Dismantling the Belt Drive

Dismantling the belt drive

Special tools:
999 5304 SEPARATOR 999 5304 Separator
999 5433 COUNTERHOLD 999 5433 Counterhold
999 5456 COMPRESSION TOOL 999 5456 Compression Tool

Note! The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.

Aligning the engine according to the marking





Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing belt cover
Remove the upper timing belt cover.

Removing the vibration damper





Remove the 4 screws. Use the crankshaft center nut as a counterhold.
Install counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold. Remove the center nut.
Remove counterhold 999 5433.
Work / pull the auxiliaries belt pulley loose.

Removing the timing belt





Slacken off the center screw for the belt tensioner slightly.
Hold the center screw in place. Turn the eccentric on the tensioner counter-clockwise to the 10 o'clock position using a 6mm Allen key.
Unhook and remove the timing belt.

Caution! Do not turn the camshafts or the crankshaft when the timing belt has been removed.

Removing the crankshaft pulley





Use puller 999 5304 SEPARATOR 999 5304 Separator and two 50 mm M10 screws with washers.
Pull off the timing gear pulley.

Caution! The crankshaft must not rotate.

Removing the belt tensioner and idler pulley

Remove the belt tensioner and idler pulley.
Check the rolling surface and the bearings.
Check for any noise. Check for any play in the bearings.
Check that the rolling surfaces are smooth and clean.

Removing oil pump





Remove
- the fuel pressure pipe
- the belt guard from the oil pump
- the four oil pump screws.

Carefully work the oil pump out. Use a groove-cut chisel with stop lugs.
Carefully draw the oil pump past the end of the crankshaft.
Carefully clean the gasket face and mating surfaces.

Checking the oil pump




Disassemble the oil pump.
Clean and check all components.
Check for damage and wear.
In particular check the half-moon shaped insert (the surface between the suction and pressure sides).
Replace the oil pump in the event of a fault.
Assemble the oil pump.
Tighten the screws. Tighten to 6 Nm.

Removing the coolant pump




Remove the screws.
Carefully tap the pump pulley with a rubber mallet.
Work the pump loose.
Carefully clean the gasket face and mating surfaces.

Removing the thermostat and thermostat housing




Remove the cover over the thermostat (Tx40).
Lift out the thermostat and remove the gasket.
Remove the screw for the engine coolant temperature sensor cable duct.
Remove the thermostat housing from the cylinder head.
Carefully clean the gasket face and mating surfaces.

Checking the opening function of the thermostat

The thermostat can be tested in warm water.
Maximum opening must occur within 2 minutes in water at opening temperature.
Marking.90° C
Starts to open at.90°C
Fully open at.105°C