High Pressure Pump Toothed Belt
High Pressure Pump Toothed Belt
Special tools, testers and auxiliary items required
• Retainer (3036)
• Crankshaft Holder (3242)
• Puller (T10320)
• Socket (T40058)
• Locking Tool (T40135) for adjusting the high pressure pump.
Removing
- Remove engine cover. Refer to => [ Engine Cover ] Service and Repair.
- Tilt the toothed belt guard forward - arrows - and disengage the pins on the bottom side of the guard.
• The toothed belt guard is shown with the intake manifold upper section removed.
A used toothed belt could be destroyed if the running direction is reversed.
Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for installation later.
- Loosen the toothed belt tensioning roller bolts - arrow - 2 turn.
- Loosen the toothed belt drive sprocket bolt - 1 - 2 turns using the (3036).
- Remove the toothed belt drive sprocket using the (T10320).
• The toothed belt drive sprocket remains on the camshaft.
- First remove the toothed belt from the high pressure pump sprocket and then from the drive sprocket.
Installing
Install in reverse order, paying attention to the following:
- Remove noise insulation.
- Insert the (T40058) guide pins 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.
• Turn the crankshaft only in direction of engine rotation - arrow -.
- Use the (T40058) to rotate the crankshaft to "TDC".
• As shown in the illustration, the marking - arrow - must be vertical on the center of the crankshaft.
- Remove the air guide hose.
- Remove the plug - arrow - behind the right cylinder head.
• To provide a better illustration, installed position is shown with the engine removed from behind.
- Check to see if the groove - arrow - in the camshaft flange can be seen through the sealing plug hole - 1 -.
- Shine a small flashlight in the sealing plug hole to see.
• The camshaft flange is shown without chain drive and without timing chain guard to make the illustration better.
- Turn the crankshaft 360 degrees in the direction of engine rotation if the groove is not under the hole.
• To collect escaping engine oil, place a clean cloth under the upper section of the oil pan.
- Remove the sealing plug - arrow - from the upper section of the oil pan.
Risk of injury when touching Top Dead Center (TDC) hole with finger.
• Do not rotate crankshaft - 1 -.
- Install the (3242) in the hole and tighten to 20 Nm. Turn the crankshaft back slightly to completely center the bolt, if necessary.
• The high pressure pump and its toothed belt gear must be installed securely before installing the toothed belt.
- Stop the high pressure pump toothed belt wheel with the (T40135).
• Stop the high pressure pump toothed belt using the (T40135) before installing the toothed belt. (Do not allow the toothed belt to swing!)
• The hole - arrow in the toothed belt sprocket - is situated at the - 3 o'clock position -.
• Insert the (T40135) all the way in.
- Check the installation position of the toothed belt tensioning roller:
• The claw - arrow 2 - must fit into the recess in the high pressure pump bracket.
• The tension roller must be relieved of tension and the hex mount - arrow 1 - faces downward.
- Install the toothed belt.
- Install the toothed belt tension roller bolt - 1 - without using force until the eccentric pulley for the tensioning roller can be turned without tipping.
- Install the toothed belt drive sprocket bolt - 2 - far enough until the sprocket can be turned without tilting.
- Stop the high pressure pump toothed belt wheel with the (T40135).
- Continue to tension the toothed belt tensioning roller in the direction of the - arrow - with the hex socket wrench until the hex mount is in the - 1 o'clock position -.
Never remove while in the "12 o'clock position" or above.
- Release - arrow - the toothed belt tensioning roller to the point where the hex mount is in the - 3 o'clock position -.
- Pretension the toothed belt tensioning roller 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 tensioning roller in this position and tighten the bolt - arrow - - item 12 - => [ (Item 12) Bolt ] Service and Repair.
- Tighten the toothed belt drive wheel bolt - 1 - using the (3036) - item 11 - => [ (Item 11) Bolt ] Service and Repair.
- Remove the (3242).
- Install the bolt - arrow - for the TDC marking into the upper section of the oil pan.
- Insert the (T40058) guide the pins 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.
• Turn the crankshaft only in direction of engine rotation - arrow -.
- Turn the crankshaft one turn using the (T40058).
- Check the toothed belt tension:
• The tab - 1 - must align with the notch - 2 -.
- If the specified value is not reached, adjust the toothed belt tension one more time.
Assembly is performed in reverse order.
• Tightening specifications: High pressure pump toothed belt assembly overview, refer to => [ High Pressure Pump Toothed Belt Overview ] Service and Repair.