Place the square pipes (T40091/1) with connector (T40093/4) in the connector (T40091/3) and supports (T40093/3-3) as shown in the illustration.
- Slide support (T40091/2) into both connectors (T40093/4) with slide (T40093/5).
Risk of accident due to loose engine support bridge spindles.
• Secure the (T40091/2) with connector pins and splints (T40093/4).
• Secure connector and supports with clamping bolts.
- Install (10 - 222 A /11) with (10 - 222 A /20) on slide and on engine lifting eye.
- Tension engine/transmission subframe by evenly tightening the 2 spindles.
- 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.
- Lift the engine with the (10-222A) so far that both upper bolts - 1 and 2 - of the engine support can be loosened and removed.
- 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.
- Remove the bolts from lower section of the toothed belt guard - arrows -.
- Loosen the lower bolts - 3 - and remove the engine support downward and out.
- Remove remaining bolts from toothed belt guard - arrows - and remove toothed belt guard 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, without Divided Toothed Belt Guard Overview ] Toothed Belt Drive, Without Divided Toothed Belt Guard Overview.
• When turning the camshaft, the crankshaft must not be at TDC. Valves and/or pistons may be damaged.
• The engine must be no more than warm to touch.
- Place the toothed belt onto the crankshaft sprocket (observe direction of rotation).
- Secure the lower toothed belt guard with the two lower bolts.
- Install vibration damper with new bolts.
- Set the crankshaft and camshaft to TDC at cylinder 1 - arrows -.
- 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. Do this by turning the hex key at the eccentric toward the right (in direction of - arrow -) until the notch is positioned above the tab.
- 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 tension of toothed belt again. Specified value: Tab and notch align.
- Check the valve timing again.
If the markings do not match:
- Repeat valve timing adjustment.
If the markings match:
- Install the toothed belt guard - arrows -.
• Note different length of bolts. Bolt - 3 - is approximately 25 mm shorter than bolts - 1 and 2 -.
- Insert the lower bolt - 3 - into the engine support.
- Install the engine support from below onto the cylinder block and hand-tighten the bolt.
- Lift the engine with the (10-222A) so far that both upper bolts - 1 and 2 - can be screwed in.
- Tighten all bolts.
- Lower engine to installation position.
- Install subframe mount for engine completely.
- Fasten engine assembly mount to engine support - arrows -, bringing the contact surfaces into contact using the (10-222A).
- Adjust the engine mounts. Refer to => [ Subframe Mount, Adjusting ] Adjustments.
- Connect fuel hoses to connections. Make sure connector couplings are securely fastened.
- Install air guide pipes and connector. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections with Connector Couplings, Assembling.
- Install coolant expansion tank.
- Install noise insulation.
- Install the engine cover.
- Install vibration damper. Refer to => [ Vibration Damper ] Service and Repair.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.