High Pressure Pump Toothed Belt, Removing And Installing: Installing

WARNING: This page is about a different variant/trim than selected.

Install in reverse order of removal. Note the following:

-- Remove noise insulation.

-- Insert the Crankshaft SocketT40058 guide pins as follows:

Fig 1: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Fig 2: Identifying TDC With Special Tool Adapter T140058

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CAUTION:

Components could be destroyed by the camshaft timing chains jumping off.

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

-- Use the Crankshaft SocketT40058 to rotate the crankshaft to "TDC".

As shown in the illustration, the marking -arrow- must be vertical on the center of the crankshaft.

Fig 3: Identifying Vertical Mark -Arrow- On Center Of Crankshaft
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-- Remove the air guide hose.

-- Remove the plug -arrow- behind the right cylinder head.

Fig 4: Identifying Plug -Arrow- Behind Right Cylinder Head

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NOTE:

To provide a better illustration, installed position is shown with engine removed from behind.

-- Check to see if the groove -arrow- in the camshaft flange can be seen through the sealing plug hole -1-.

-- Shine a small flashlight in the sealing plug hole to see.

Fig 5: Identifying Groove -Arrow- In Camshaft Flange And Plug Hole -1-

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NOTE:

The camshaft flange is shown without chain drive and without timing chain guard to make the illustration better.

-- Turn the crankshaft 360 degrees in the direction of engine rotation if the groove is not under the hole.

NOTE:

To collect escaping engine oil, place a clean cloth under the upper part of the oil pan.

Fig 6: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Remove the sealing plug -arrow- from the upper section of the oil pan.

Fig 7: Identifying Crankshaft Holder 3242

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WARNING:

Risk of injury when touching "TDC" hole with finger.

Do not rotate crankshaft -1-.

-- Install the Crankshaft Holder3242 in the hole and tighten to 20 Nm. Turn the crankshaft back slightly to completely center the bolt, if necessary.

NOTE:

The high pressure pump and its toothed belt gear must be installed securely before installing the toothed belt.

-- Stop the high pressure pump toothed belt wheel with the High Pressure Pump Sprocket Locking ToolT40135.

Fig 8: Identifying Locking Tool T40135 For High Pressure Pump Toothed Belt

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NOTE:

Stop the high pressure pump toothed belt using the High Pressure Pump Sprocket Locking ToolT40135 before installing the toothed belt. (Do not allow the toothed belt to swing!).

The hole -arrow in the toothed belt sprocket- is situated in the -3-'o'clock-position-.

Fig 9: Identifying Hole -Arrow In Toothed Belt Sprocket- Situated At -3 O'clock Position-

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Insert the High Pressure Pump Sprocket Locking ToolT40135 all the way in.

Fig 10: Identifying Locking Tool T40135 For High Pressure Pump Toothed Belt

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-- Check the installation position of the toothed belt tensioning roller:

Fig 11: Identifying Hex Mount -Arrow 1- And Claw -Arrow 2-

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The claw -arrow 2- must fit into the recess in the high pressure pump bracket.

The tension roller must be relieved of tension and the hex mount -arrow 1- faces downward.

-- Install the toothed belt.

Fig 12: Identifying Toothed Belt Tensioner Bolt -1-, Toothed Belt Sprocket Bolt -2- And Locking Tool T40135

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

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

-- Stop the high pressure pump toothed belt wheel with the High Pressure Pump Sprocket Locking ToolT40135.

-- Continue to pretension the toothed belt tensioning roller the direction of the -arrow- with the hex socket wrench until the hex mount is in the -1-'o' clock-position-.

Fig 13: Identifying Hex Socket And Toothed Belt Tensioning Roller

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CAUTION:

Never remove while in the "12-'o'clock-position" or above.

-- Release the toothed belt tensioning roller to the point where the hex mount is in the -3-'o' clock position- in direction of -arrow-.

Fig 14: Identifying Toothed Belt Tensioning Roller Aligned With Hex Mount

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-- Pretension the toothed belt tensioning roller from the -3-'o' clock-position- in direction of -arrow- to the point where the tab -1- and the notch -2- are exactly opposite each other.

Fig 15: Identifying Toothed Belt Tensioning Roller With Tab -1- And Notch -2- Held In Position

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-- Hold the toothed belt tensioning roller in this position and tighten the bolt -arrow- -item 12- OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT.

Fig 16: Identifying Toothed Belt Tensioning Roller And Bolt -Arrow-

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-- Tighten the toothed belt drive wheel bolt -1- using the Wrench - Pin Type3036 -item 11- OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT.

Fig 17: Identifying Toothed Belt Drive Sprocket Bolt -1- And 3036

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-- Remove the Crankshaft Holder3242.

Fig 18: Identifying Crankshaft Holder 3242

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-- Install the bolt -arrow- for the "TDC" marking into the upper section of the oil pan. .

Fig 19: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Insert the Crankshaft SocketT40058 guide pins as follows:

Fig 20: Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Fig 21: Identifying TDC With Special Tool Adapter T140058

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CAUTION:

Components could be damaged by the camshaft timing chain jumping off.

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

-- Turn the crankshaft one turn using the Crankshaft SocketT40058.

-- Check the toothed belt tension:

Fig 22: Identifying Tab -1- Aligned With Notch -2-

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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.

Tightening specifications. Refer to OVERVIEW - HIGH PRESSURE PUMP TOOTHED BELT