High Pressure Fuel Pump Toothed Belt

High Pressure Fuel Pump Toothed Belt

Special tools, testers and auxiliary items required

• Retainer (3036)

• Crankshaft Holder (3242)

• Puller (T10320)

• Socket (T40058)

• Locking Tool (T40135)

Removing

- Remove the engine cover.

- Tilt the toothed belt guard forward - arrows - and disengage the pins on the underside of the guard.





• The toothed belt guard is shown with the upper intake manifold removed.

CAUTION!
A used toothed belt could be destroyed if the running direction is reversed.

Before removing the ribbed belt, mark the running direction with chalk or a felt tip pen for installation later.

- Set the engine to Top Dead Center (TDC).

• To prevent engine oil from running out, place a cloth under the upper oil pan.





- Remove the plug - arrow - from the upper oil pan.







CAUTION!
Risk of injury when inserting your finger in the TDC hole.

• Do not rotate crankshaft - 1 -.

- Install the (3242) in the hole and tighten it to 20 Nm. Turn the crankshaft back slightly to completely center the bolt, if necessary.

- Use the (T40135) to secure the high pressure pump toothed belt sprocket.

- Loosen the bolt - 1 - for the toothed belt tensioner one turn. Ignore item - 2 -.





- Loosen the toothed belt drive sprocket bolt - 1 - 2 turns counter hold using (3036).





- Remove the toothed belt drive sprocket using (T10320).





• The toothed belt drive sprocket remains on the camshaft.

- First remove the toothed belt from the high pressure pump sprocket and then from the drive sprocket.

Installing

Installation is performed in reverse order of removal, noting the following:

Tightening specifications, refer to => [ High Pressure Fuel Pump Toothed Belt Overview ] High Pressure Fuel Pump Toothed Belt Overview.

• Before installing the toothed belt, make sure the high pressure pump and its toothed belt sprocket are securely installed.

- Check the installed position of the toothed belt tensioner:





• The claw - arrow - must fit into the recess in the high pressure pump bracket.

- Use the (T40135) to secure the high pressure pump toothed belt sprocket.





- Install the toothed belt tensioner bolt - 1 - without using force until the eccentric pulley for the tensioner can be turned without tipping.

- Install the toothed belt drive sprocket bolt - 2 - far enough until the sprocket can be turned without tilting.

- Install the toothed belt.

- Pretension the toothed belt tensioner using a socket and ratchet in the - direction of the arrow - until the tab is under the notch at dimension - a -.





• Dimension - a - = approximately 5 mm.

- Release the tension on the toothed belt tensioner - arrow - until the tab - 1 - and the notch - 2 - are exactly aligned.





- Hold the roller in this position and tighten the bolt - arrow -.





- Tighten the toothed belt drive sprocket bolt - 1 - counter hold using (3036).





- Remove the (3242).





- Install the plug - arrow - for the TDC mark into the upper oil pan.





- Insert the (T40058) guide pins as follows:





• The large diameter - arrow 1 - faces the engine.

• Small diameter - arrow 2 - points to adapter.







CAUTION!
Components could be destroyed by the camshaft timing chain jump off.

• Turn the crankshaft only in the direction of engine rotation - arrow -.

- Rotate the crankshaft one turn using (T40058).

- Check the toothed belt tension:





• The tab - 1 - must align with the notch - 2 -.

- If the specified value is not reached, adjust the toothed belt tension one more time.

Assembly is performed in reverse order.