Page 6 of 11

5. Attach the power steering fluid reservoir to the radiator grille

opening panel.

6. Using the special tool, align the high pressure fuel pump pulley
(engine shown removed for clarity) .

If there is no hole in the high pressure fuel pump bracket
to install the special tool go to the next step.

7. Make sure the high pressure fuel pump alignment holes are in
line (engine shown removed for clarity).

8. Remove the special tool from the high pressure fuel pump pulley
(engine shown removed for clarity).

9. Make sure the camshaft alignment holes are in line.

10. Raise and support the vehicle. For additional information, refer
to Section 100-02 Jacking and Lifting.

http://127.0.0.1:8888/wsm/js/procedure.do?variantId=614&proc-uid=G152697&guid=G505330&lan...

27.07.2010

Page 7 of 11
11. Check the correct position of the crankshaft timing belt pulley
Woodruff key.

12. CAUTION:Do not touch the outer sensor ring.

NOTE:Install the old crankshaft pulley bolt.
NOTE:Do not tighten the crankshaft pulley bolt at this
stage.
Install the crankshaft timing belt pulley.

13. CAUTION:Do not touch the outer sensor ring.

Using the special tool, align the crankshaft.

14. Lower the vehicle.

15. NOTE:Using an allen key, maintain tension until the timing
belt tensioner bolt is tightened.
Tension the timing belt (engine shown removed for clarity).
1. Turn the timing belt tensioner adjustment arm
counterclockwise to tension the timing belt slightly.
2. The pointer must be positioned between the sides of the
window.
3. Tighten the timing belt tensioner retaining bolt.

16. Raise and support the vehicle. For additional information, refer
to Section 100-02 Jacking and Lifting.
17. CAUTION:Do not touch the outer sensor ring.
Remove the special tool from the crankshaft timing belt
pulley.

18. Install the timing belt guide.

http://127.0.0.1:8888/wsm/js/procedure.do?variantId=614&proc-uid=G152697&guid=G505330&lan...

27.07.2010

Page 8 of 11

19. NOTE:Only turn the engine in the normal direction of

rotation.
Turn the engine ten revolutions.

20. CAUTION:Do not touch the outer sensor ring.

Using the special tool, align the crankshaft.

21. Lower the vehicle.

22. Install the special tool.

If the special tool cannot be installed, repeat the previous
steps.

23. CAUTION:Do not touch the outer sensor ring.

Remove the special tool from the crankshaft timing belt
pulley.

24. Install the special tool (engine shown removed for clarity) .

If there is no hole in the high pressure fuel pump bracket
to install the special tool go to the next step.

http://127.0.0.1:8888/wsm/js/procedure.do?variantId=614&proc-uid=G152697&guid=G505330&lan...

27.07.2010

Page 9 of 11
25. Check that the high pressure fuel pump alignment holes are in
line (engine shown removed for clarity).

If the alignment holes are not in line, repeat the previous
steps.

26. Remove the special tool (engine shown removed for clarity).

27. Remove the special tool.

28. Raise and support the vehicle. For additional information, refer
to Section 100-02 Jacking and Lifting.
29. CAUTION:Do not touch the outer sensor ring.
Remove the crankshaft pulley retaining bolt.

Discard the bolt.

30. Install the timing belt lower cover.

31. Attach the crankshaft speed sensor wiring harness to the timing
belt lower cover.

http://127.0.0.1:8888/wsm/js/procedure.do?variantId=614&proc-uid=G152697&guid=G505330&lan...

27.07.2010

Page 10 of 11

32. CAUTION:Make sure the special tool engages correctly.

NOTE:Only turn the engine in the normal direction of
rotation.
Using the special tool, lock the flywheel.

Turn the engine until the special tool aligns with one of
the slots in the flywheel.

33. NOTE:Install a new crankshaft pulley retaining bolt.

Install the crankshaft pulley.

Tighten the crankshaft pulley bolt in two stages.

Stage 1: 30 Nm.

Stage 2: 180 degrees.

34. Remove the special tool from the flywheel.

35. Install the accessory drive belt. For additional information, refer
to Section 303-05 Accessory Drive.
36. Install the timing belt upper cover.

37. Attach the wiring harness to the timing belt upper cover.

http://127.0.0.1:8888/wsm/js/procedure.do?variantId=614&proc-uid=G152697&guid=G505330&lan...

27.07.2010

Page 11 of 11

38. Connect the fuel temperature sensor electrical connector.

39. Attach the coolant expansion tank to the coolant expansion tank
bracket.

40. Connect the coolant degas hose to the coolant expansion tank.

41. Fill and bleed the cooling system. For additional information,
refer to Section 303-03A Engine Cooling / 303-03B Engine
Cooling / 303-03C Engine Cooling.
42. Connect the battery ground cable. For additional information,
refer to Section 414-01 Battery, Mounting and Cables.

http://127.0.0.1:8888/wsm/js/procedure.do?variantId=614&proc-uid=G152697&guid=G505330&lan...

27.07.2010