11 31 110

Removing toothed belt for camshaft drive (M40)

Remove bulkhead heater (air collector). This operation is described in the section on removing complete wiper console, refer to 61 61 270

Drain off and dispose of coolant. Installation: Replace sealing ring. Tightening Torque, refer to Technical Data 11 11 5AZ

Caution! Left-hand threads. Lock belt pulley in position using special tool 11 5 050. Release union nut with special tool 11 5 040 from water pump. Remove fan wheel and fan coupling from water pump and remove together with fan cowl. Removing fan cowl, refer to 17 11 031

Installation: Tightening Torque, refer to Technical Data 11 52 1AZ Note: Tightening Torque 40 Nm when using special tool 11 5 040 is equivalent to 30 Nm on scale of a torque wrench.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Remove water hose from thermostat. Unfasten pulley from water pump and remove alternator drive belt.

Removing distributor cap, refer to 12 11 091 Removing distributor rotor, refer to 12 11 111

Unclip cable duct with ignition leads from the cylinder head cover. Pull off the hose for the engine breather. Unfasten cover screws and remove cylinder head cover.

Installation: Check seal, replace if necessary. Preassemble cylinder head seal on cylinder head. When installing cylinder head cover, make sure that cylinder head cover seal is correctly seated on rear side of cylinder head.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Install cover bolts and align cylinder head cover. Hand-tighten all cover bolts without preload. Tighten cylinder head screws crosswise, starting with inner ones. Tightening Torque, refer to Technical Data 11 12 11AZ

Remove camshaft cover (1).

Remove vibration damper. Installation: The installation position of the vibration damper is secured with a dowel pin. Replace screws. Tightening Torque, refer to Technical Data 11 23 3AZ

Remove lower toothed belt cover.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Remove upper toothed belt cover. Installation: Note dowel sleeves on upper screws.

Turn central screw to rotate crankshaft in normal direction of rotation until piston of first cylinder is at firing TDC. Secure crankshaft in TDC position with special tool 11 2 300. Caution! Remove special tool 11 2 300 before switching on the engine.

Locate camshaft with special tool 11 3 190 in firing TDC position of first cylinder.

Unfasten camshaft gear approx. half a turn.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Unfasten nut on tensioning roller approx. half a turn. Relieve tension on toothed belt and remove.

Turn camshaft gear engine-wise to limit position.

Install new toothed belt, first placing it on crankshaft gear then, under tension, onto tensioning roller.

Fit tensioning roller on toothed belt then tighten nut slightly so that tensioning roller is still able to move.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Prepare special tool 11 2 080 for measurement of voltage. (Also refer to operating manual for special tool 11 2 080) Pull lockpin (1) upwards and set bearing pins to maximum opening with slide (2). Set gage needle to "0" and align drag needle with gage needle.

Apply tester between camshaft and small intermediate roller in such a way that both rollers of tester bear on back of teeth and center pin is located in a tooth gap.

Press slide (2) in until engagement of the lockpin is noticed.

Set toothed belt tension by turning tensioning roller to 45 scale units. Tighten down tensioning roller. Caution! The toothed belt tension of 45 scale units is a provisional value; it must be reduced in the work sequence described later.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Tighten down camshaft gear. Tightening Torque, refer to Technical Data 11 31 2AZ

Remove special tool 11 2 300.

Remove special tool 11 3 190 from camshaft.

Remove special tool 11 2 080.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Rotate engine twice enginewise on central screw.

Secure crankshaft in TDC position with special tool 11 2 300. Caution! Remove special tool 11 2 300 before switching on the engine.

Locate camshaft with special tool 11 3 190 in firing TDC position of first cylinder.

To determine toothed belt tension precisely, account must be taken of temperature expansion of engine components. Use special tool 11 5 060 to measure the temperature.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Apply temperature sensor on the ground-cast surface of the cylinder head above the coolant outlet and read the temperature.

Unfasten camshaft gear approx. half a turn.

Apply tester between camshaft and small intermediate roller in such a way that both rollers of tester bear on back of teeth and center pin is located in a tooth gap.

Press slide (2) in until engagement of the lockpin is noticed. Measure toothed belt tension.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Unfasten nut on tensioning roller approx. half a turn. Increase toothed belt tension to 45 scale units for brief period by rotating the tensioning roller, then reduce it to the specified scale value in accordance with the temperature table. Tighten down nut on tensioning roller.

Table for adjustment of toothed belt tension Caution! Adjustment of toothed belt tension is only permitted at a component temperature (cylinder head) of 20 C . . . 50 C. Skt = Scale units on tester
C = Component temperature at measuring point on cylinder head

Example: Component temperature (cylinder head) at measuring point 40 C. Tighten toothed belt on tensioning roller to 36 scale units. Permitted tolerance + 2 scale units.

Tighten down camshaft gear. Tightening Torque, refer to Technical Data 11 31 2AZ

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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Remove special tool 11 2 300.

Remove special tool 11 3 190 from camshaft.

Remove special tool 11 2 080. Assemble engine.

RA Removing toothed belt for camshaft drive (M40) Issue status (08/2003) Valid only until next CD is issued

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