Removing/installing a timing belt

AR05.00-P-7601ORA

Removing/installing a timing belt

04.10.2018

Engine

607 in model 117, 156, 176, 246

Modification notes

08.08.2018

Operation incorporated

Step 9

08.08.2018

Condition added

Operation step 8, 12

07

High pressure pump

1o

Upper section of upper toothed belt cover

1u

Lower section of upper toothed belt cover

2

Lower toothed belt cover

3

Center bolt

4

Washer

5

Belt pulley

01

Cylinder head

07

High pressure pump

07R

High pressure pump wheel

6

Crankshaft gear

8

Camshaft sprocket

8s

Screw

8Z

Bolts

9

Tensioner pulley

9H

Retaining lug

9s

Screw

10

Toothed belt

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Warning

Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension

Use only approved tensioning devices; additionally screen off hazardous area if necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves.

AS00.00-Z-0001-01A

 Warning

Risk of injury. Moving parts can pinch, crush or, in extreme cases even sever extremities.

No parts of the body or limbs should be within the operating area of mechanical components when moving components.

AS00.00-Z-0009-01A

 Warning

Risk of injury due to fan starting unexpectedly

Do not reach into the rotation or hazard area of the fan. Wear closed and close-fitting work clothes.

AS20.40-Z-0001-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A



Remove

1

Set timings on engine; to do this, block the camshaft and crankshaft with the locking bolts.

AR05.20-P-6020ORA

 Turn crankshaft without any jerky movements in direction of engine rotation until the crankshaft touches the lock pin.

2

Remove center bolt (3) of the crankshaft and remove belt pulley (5) from the crankshaft.

AR03.30-P-1600MT

 Replace center bolts (3) every time they are removed.

3

Mark position of the quadratic marking on the high pressure pump wheel (07R) relative to the housing of the high-pressure pump (07) on the housing of the high-pressure pump (07) in color (see arrow).

4

Loosen screw (9s) of the tensioner pulley (9).

 Replace bolts (9s) every time they are removed.

5

Slacken toothed belt (10) by turning the eccentric plate of the tensioner pulley (9) clockwise.

6

Remove toothed belt (10).

7

Remove tensioner pulley (9) of the toothed belt (10).

 Always install new tensioner pulley (9) and toothed belt (10) in combination.

8

Remove coolant pump.

If the coolant pump is damaged or a new toothed belt (10) is installed.

AR20.10-P-1271ORA



Check

9

Check toothed belt (10) for soiling and damage.

If the toothed belt (10) exhibits soiling due to oil, coolant, or damage,



replace toothed belt (10) with tensioner pulley (9).

10

Check radial shaft sealing ring of the crankshaft for leakage.

If a leakage can be detected,



Replace radial shaft sealing ring for crankshaft.

AR03.20-P-3000ORA

11

Check radial shaft sealing ring of the camshaft for leakage.

If a leakage can be detected,



Replace radial shaft sealing ring for camshaft.

AR05.20-P-7000ORA



Install

12

Install coolant pump.

If the coolant pump was removed.

AR20.10-P-1271ORA

13

Install tensioner pulley (9) of the toothed belt (10) with screw (9s) on cylinder head (01).

 Ensure that the retaining lug (9H) of the tensioner pulley (9) sits correctly in the groove in cylinder head (01).

14

Check position of the quadratic marking on the high pressure pump wheel (07R) relative to the marking (arrow) on the housing of the high-pressure pump (07) and correct if necessary.

15

Check position of the crankshaft.

If required.

 The correct position of the crankshaft can be recognized by the fact that the marking (punch mark, see arrow) on the crankshaft gear (6) is located vertically downwards and the feather key on the crankshaft points vertically upwards.

16

Remove bottom screw (8s) from camshaft sprocket (8).

17

Release screws (8Z) from camshaft sprocket (8).

 Loosen until the camshaft sprocket (8) until the camshaft can be turned against the camshaft.

18

Fit toothed belt (10) and tension.

AR05.10-P-7700-02ORA

 Bolt securing toothed belt tensioning pulley

*BA05.10-P-1002-01S

 Bolt, camshaft sprocket to driver

*BA05.20-P-1003-01O

 Drift

*607589001500

 Drift catch

*607589011500

19

Check basic position of camshafts.

AR05.20-P-6010ORA

20

Install engine carrier.

 Bolt, engine support to cylinder head

*BA22.10-P-1012-01V

21

Install toothed belt coverings (1o, 1u, 2).

AR05.10-P-7605ORA

22

Install right engine mount.

AR22.10-P-1102NKB

23

Change washer (4) of the center bolt (3).

 Install new center bolt (3).

24

Install belt pulley (5) on crankshaft, screw on new center bolt (3) firmly, and tighten.

AR03.30-P-1600MT

25

Remove engine support fixture.

AR33.10-P-0105NKB

26

Tighten cover screw in crankcase.

 Cover bolt to cylinder crankcase

*BA01.40-P-1003-01I

27

Install poly-V-belt.

AR13.20-P-0001ORA

28

Install right front fender liner.

AR88.10-P-1300NKB

29

Install bottom section of soundproofing.

AR94.30-P-5300NKB

30

Install top support.

AR22.10-P-1125NKB

31

Clip in coolant line on top support.

32

Install coolant expansion reservoir.

33

Clip on ground line at on-board electrical system battery (G1).

AR54.10-P-0003NKB

34

Install upper engine cover.

AR01.20-P-5014-02OLB



Check

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

35

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

 Cylinder crankcase, timing case cover, end cover

Number

Designation

Engine 607

BA01.40-P-1003-01I

Cover bolt to cylinder crankcase

Nm

25

 Toothed belt drive

Number

Designation

Engine 607

BA05.10-P-1002-01S

Bolt securing toothed belt tensioning pulley

M8

Nm

27

 Camshaft

Number

Designation

Engine 607

BA05.20-P-1003-01O

Bolt, camshaft sprocket to driver

Nm

14

 Engine suspension, engine mounts, engine supports

Number

Designation

Engine 607 in model 117

Engine 607 in model 156

BA22.10-P-1012-01V

Bolt, engine support to cylinder head

Stage 1

Nm

20

20

Stage 2

°

90

90

 Engine suspension, engine mounts, engine supports

Number

Designation

Engine 607 in model 176, 246

BA22.10-P-1012-01V

Bolt, engine support to cylinder head

Stage 1

Nm

20

Stage 2

°

90