Engine, disassembly and
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- Martin Jenkins
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1 Page 1 of Engine, disassembly and assembly Ribbed belt, removing and installing Removing - Remove noise insulation -arrows-. - Remove bumper Repair Manual, Body Exterior, Repair Group 63 - Move lock carrier to service position - Remove viscous fan (counter-hold with pin wrench 3212). Viscous fan has left-hand thread: turn in direction indicated.
2 Page 2 of Mark direction of rotation of ribbed belt. - To slacken ribbed belt, turn to the right using a 17 mm ring spanner until the two holes are aligned with each other -arrow- and hold in position with mandrel Mark the direction of rotation of the ribbed belt with chalk or felt pen before removing. A used belt can break if it rotates in the opposite direction when reinstalled. - Take off ribbed belt.
3 Page 3 of Installing - Install ribbed belt onto crankshaft pulley and idler wheel first, and push belt onto tensioning roller last. Routing of ribbed belt D1 - vehicles without air conditioner D2 - vehicles with air conditioner - Take out mandrel Counter-hold belt pulley for viscous fan using spanner wrench 3212 and tighten viscous fan using open end spanner 3312 and torque wrench 1331 (left hand thread). Viscous fan has left-hand thread: turn against direction indicated. - Install lock carrier. Repair Manual, Body Exterior, Repair Group 50 - Install bumper. Repair Manual, Body Exterior, Repair Group 63 - Install noise insulation.
4 Page 4 of Toothed belt, removing and installing Removing - Remove ribbed belt Page Remove bolts -arrows- and remove engine cover panel -C-. - Remove pressure hoses -arrows- between charge air coolers and pressure pipes (left and right sides).
5 Page 5 of Remove pressure pipes -1-. Watch position of retaining strips Remove tensioner -1- for ribbed belt. - Remove left and right toothed belt guards Remove center toothed belt guard -3-.
6 Page 6 of Turn crankshaft to TDC by hand. Marks -A- and -B- must be aligned. Turn over the engine at the central bolt on the crankshaft. - Check position of camshafts: larger holes in securing plates on camshaft sprockets must align opposite one another on inside. If not, turn crankshaft one revolution further. - Remove sealing plug from cylinder block, left. - The TDC drilling in the crankshaft must be visible (or able to be felt) in line with the sealing plug hole. CAUTION! Injury risk - do not turn engine while feeling for TDC drilling. - Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.
7 Page 7 of Remove vibration damper on crankshaft. The central bolt does not have to be loosened to remove the vibration damper. - Remove idler wheel for ribbed belt -arrows-. - Remove toothed belt guard behind vibration damper -arrows-.
8 Page 8 of Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when reinstalled. The toothed belt tensioning element is oildamped and can therefore only be compressed slowly by applying constant pressure. - Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until tensioning lever -2- compresses tensioning element -3- sufficiently to enable special tool T to be fitted in drilling and in plunger. - Insert special tool T , release toothed belt tensioning roller. - Take off toothed belt.
9 Page 9 of Installing - Insert camshaft clamp 3391 in securing plates of two camshafts. - Slacken both camshaft bolts and remove approx. 5 turns. - Take out camshaft clamp Pull off both camshaft sprockets with special tool T Reinstall both camshaft sprockets with securing plates and tighten hand-tight again. The camshaft sprockets should be just tight enough on the camshaft tapers so that they can still be turned but do not move axially. - Install toothed belt on all sprockets as illustrated. - Install camshaft clamp 3391.
10 Page 10 of Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until special tool T can be removed. - Pre-tension toothed belt by a turning in direction of arrow with a torque of 15 Nm using a torque wrench. - Tighten bolts on camshaft sprockets.
11 Page 11 of Install idler wheel for ribbed belt -arrows-. - Install toothed belt guard behind vibration damper -arrows-. - Install vibration damper. Note positions of locating lugs -arrows- on belt sprocket.
12 Page 12 of Install toothed belt guard. - Install ribbed belt Page Tightening torques Toothed belt sprocket to camshaft Idler wheel Toothed belt tensioning roller Pulley to crankshaft Toothed belt tensioning element 55 Nm 45 Nm 20 Nm 20 Nm 10 Nm Central bolt 1) to crankshaft 200 Nm ) 1) The central bolt must always be replaced. 2) Turning in two stages of 90 is also permissible.
13 Page 13 of Vibration damper, removing and installing - Remove ribbed belt Page The central bolt does not have to be loosened to remove the vibration damper. - Remove vibration damper. - When installing, ensure that notches -arrows- in vibration damper are aligned with locating lugs on toothed belt sprocket. Tightening torque: 25 Nm
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Page 1 of 38 13-1 Engine, disassembling and assembling Lock carrier, moving into service position Special tools and equipment 3369 support tool 1 - Bolts 2 - Bolts 3 - Bolts 4 - Bolts 5 - Bore 45 Nm (33
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