Dismantling the Belt Drive

Dismantling the belt drive

Special tools:
999 5304 SEPARATOR 999 5304 Separator
999 5433 COUNTERHOLD 999 5433 Counterhold
999 5456 COMPRESSION TOOL 999 5456 Compression Tool

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Aligning the engine according to the marking





Install the upper timing belt cover.
Turn crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing belt cover
Remove the upper timing belt cover.

Removing the vibration damper





Remove the 4 screws. Use the crankshaft center nut as a counterhold.
Install counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold and remove the center nut.
Remove counterhold 999 5433.
Work / pull the auxiliaries belt pulley loose.

Removing the timing belt





First remove the upper screw of the tensioner / damping unit and slacken off the lower screw.
Counterhold with TX 55 in the variable valve timing unit center plug and twist the tensioner / damping element so that the piston is freed.

Remove
- the lower screw.
- the tensioner / damping unit.
- the timing belt.

Carefully release the counterhold and allow the variable valve timing to rotate back into place.

Installing the tensioner / damping unit





Check that there is no visible leakage.
Press the tensioner / damping unit together with tool 999 5456 COMPRESSION TOOL 999 5456 Compression Tool.
Position the tensioner / damping unit in the tool and screw the tool center nut to the bottom.
Wait until it is compressed and then install a lock pin in the piston.

Note! If there is leakage or no resistance when compressed or if it cannot be compressed in the tensioner damping unit must be replaced.

Removing the crankshaft pulley





Use puller 999 5304 SEPARATOR 999 5304 Separator and two M10 x 50 mm (1.9 in) screws) with washers.
Pull off the timing gear pulley.

Removing the belt tensioner and idler pulley





Remove the belt tensioner and idler pulley.
Check the rolling surface and the bearings.
Check for any noise. Check for any play in the bearings.
Check that rolling area is smooth and clean.

Removing oil pump





Remove
- the fuel delivery line.
- the belt protector from the oil pump.
- the four oil pump screws.

Carefully work the oil pump out. Use a groove-cut chisel with stop lugs.
Carefully draw the oil pump past the end of the oil pump.
Carefully clean the gasket face and mating surfaces.

Checking the oil pump




Disassemble the oil pump.
Clean and check all components.
Check for damage and wear.
In particular check the half-moon shaped insert (the surface between the suction and pressure sides).
Replace the oil pump in the event of a fault.
Assemble the oil pump.

Removing the coolant pump




Remove the screws.
Carefully tap the pump pulley with a rubber mallet.
Work the pump loose.
Carefully clean the gasket face and mating surfaces.

Removing the thermostat / thermostat housing




Remove the cover over the thermostat (Tx40).
Lift out the thermostat and remove the gasket.
Remove the screw for the engine coolant temperature sensor cable duct.
Remove the thermostat housing from the cylinder head.
Carefully clean the gasket face and mating surfaces.

Checking the opening function of the thermostat

The thermostat can be tested in warm water.
Maximum opening must happen within 2 minutes in water at opening temperature.
Marking.90°C
Begins to open at.90°C
Fully open at.105°C