High Pressure Fuel Pump Toothed Belt
High Pressure Fuel Pump Toothed Belt
Special tools, testers and auxiliary items required
• Retainer (3036)
• Crankshaft Holder (3242)
• Puller (T10320)
• Socket (T40058)
• Locking Tool (T40135)
Removing
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Tilt the toothed belt guard forward - arrows - and disengage the pins on the underside of the guard.
• The toothed belt guard is shown with the upper intake manifold removed.
A used toothed belt could be destroyed if the running direction is reversed.
Before removing the toothed belt, mark the running direction with chalk or a felt-tip pen for reinstallation later.
- Remove the noise insulation.
- Set the engine to Top Dead Center (TDC):
• To prevent engine oil from leaking out, place a cloth under the upper oil pan.
- Remove the plug - arrow - from the upper oil pan.
Risk of injury when touching the TDC hole with finger.
• Do not rotate the crankshaft - 1 -.
- Install the crankshaft holder (3242) in the hole and tighten it to 20 Nm. Turn the crankshaft back slightly to completely center the holder, if necessary.
- Use the locking tool (T40135) to secure the high pressure pump toothed belt sprocket.
- Loosen the bolt - 1 - for the toothed belt tensioner one turn. Ignore - 2 -.
- Loosen the toothed belt pulley bolt - 1 - 2 turns using the retainer (3036).
- Remove the toothed belt pulley using the puller (T10320).
• The toothed belt sprocket remains on the camshaft.
- First, remove the toothed belt from the toothed belt pulley and then from the sprocket.
Installing
Install in the reverse order of removal. Note the following:
- Assemble the adapter (T40058) as follows:
• The large diameter - arrow 1 - faces the engine.
• The small diameter - arrow 2 - faces the adapter.
Components could be destroyed by the camshaft timing chains jumping off.
• Rotate the crankshaft only in engine rotation direction - arrow -.
- Use the adapter (T40058) to rotate the crankshaft to TDC.
• As shown in the illustration, the mark - arrow - must be vertical on the center of the vibration damper.
- Remove the plug - arrow - behind the right cylinder head.
• To provide a better illustration, the installed position is shown with the engine removed and from behind.
- Check to see if the groove - arrow - in the camshaft flange can be seen through the plug hole - 1 -.
- Shine a small flashlight in the plug hole to see.
• The camshaft flange is shown without a chain drive and without the timing chain guard to make the illustration better.
- Rotate the crankshaft 360 degrees in engine rotation direction if the groove is not under the hole.
• To collect leaking engine oil, place a clean cloth under the upper oil pan.
- Remove the plug - arrow - from the upper oil pan.
Risk of injury when touching the TDC hole with finger.
• Do not rotate the crankshaft - 1 -.
- Install the crankshaft holder (3242) in the hole and tighten it to 20 Nm. Turn the crankshaft back slightly to completely center the bolt, if necessary.
• The high pressure pump and its toothed belt sprocket must be installed securely before installing the toothed belt.
- Check the installed position of the toothed belt tensioner:
• The claw - arrow 2 - must fit into the recess in the high pressure pump bracket.
• The tensioner must be relieved of tension and the hex mount - arrow 1 - faces downward.
- Install the toothed belt.
- Install the toothed belt tensioner bolt - 1 - without using force until the eccentric pulley for the tensioner can be turned without tilting.
- Install the toothed belt pulley bolt - 2 - far enough until the pulley can be turned without tilting.
- Secure the high pressure pump toothed belt sprocket using the locking tool (T40135).
- Continue to tension the toothed belt tensioner in the - direction of the arrow - with the hex wrench until the hex mount is in the 1 o'clock position - arrow -.
Never remove while in the 12 o'clock position or above.
- Release the toothed belt tensioner to the point where the hex mount is in the 3 o'clock position.
- Tension the toothed belt tensioner from the 3 o'clock position - arrow - to the point where the tab - 1 - and the notch - 2 - are exactly opposite each other.
- Hold the toothed belt tensioner in this position and tighten the bolt - arrow - to specifications, see - item 12 - in the => [ High Pressure Pump Toothed Belt Overview ] High Pressure Pump Toothed Belt Overview.
- Tighten the toothed belt pulley bolt - 1 - using the retainer (3036) to specification, see - item 11 - in the => [ High Pressure Pump Toothed Belt Overview ] High Pressure Pump Toothed Belt Overview.
- Remove the crankshaft holder (3242).
- Install the plug - arrow - for the TDC mark into the upper oil pan.
- Assemble the adapter (T40058) as follows:
• The large diameter - arrow 1 - faces the engine.
• The small diameter - arrow 2 - faces the adapter.
Components could be destroyed by the camshaft timing chain jumping off.
• Rotate the crankshaft only in engine rotation direction - arrow -.
- Rotate the crankshaft one turn using the adapter (T40058).
- Check the toothed belt tension:
• The tab - 1 - must align with the notch - 2 -.
- If this is not reached, adjust the toothed belt tension one more time.
Further installation is performed in the reverse order.
• Tightening specifications, refer to => [ High Pressure Pump Toothed Belt Overview ] High Pressure Pump Toothed Belt Overview.