Toothed Belt, Removing And Installing: Notes

Special tools and workshop equipment required 

• Counterhold - Camshaft Gear: T10051 
  Fig 1: Identifying Counterhold - Camshaft Gear

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• Counterhold - Multiple Use: T10172A  with Camshaft Lock: T10172/11 
  Fig 2: Counterhold - Kit - Multiple Use T10172

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• Wrench - Tensioning Roller: T10264 
  Fig 3: Identifying Wrench - Tensioning Roller T10264

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• Locking Pin: T10492 
  Fig 4: Identifying Locking Pin

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• Crankshaft Lock: T10490 
  Fig 5: Identifying Crankshaft Lock T10490

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• Diesel Injection Pump Locking Pin: 3359 
  Fig 6: Diesel Injection Pump Locking Pin 3359

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• Tensioning Roller Locking Tool: T10265 
  Fig 7: Identifying Tensioning Roller Locking Tool T10265

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Removing 

-- Remove the engine support. Refer to ENGINE SUPPORT, REMOVING AND INSTALLING .

-- Remove the upper toothed belt guard. Refer to UPPER TOOTHED BELT GUARD, REMOVING AND INSTALLING .

-- Remove the lower toothed belt guard. Refer to LOWER TOOTHED BELT GUARD, REMOVING AND INSTALLING .

• Only turn the crankshaft in the direction of engine rotation.

-- Turn the crankshaft at the crankshaft toothed belt sprocket bolt until the camshaft toothed belt sprocket is at "TDC".

-- Secure the camshaft hub with the Diesel Injection Pump Locking Pin: 3359  by inserting the pin into the fork on the drive plate -2- and into the hole behind it -1- in the cylinder head.

-- Remove the locating bolt -1- and install a new camshaft locking pin until it contacts, in the center position in the oblong hole -2-.

-- Secure the crankshaft toothed belt sprocket with the Crankshaft Lock: T10490  .

• The pins on the Crankshaft Lock: T10490  must engage in the threaded holes on the toothed belt sprocket.
• The pin on the Crankshaft Lock: T10490  must engage in the hole on the sealing flange.

-- Pull the pin and loosen the camshaft bolt. Before completely loosening, replace the pin.

-- Loosen the bolt -arrow- for the camshaft toothed belt sprocket by using the Counterhold - Multiple Use: T10172A  with Camshaft Lock: T10172/11  .

-- Secure the high pressure pump hub using the Locking Pin: T10492  -3- by inserting the pin into the fork -2- on the hub and into the hole behind it -1- in the sub-assembly bracket.

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-- Pull the pin and loosen the high pressure pump toothed belt sprocket nut. Before completely loosening, replace the pin.

-- Loosen the nut -arrow- for the high pressure pump toothed belt sprocket approximately 90° using the Counterhold - Camshaft Gear: T10051  -A-.

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-- Loosen the nut -1- for the tensioning roller.

-- Turn the tensioning roller eccentric pulley counter-clockwise using the Wrench - Tensioning Roller: T10264  -arrow- until the roller can be secured with the Tensioning Roller Locking Tool: T10265  .

-- Then turn the tensioning roller eccentric pulley clockwise all the way using the Wrench - Tensioning Roller: T10264  -arrow- and tighten the nut -1- by hand.

-- Remove the toothed belt first from the coolant pump and then from the remaining toothed belt gears.