Vehicles with friction damper tensioning

system
Note
Adjustment work on toothed belt must be performed on cold engines
only.
Removing
– Remove poly-V-belt → Chapter.
– Remove poly-V-belt tensioner.
Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR:
– Remove right headlight → Rep. Gr.94
Remove charge air pipe between charge air cooler and
–
turbocharger → Chapter.
Continuation for all vehicles
– Remove coolant expansion tank (coolant hoses remain connected).
Unbolt power steering reservoir and fuel filter and place to one side
–
(hoses remain connected).
– Detach fuel line from cylinder head cover.

WARNING
The fuel and the fuel lines in the fuel system can become very hot

(danger of scalding)!
The fuel system is also under pressure! Before opening the
 system, place cloths around the connections. Then carefully
loosen connection to release the pressure!
Wear eye and hand protection when performing any type of repair

work on the fuel system!
Fit support bracket -10-222A- and take up weight of
–
engine in installation position.
 Remove securing bolts from assembly
mounting/engine bracket, assembly mounting/body
–
and assembly mounting/body bracket -arrows- and
remove assembly mounting complete.

Note
The assembly mounting should only be removed if
 the engine is supported with support bracket -10-
222A-!
Do not loosen engine bracket until the assembly

mounting has been removed.

Unbolt engine bracket from cylinder block -arrows-

–
and remove.

Note
When loosening both upper engine mounting bolts
 the engine must be raised slightly with the support
bracket.
When loosening the lower engine mounting bolt the
 engine must be lowered slightly with the support
bracket.
– Remove vibration damper/belt pulley.
– Remove centre and lower toothed belt guards.
– Turn crankshaft to TDC No. 1 cylinder.

Note
When doing this, turn the crankshaft until the mark on
the crankshaft pulley is facing up and the arrow on the
rear section of the toothed belt guard aligns with the
lugs on the hub sender wheel -arrows-.
Lock the hub using diesel injection pump locking pin
– -3359-. To do this, slide locking pin through free
elongated hole on left into hole in cylinder head.
Lock crankshaft belt pulley with crankshaft stop -
– T10050-. To do this, push crankshaft stop into teeth
of belt pulley from its face side.

Note
The marks on the crankshaft belt pulley and the
crankshaft stop must align. When doing this, the
crankshaft stop pin must locate in the hole of the sealing
flange.
– Mark direction of rotation of toothed belt.
– Loosen tensioning roller securing nut.

Loosen securing bolts -1- of camshaft belt pulley

– until camshaft pulley can be moved within the
elongated holes.
 Now turn pin wrench -3387- anti-clockwise (against
– direction of arrow) until toothed belt tensioning roller
can be locked with locking pin -T10115-.
Now turn pin wrench in direction of arrow onto stop
–
and tighten securing nut by hand.
Remove toothed belt first from coolant pump and
–
then from remaining pulleys.
Installing

Note
Adjustment work on toothed belts must be
performed only on cold engines, as the indicator on

the tensioning element changes depending on the
engine temperature.
Tensioning roller must be locked with locking pin -

T10115- and fixed against right limit stop.

Turn camshaft pulley in elongated holes anti-

–
clockwise -direction of arrow- onto stop.
Fit toothed belt to crankshaft belt pulley, tensioning
–
roller and camshaft belt pulley
– Finally, fit toothed belt on coolant pump belt pulley.

Note
Ensure that tensioning roller seats correctly in rear
toothed belt guard -arrow-.
– Loosen tensioning roller securing nut.
Then release tension on tensioning roller by turning
– against direction of arrow with pin wrench and
remove locking pin from tensioning roller.

Now carefully turn tensioning roller in direction of

– arrow using pin wrench -3387- until indicator is in
middle of gap in base plate -arrow-.
Hold tensioning roller in this position and tighten
– tensioning roller securing nut as follows: 20 Nm and
45° (1/8 turn) further.
Tighten securing bolts of camshaft belt pulley to 25
–
Nm.
Remove locking pin for diesel injection pump -3359-
–
and crankshaft stop -T10050-.
Turn crankshaft two rotations in engine DOR and set
–
again to TDC no. 1 cylinder.

Note
When doing this, the crankshaft stop pin must
 engage in the sealing flange from the rotational
movement.
If the crankshaft is turned past TDC no. 1 cylinder
and the crankshaft stop could not engage in the
sealing flange, turn the crankshaft back 1/4 turn so
 that the crankshaft can again be turned in engine
DOR to allow it to be set to TDC no. 1 cylinder.
Making corrections against engine DOR in order to
insert the crankshaft stop is not permissible.
Once crankshaft stop -T10050- is fitted, check
– whether hub can be locked using locking pin for
diesel injection pump -3359-.
If the hub cannot be locked:
Pull crankshaft stop pin out of hole in sealing flange
– and turn crankshaft until hub can be locked with
locking pin.
– Loosen securing bolts -1- of camshaft belt pulley.

Turn crankshaft against engine DOR slightly until pin

– of crankshaft stop is located just before hole in
sealing flange -arrow-.
Now turn crankshaft in engine DOR until crankshaft
– stop pin engages in sealing flange from rotational
movement.
Tighten camshaft belt pulley securing bolts to 25
–
Nm.
Remove locking pin for diesel injection pump -3359-
–
and crankshaft stop -T10050-.
Turn crankshaft two rotations in engine D.O.R. until
–
crankshaft is set to TDC No. 1 cylinder again.

Note
When doing this, the crankshaft stop pin must
 engage in the sealing flange from the rotational
movement.
If the crankshaft is turned past TDC no. 1 cylinder
and the crankshaft stop could not engage in the
sealing flange, turn the crankshaft back 1/4 turn so
 that the crankshaft can again be turned in engine
DOR to allow it to be set to TDC no. 1 cylinder.
Making corrections against engine DOR in order to
insert the crankshaft stop is not permissible.
– Repeat check.
Install lower toothed belt guard and vibration
–
damper/pulley.
– Install centre toothed belt guard.
 Fit engine bracket to cylinder block and tighten -
–
arrows-. Torque setting: 45 Nm.
– Install upper toothed belt guard.

Note
Before installing assembly mounting, tighten all engine
bracket bolts to prescribed torque.
Install assembly mounting between engine and body
– (renew securing bolts). Tightening torque: 40 Nm +
90° (1/4 turn)
Align assembly mounting on engine side → Chapter
–
Aligning assembly mounting for engine and gearbox.
Fit engine assembly mounting to engine bracket by
– bringing contact surfaces together using support
bracket -10-222 A-. Torque setting: 100 Nm.
Install assembly mounting bracket to body. Torque
–
setting: 25 Nm.
– Install coolant expansion tank.
– Install power steering reservoir and fuel filter.
Vehicles with engine codes AJM, ASZ, ATD, AUY, AXR
Install charge air pipe between charge air cooler and
–
intake connection → Chapter.
– Install right headlight → Rep. Gr.94.
Continuation for all vehicles
Install poly-V-belt tensioning element. Torque
–
setting: 25 Nm.
– Install poly-V-belt → Chapter.
– Install noise insulation tray.