Toothed Belt, Removing And Installing, Vehicles Without Adjustable Exhaust Camshaft: Installing

-- Check the "TDC" position of the camshaft and crankshaft.

• Attach the : T10494  to the camshaft housing.
  Fig 1: Identifying Camshaft Lock

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• : T10340  installed all the way into the cylinder block and tightened to 30 Nm.
  Fig 2: Identifying Crankshaft Locking Pin - T10340-

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• Crankshaft in direction of engine rotation touching the : T10340  = "TDC" position.

-- Replace the bolts -1 and 2- for the camshaft sprockets and install them loosely.

• The camshaft sprockets must still turn on the camshafts and may not tip.

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

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• Mount the crankshaft toothed belt sprocket on the crankshaft.
  Fig 4: Identifying Milled Surface On Crankshaft Toothed Belt Gear

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• The contact surface between the ribbed belt pulley and the crankshaft toothed belt sprocket must not have any oil or grease on it.
• The milled surface -arrow- on the crankshaft toothed belt sprocket must fit on the milled surface on the crankcase pin.

Toothed Belt Bending Radius 

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There is a risk of destroying a used toothed belt if the running direction is reversed.

The toothed belt is made out of a fiberglass cord webbing.

The bending radius -r- on the toothed belt -2- must not exceed 25 mm.

Otherwise the service life of the toothed belt would be impaired.

-- Install the toothed belt -1- on the crankshaft toothed belt sprocket -2- from underneath.

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

-- Install the vibration damper. Refer to Installing .

Follow the Sequence When Installing the Toothed Belt

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-- Pull the toothed belt upward and route it over the idler roller -1-, the tensioning roller -2- and the camshaft sprockets -3 and 4-.

-- Adjust the valve timing. Refer to VALVE TIMING, ADJUSTING .

Further assembly is performed in reverse order.

Tightening Specifications 

• Refer to OVERVIEW - RIBBED BELT DRIVE
• Refer to OVERVIEW - TOOTHED BELT GUARD 
• Refer to OVERVIEW - TOOTHED BELT 
• Refer to Figure
• Refer to OVERVIEW - CAMSHAFT HOUSING 
• Refer to OVERVIEW - TURBOCHARGER
• Refer to OVERVIEW - CHARGE AIR SYSTEM
• Overview - Noise Insulation. Refer to OVERVIEW - NOISE INSULATION .