Toothed belt drive – assembly overview and fastening

• 1 Toothed belt
  • Mark direction of rotation before removing
  • Check for wear
  • Do not kink
  • Removing, installing and tensioning ⇒ 2.1.1 Removing and installing engine bracket.
• 2 120 Nm + 90° further
  • Renew
  • Use counterhold - 3415 - to loosen and tighten.
  • Do not additionally oil or grease the threads and shoulder
• 3 Crankshaft pulley
• 4 20 Nm
• 5 Lower idler roller

• 6 20 Nm + 45° further
• 7 Tensioning pulley
  • Remove engine bracket to remove and install ⇒ 2.1 Assembly overview - toothed belt drive.

• 8 25 Nm
• 9 Camshaft sprocket
• 10 15 Nm
• 11 100 Nm
• 12 Hub
  • Use counterhold - T10051- to loosen and tighten.
  • To remove, use puller - T10052-.
  • Removing and installing ⇒ 3.5 Removing and installing camshafts
• 13 Rear toothed belt guard
• 14 20 Nm + 90° further
• 15 10 Nm
  • Renew
• 16 Upper idler roller
• 17 50 Nm + 90° further
• 18 Hub
  • Use counterhold - T10051- to loosen and tighten.
  • To remove, use puller - T40064-.
  • Removing and installing ⇒ 4.1 Assembly overview - high-pressure pump
• 19 95 Nm
• 20 Toothed belt pulley on high-pressure pump
• 21 20 Nm
• 22 Coolant pump
  • Removing and installing ⇒ 2.2 Removing and installing 4/2-way valve with thermostat
• 23 15 Nm
• 24 Toothed belt guard upper part
• 25 Toothed belt guard lower part
• 26 10 Nm
  • Renew
• 27 10 Nm + 90° further
  • Renew
• 28 Belt pulley and vibration damper
  • Can only be installed in one position, holes are offset.
• 29 5 Nm
• 30 Protective plate
• 31 40 Nm + 180° further
  • Renew
  • Observe tightening sequence ⇒ 2.1.1 Removing and installing engine bracket
• 32 Engine support
  • Removing and installing ⇒ 2.1 Assembly overview - toothed belt drive

Lower toothed belt guard

• Tighten bolts -arrows- to 9 Nm.

2.1.1 Removing and installing engine bracket

Special tools and workshop equipment required

• Support - 10-222 A-
• Adapter - 10 - 222 A /8-
• Hook - 10-222 A/10-
• Shackle - 10-222 A/12-

• Adapter - 10-222 A/18-

At a later point, support bracket - 10-222 A- will be fitted onto longitudinal members with adapters - 10 - 222 A /8-.

To prevent damage to edges of wings, cover lower areas of both adapters - 10 - 222 A /8- with duct tape -arrow- ⇒ Electronic parts catalogue (ETKA, chemical substances).

»Carry out the following work sequence«

Removing

• Remove engine cover panel ⇒ 3 Engine cover panel.
• Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50; Body - front; Assembly overview - noise insulation.

• Remove upper and lower brackets for particulate filter.

• Removing and installing charge air pipe »cold« side ⇒ 2.3.2 Removing and installing charge air pipe »hot« side.
• Unclip hoses from coolant expansion tank.
• Pull connector off coolant expansion tank.

• Pull connector off pressure differential sender - G505 - -1-.
• Loosen coolant expansion tank.
• Lay coolant expansion tank, pressure differential sender - G505- and fuel filter with lines aside.

• Fit support bracket - 10 - 222 A- with the necessary adapters as shown and take up weight of engine in installation position.

• Unscrew securing bolts -arrows-.
• Remove entire engine mounting upwards.

• Unscrew securing bolts of engine bracket in sequence -3…1-.
• Remove engine bracket out upwards.

Installing

Prescribed torque and tightening sequence for assembly mounting ⇒ 2 Assembly mountings

Install in reverse order. During this procedure, observe the following:

• Insert engine bracket from above.
• First, tighten new securing bolts hand-tight in sequence -1 … 3-.

Tightening sequence for engine bracket

• Tighten securing bolts in the specified sequence to the prescribed torque.
• Then use the spindle to bring the engine bracket to rest on the engine carrier.

Further assembly is performed in the reverse order of removal.