Toothed Belt, Removing And Installing: Notes

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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.

Fig 8: Identifying Diesel Injection Pump Locking Pin

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

Fig 9: Identifying Crankshaft Holder

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

Fig 10: Identifying Crankshaft Lock T10490

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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.

Fig 11: Identifying Camshaft Toothed Belt Sprocket Bolt

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CAUTION:

There is a risk of damaging the camshaft if handled incorrectly.

- Never use the camshaft positioning tool as a counterholder.

-- 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.

Fig 12: Identifying Nut

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-- 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.

Fig 13: Identifying Wrench - Tensioning Roller T10264 And Tensioning Roller Locking Tool T10265

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CAUTION:

Risk of destroying a used toothed belt by reversing the running direction.

- Mark the running direction before removal.

- Pay attention to the running direction when reinstalling.

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