Carved versions of the rear toothed belt guard

I: option until 12.07
II: version from 01.08

Cars until 12.07

Remove engine bracket. Remove toothed belt. Remove idler pulley Unscrew all overrunning rollers from the engine. Remove the camshaft gear, including the hub, from the camshaft. Remove coolant pump. Unscrew the upper bolt of the injection pump. Unscrew securing bolt -arrow- for toothed belt guard above injection pump.



Unscrew rear securing bolt -arrow- for toothed belt guard.



Carefully detach toothed belt guard from valve cover -arrows-.




Unplug connector for Hall sender -C40- -arrow-. Remove the connector from its mount.



Unscrew hall sender -C40- -arrow-. Pull the toothed belt guard up slightly and fold it away from the engine. Remove Hall sender -G40-.



Installation in reverse order. In doing so, the following must be taken into account. Lay toothed belt and adjust valve timing. Check that the valve cover and toothed belt guard are properly connected. To install correctly, use a screwdriver to press the belt guard at the mounting points -arrows- towards the valve cover. The latches should click into place with a distinct click. Check for clearance between hub and toothed belt guard.

Cars from 01.08

Remove the front right fender liner. Remove poly V-belt. Remove vibration damper. Move crankshaft to TDC position of cylinder 1 and lock crankshaft sprocket with tool -T10050-. To do this, insert the crankshaft lock 8 teeth of the pulley from its end side. The toothed segment of the camshaft pulley must face up («12 o'clock position»).

Instruction: Markings on crankshaft pulley -2- and crankshaft lock -T10050-1- must match. In doing so, the pin of the crankshaft lock -T10050- must engage in the hole in the sealing flange.



Loosen screws -1- for camshaft pulley.



Loosen the screw -1- securing the cooling system pipe, and then the screws securing the injection pump pulley -2-.




Loosen the tensioning roller nut -1- and turn the tensioning roller eccentric counterclockwise with the Allen key -T10264- -arrow- until the tensioning roller can be locked with the locking pin -T10265-.



Turn tensioning roller eccentric clockwise -arrow- as far as it will go and tighten securing nut -1- hand-tight. Remove the toothed belt from the overrunning roller and injection pump.



Unplug connector for Hall sender -C40- -arrow-. Remove the connector from its mount.




Unscrew hall sender -C40- -arrow-.



Use a screwdriver to remove spacer and repair hole cover -arrow-. Remove Hall sender -G40- from cylinder head and insert its connector through repair hole into toothed belt guard.



Installation in reverse order. In doing so, the following must be taken into account. Close the repair hole in the toothed belt housing with a rubber plug. Lay toothed belt and adjust valve timing.