Installing (Adjusting Valve Timing)

• Tensioning roller is secured with the Tensioning Roller Locking Tool: T10265  and fastened to the right stop with the nut -1-.
  Fig 1: Identifying Long Reach T10264 And Locking Tool T10265

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• The metal tab -arrow- on the tensioning roller must fit into the cast recess from the cylinder head.
  Fig 2: Identifying Metal Tab

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• Secure the camshaft hub with the Diesel Injection Pump Locking Pin: 3359  .
  Fig 3: Identifying Diesel Injection Pump Locking Pin

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

• Loosen the bolt -1- half a turn in the center position in the oblong hole -2-.
  Fig 4: Identifying Crankshaft Holder

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• Crankshaft is secured with the Crankshaft Lock: T10490  .
  Fig 5: Identifying Crankshaft Lock T10490

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• High pressure pump hub is secured with the Locking Pin: T10492  .
  Fig 6: Identifying Locking Pin

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

-- Turn the camshaft toothed belt sprocket and the high pressure pump toothed belt sprocket all the way clockwise in their oblong holes.

Fig 7: Drive Belt Routing (Toothed Belt)

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-- Mount the toothed belt in the sequence given:

1. Crankshaft Toothed Belt Sprocket
2. Tensioning Roller
3. Camshaft Toothed Belt Sprocket
4. High Pressure Pump Toothed Belt Sprocket
5. Coolant Pump Toothed Belt Sprocket

-- Loosen the tensioning roller nut -1- and remove the Tensioning Roller Locking Tool: T10265  .

Fig 8: Identifying Wrench - Tensioning Roller T10264 And Tensioning Roller Locking Tool T10265

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• Tensioning roller metal tab must fit into the cast recess of the cylinder head.
  Fig 9: Identifying Metal Tab

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• The crankshaft holder -1- must not come into contact with the oblong hole upper stop after tensioning the toothed belt.
  Fig 10: Identifying Crankshaft Holder

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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 -arrow- using the Wrench - Tensioning Roller: T10264  until the indicator -2- is located centrally in the gap of the base plate.

Fig 11: Identifying Wrench - Tensioning Roller T10264

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• The nut -1- must not turn with it.

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

-- Position the Counterhold - Multiple Use: T10172A  on the camshaft toothed belt sprocket with the Camshaft Lock: T10172/11  as shown.

Fig 12: Identifying Bolts

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-- Push the counterholder counter-clockwise -arrow- and hold at pretension.

-- In this position, tighten the bolt -1- for the camshaft toothed belt sprocket and the nut -2- for the high pressure pump toothed belt sprocket to 20 Nm.

-- 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 pin. If necessary adjust the position of the high pressure pump sprocket one tooth clockwise and install the toothed belt again.

Fig 13: Identifying Locking Pin T10492

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-- Remove the Diesel Injection Pump Locking Pin: 3359  , Locking Pin: T10492  and Crankshaft lock: T10490  and check the valve timing. Refer to Valve Timing, Checking: .