Removing/installing a timing belt

AR05.00-P-7601MFE

Removing/installing a timing belt

22.01.2020

Engine

608 in model 118, 177, 247

01

Cylinder head

3

Key

5

High pressure pump wheel

1

Toothed belt

4

Camshaft sprocket

6

High pressure pump

2

Crankshaft gear

4s

Screw

7

Tensioner pulley

2m

Marking

4t

Bolts

7s

Screw

8

Cover bolt

 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



Remove

1

Check basic position of camshafts.

AR05.20-P-6010MFE

2

Remove center bolt of the crankshaft and remove belt pulley from crankshaft.

AR03.30-P-1600MFE

3

Mark position of the rectangular marking of the high pressure pump wheel (5) on the housing of the high-pressure pump (6) in color.

4

Loosen screw (7 s) of the tensioner pulley (7).

5

Slacken toothed belt (1) by twisting the eccentric plate of the tensioner pulley (7) clockwise.

6

Remove toothed belt (1).

7

Remove tensioner pulley (7) of the toothed belt (1).

8

Remove coolant pump.

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

AR20.10-P-1271MFE



Check

9

Check radial shaft sealing ring of the crankshaft for leakage.

If there is a problem,



Replace radial shaft sealing ring for crankshaft.

AR03.20-P-3004MFE

10

Check radial shaft sealing ring of the camshaft for leakage.

If there is a problem,



Replace radial shaft sealing ring for camshaft.

AR05.20-P-7000MFE



Install

11

Install coolant pump.

If the coolant pump has been removed.

AR20.10-P-1271MFE

12

Install tensioner pulley (7) of the toothed belt (1) with screw (7 s) on cylinder head (01).

 Install new tensioner pulley (7) and screw (7 s).

 Ensure that the retaining lug of the tensioner pulley (7) is seated correctly in the groove in the cylinder head (01).

 Bolt, tensioner pulley to cylinder head

*BA05.10-P-1001-03C

13

Check position of the rectangular marking on the high pressure pump wheel (5) relative to the marking on the housing of the high-pressure pump (6); correct if necessary.

14

Check position of the crankshaft.

If necessary.

 When the crankshaft is positioned correctly:
- The marking (2 m) on the crankshaft gear (2) points vertically downward.
- The feather key (3) on the crankshaft points vertically toward the top.

15

Remove bottom screw (4 s) from camshaft sprocket (4).

16

Loosen screws (4 t) from camshaft sprocket (4) until the camshaft sprocket (4) can be twisted against the camshaft.

17

Fit toothed belt (1) and tension.

AR05.10-P-7700-02ORA


Check toothed belt tension at ignition TDC of the first cylinder on the side delivering power.
Engine damage can occur otherwise.

 Install new toothed belt (1).

 Bolt, tensioner pulley to cylinder head

*BA05.10-P-1001-03C

 Bolt, camshaft sprocket to driver

*BA05.20-P-1003-01O

 Drift

*608589001500

 Drift catch

*607589011500

18

Check basic position of camshafts.

AR05.20-P-6010MFE


Check toothed belt tension at ignition TDC of the first cylinder on the side delivering power.
Engine damage can occur otherwise.

If the basic position of the camshaft is not correct,



remove toothed belt (1) and reposition.

AR05.10-P-7700-02ORA

 Bolt, tensioner pulley to cylinder head

*BA05.10-P-1001-03C

 Bolt, camshaft sprocket to driver

*BA05.20-P-1003-01O

 Drift

*608589001500

 Drift catch

*607589011500

19

Install engine carrier on cylinder head (01).

 Screw/bolt, engine support to cylinder head

*BA22.10-P-1001-02F

20

Install toothed belt covers.

AR05.10-P-7605MFE

21

Install right engine mount.

AR22.10-P-1102MFE

22

Change washer of center bolt.

23

Place belt pulley on crankshaft, screw down center bolt and tighten.

AR03.30-P-1600MFE

 Install new center bolt.

24

Remove engine support fixture from engine.

AR01.10-P-0107MFA

25

Tighten cover bolt (8) in crankcase.

 Cover screw to crankcase

*BA01.40-P-1002-03C

26

Install poly-V-belt.

AR13.22-P-1202MFE

27

Install fender liner in right front fender.

AR88.10-P-1301MFA

28

Install lower engine compartment paneling.

AR61.20-P-1105MFE

29

Clip in coolant line on engine mount.

30

Install coolant expansion reservoir.

AR20.30-P-4949MFE

31

Connect ground line of on-board electrical system battery (G1).

AR54.10-P-0003MFA



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

 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

32

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

33

Install upper engine cover.



AP01.10-P-2405-01B

 Crankcase, timing case cover, end cover

Number

Designation

Engine 608

BA01.40-P-1002-03C

Cover screw to crankcase

Nm

25

 Chain drive, belt drive

Number

Designation

Engine 608

BA05.10-P-1001-03C

Bolt, tensioner pulley to cylinder head

M8

Nm

27

 Camshaft

Number

Designation

Engine 608

BA05.20-P-1003-01O

Bolt, camshaft sprocket to driver

Nm

14

 Engine support (engine side)

Number

Designation

Engine 608

BA22.10-P-1001-02F

Screw/bolt, engine support to cylinder head

M8

Nm

20