Installing (Adjusting Valve Timing)

• The tensioning roller must be secured with the : T10265  and fasten to the right stop with the nut -1-.

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• The metal tab -arrow- on the tensioning roller must fit into the cast depression in the cylinder head.

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• Secure the camshaft hub with the :3359  .

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• Bolt loosely installed.
• It must still be possible to rotate the camshaft toothed belt gear and it must not tip.

• Loosen the carrier bolt -1- half a turn in the center position in the oblong hole -2-.

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• Secure crankshaft using the :T10490  .

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• Secure the hub on the high pressure pump with the :T10492  .

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• Nut loosely installed.
• It must still be possible to rotate the high pressure pump toothed belt gear and it must not tip.

-- Turn the camshaft toothed belt gear and the high pressure pump toothed belt gear all the way clockwise by the oblong holes.

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-- Mount the toothed belt in the following sequence:

1. Crankshafts - toothed belt gear
2. Tensioning roller
3. Camshaft toothed belt gear
4. Toothed belt sprocket for the high pressure pump
5. Coolant pump toothed belt gear

-- Loosen the nut -1- on the tensioning roller and remove the :T10265  .

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• Tensioning roller metal tab must fit into the cast recess of the cylinder head.

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• The crankshaft holder -1- must not come into contact with the oblong hole upper stop after tensioning the toothed belt.

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-- Check if the crankshaft holder -1- is between the center oblong hole and the lower stop -2-. If necessary adjust the position of the camshaft sprocket one tooth clockwise and install the toothed belt again.

-- Carefully turn the tensioning roller eccentric pulley clockwise in direction of -arrow- with the :T10264  until the indicator is located centrally in the gap of the base plate -2-.

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• The nut -1- must not turn with it.

-- Hold the tensioning roller in this position and tighten the nut.

-- Mount the :T10172A  with the :T10172/11  on the camshaft toothed belt sprocket as illustrated.

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-- Press the counterhold tool counter-clockwise -arrow- and hold it at pre-load.

-- Tighten the bolts -1- for the camshaft toothed belt gear and the nuts -2- for the high pressure pump toothed belt gear to 20 Nm in this position.

-- Check after tensioning that the toothed belt sprocket is not on the >>stop<< of the range of rotation.

-- Make sure that the high pressure pump toothed belt sprocket is not aligned with the locking pin. If necessary adjust the position of the camshaft sprocket one tooth clockwise and install the toothed belt again.

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-- Remove the :3359  , :T10492  and the :T10490  and check the valve timing. Refer to TOOTHED BELT, REMOVING FROM CAMSHAFT .

Check Valve Timing 

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

-- Turn the crankshaft by the toothed belt pulley bolt 2 turns in the direction of engine rotation until the crankshaft is once again just before "TDC".

-- Mount the :T10490  on the crankshaft toothed belt gear.

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-- Turn the crankshaft in direction of engine rotation, until the tip -arrow- on the crankshaft stop fits into the sealing flange.

• If the crankshaft was turned past "TDC" : Turn the crankshaft again two turns until it is just in front of "TDC". Then secure the crankshaft from moving using the : T10490  .

• It must be possible to secure the camshaft hub with the :3359  .

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• It is very difficult to find the locking point on the high pressure pump hub. A small deviation -arrow- does not affect engine operation.

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• The pointer on the tensioning roller -2- must be in the middle between the tabs -1 and 3- on the plate.

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• Permissible lateral offset: maximum 5 mm.

If the conditions are met, then continue with the correct valve timing. Refer to TOOTHED BELT, REMOVING FROM CAMSHAFT .

If the conditions are not met, correct the valve timing. Refer to TOOTHED BELT, REMOVING FROM CAMSHAFT .