Removing/installing a timing belt

AR05.00-S-7601CE

Removing/installing a timing belt

18.04.2019

Engine

608 in model 415

1

Toothed belt

4

Cylinder head

7

Screw

2

Tensioner pulley

5

Gear

8

Bolts

2a

Eccentric plate

6

Key

9

Gear

3

Screw

10

Screw plug

 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. 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Notes on evaluating leakages

AH00.00-N-0011-01A



Remove

1

Check basic position of camshaft.

AR05.20-S-6035CE

 Tools for locking camshaft and crankshaft remain installed.

2

Remove lower toothed belt cover.

AR05.10-S-7605CE

3

Remove retaining lock at ring gear.

 Retaining lock

*607589014000

4

Release screw (3) of tensioner pulley (2).

5

Release tension of toothed belt (1) by turning eccentric plate (2a) of tensioner pulley (2) clockwise.

6

Remove toothed belt (1).

7

Remove tensioner pulley (2).

 Dispose of tensioner pulley (2) and screw (3).

8

Remove coolant pump.

If the coolant pump is damaged or the toothed belt (1) is replaced.

AR20.10-S-1271CE



Check

9

Check radial shaft sealing ring of crankshaft for leaks.

Depending on the findings,



Replace radial shaft sealing ring for crankshaft.

AR03.20-S-3000CD

10

Check radial shaft sealing ring of camshaft for leaks.

Depending on the findings,



Replace radial shaft sealing ring for camshaft.

AR05.20-S-7000CE



Install

11

Install new coolant pump.

If coolant pump was removed.

AR20.10-S-1271CE

12

Install new tensioner pulley (2) with new screw (3).

 Manually slightly tighten screw (3).
Ensure tensioner pulley (2) is correctly seated in groove (arrow A) at cylinder head (4).

If necessary



Correct seat of tensioner pulley (2) in groove (arrow A).



Check

13

Check position of the crankshaft.

 Marking (arrow B) at gearwheel (5) must point vertically downwards and key (6) at crankshaft must point vertically upwards.

If position of crankshaft is incorrect



Correct position of crankshaft.

14

Remove screw (7) of gearwheel (9).

15

Release screws (8) of gearwheel (9) until gearwheel (9) can be turned.

16

Mount and tension new toothed belt (1).

AR05.10-S-7700-02CD

 Observe markings (arrows C, D) during mounting of toothed belt (1).

 Bolt, tensioner pulley for toothed belt to crankcase

*BA05.10-N-1001-01I

 Bolt, camshaft sprocket to driver

*BA05.20-N-1003-02B

 Drift catch

*607589011500

 Retaining lock

*607589014000

 Drift

*608589001500

17

Check basic position of camshaft again.

AR05.20-S-6035CE

 Do not yet install retaining plate and upper toothed belt cover.

If basic position of camshaft is incorrect



Remove and remount toothed belt (1).

Lay on the timing chain

AR05.10-S-7700-02CD

 Bolt, tensioner pulley for toothed belt to crankcase

*BA05.10-N-1001-01I

 Bolt, camshaft sprocket to driver

*BA05.20-N-1003-02B

 Drift catch

*607589011500

 Retaining lock

*607589014000

 Drift

*608589001500

18

Install both toothed belt covers.

AR05.10-S-7605CE

 Do not install the belt pulley yet.

19

Install retaining lock at ring gear.

 Retaining lock

*607589014000

20

Change washer of center bolt.

21

Install the belt pulley.

AR03.30-S-1700CE

 Only perform steps for installation of belt pulley.

22

Remove retaining lock at ring gear.

 Retaining lock

*607589014000

23

Screw in screw plug (10).

 Screw plug to crankcase

*BA01.40-N-1001-01W

24

Install starter.

AR15.30-S-7100CE

25

Install poly-V-belt.

AR13.22-S-1202CD



Check

 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

26

Perform engine test run.

 Crankcase, timing case cover, end cover

Number

Designation

Engine 608 in model 415

BA01.40-N-1001-01W

Screw plug to crankcase

Nm

25

 Timing chain drive, toothed belt drive

Number

Designation

Model 415 with engine 607, 608

BA05.10-N-1001-01I

Bolt, tensioner pulley for toothed belt to crankcase

Nm

27

 Camshaft, camshaft adjustment

Number

Designation

Engine 607, 608 in model 415

BA05.20-N-1003-02B

Bolt, camshaft sprocket to driver

Nm

14