Contents: Removal ⬇ Installation ⬇
Note.
- Necessary special devices, control and measuring instruments, as well as auxiliary means:
- Counter support -T30004 (3415)-.
- Puller "T10094A".
- Adapter for the dial indicator "T10170" or "T10170A".
- Camshaft position lock "T10171A".
- Clamping device "T10172".
- Fixing pin "T40011".
- Dial type deviation indicator, standard.
Removal
1. Remove the upper decorative engine cover assembly.
2. Unscrew the fastening screws (2), remove the clamp (1), shown in the figure below.
3. Disconnect the wiring harness connector (3) from the boost pressure sensor "G31" with the intake air temperature sensor 2 "G299".
4. Hang the hoses on the pressure pipeline and open the cable routing.
5. Move the clamps outward (arrows) and pull the pressure pipe upward as shown in the figure below.
6. Then remove the pressure line from the turbocharger.
7. Disconnect the wiring harness connector (arrow) from the oil pressure drop sensor "F1" as shown in the figure below.
8. Unscrew the screw (1) securing the ground wire, as shown in the figure below.
9. Unscrew the fastening screws (1) and (2), move the cooling system pipes to the left.
10. Unscrew the fastening screws (arrows), remove the cover (1) and (2), shown in the figure below.
11. Remove the ignition coil of the 1st cylinder.
12. Screw the adapter for the dial indicator "T10170" into the spark plug thread until it stops.
13. After inserting the dial indicator (A) with the extension "T10170/1" as far as it will go, clamp it with the clamping nut (arrow), as shown in the figure below.
14. Turn the crankshaft in the direction of engine shaft travel until the piston of the 1st cylinder is at TDC.
15. Mark the position of the small dial indicator handle.
16. The holes (arrows) in the camshafts must be in the position shown in the figure. If necessary, turn the crankshaft one revolution (360°).
Note.
- If the crankshaft turns more than 0.01 mm past TDC, then turn the crankshaft back approximately 45°. Then turn it in the direction of engine shaft rotation to the TDC position of the 1st cylinder.
- Permissible deviation from TDC of piston of the 1st cylinder: ±0.01 mm.
17. The camshaft position lock "T10171 A" should be inserted into the camshaft holes until it stops. The locking mandrels (arrows 1) should enter the holes (arrows 2). It is necessary that the inscription "TOP" (arrow 3) can be read from above.
18. To lock the camshaft position lock "T10171 A", screw the M6 screw by hand into the corresponding hole (arrows), without tightening.
Note: Please note that the camshaft position lock "T10171 A" has different mounting points.
19. Remove the timing chain cover (for more details, see the relevant section in this chapter).
20. Remove the oil pump drive sprocket cover (1) as shown in the figure below.
21. Move the tensioning rack (1) in the direction of the arrow and lock the plunger of the chain tensioner (2) with the locking mandrel "T40011", as shown in the figure below.
22. Remove the chain tensioner (2) as shown in the figure below.
23. Using a suitable felt-tip pen, mark the direction of movement of the camshaft drive chain (3).
Note: The camshaft phase shifter mounting screw (2) has a left-hand thread.
24. Unscrew the fastening screws (2) and (4), remove the camshaft phase shifter (1) with the camshaft drive chain (3), as shown in the figure below. To support it, use the clamping device "110172".
25. Hold the oil pump chain sprocket with the clamping device "T10172" and loosen the mounting bolt (1), shown in the figure below.
26. Disconnect the tension spring (1) with a screwdriver on the screw (2) remove the tension spring (1), as shown in the figure below.
27. Unscrew the fastening screw "3" and remove the chain tensioner.
28. Using a suitable felt-tip pen, mark the direction of movement of the oil pump drive chain (2), as shown in the figure below.
29. Loosen the chain sprocket (1) fastening screw, remove the chain sprocket (1) and (3) together with the oil pump drive chain (2), as shown in the figure below.
Installation
Note: The crankshaft must be at TDC of the piston of the 1st cylinder.
1. Install the chain drive sprocket (1) in the direction of the arrow onto the crankshaft journal until it stops.
Caution: The boss (2) on the chain sprocket (1) must fit into the spline (3) on the crankshaft journal as shown in the figure below.
2. Mark the position of the chain sprocket and crankshaft in relation to the cylinder block with a suitable felt-tip pen.
3. Place the oil pump drive chain (3) onto the chain drive sprocket (1) as shown in the figure below.
4. After inserting the oil pump chain sprocket (2) into the oil pump drive chain (3), place it on the oil pump drive shaft as shown in the figure below.
Note.
- Observe the marked direction of movement of the oil pump drive chain.
- The oil pump drive gear is installed on the oil pump drive shaft (arrow) in only one single position.
5. Hold the oil pump chain sprocket with the clamping device "T10172".
6. Tighten the fastening screw (1) with a tightening torque of 20 Nm, then turn it an additional 45° (¼ turn).
7. After placing the chain tensioner on the oil pump drive chain, tighten the fastening screw (3) with a torque of 15 Nm.
8. Using a screwdriver, install the tension spring (1) onto the screw (2) as shown in the figure below.
Note.
- Follow the markings (arrows).
- The crankshaft must not be allowed to turn.
9. Install and hand tighten the new exhaust camshaft sprocket bolt (3) as shown in the figure below.
10. Place the camshaft drive chain (1) on the crankshaft chain drive sprocket (4), on the exhaust camshaft chain drive gear (3), and install and hand tighten the camshaft phase shifter mounting bolt (2), as shown in the figure below.
Note.
- Observe the direction of travel marked on the camshaft drive chain (1).
- Ensure that a guide sleeve is installed between the intake camshaft and the mechanical camshaft adjuster.
- The mounting screw of the mechanical device for adjusting the camshaft (2) has a left-hand thread.
11. The camshaft drive chain must fit against the guide bar (1) and the chain drive sprocket on the crankshaft (arrow).
12. Install the chain tensioner (1), tighten the fastening screws (2) with a torque of 9 Nm.
13. Tighten the camshaft drive chain by pulling the locking pin "T40011" from the chain tensioner.
14. Check the markings on the crankshaft chain drive sprocket and on the cylinder block; they should be located opposite each other.
15. The fastening bolt (2) should be tightened to a torque of 40 Nm and the bolt (4) to a torque of 50 Nm (use the clamping device "T10172").
Note.
- The fastening bolts (2) and (4) are tightened by turning 90° only after checking the timing distribution.
- The camshaft phase shifter mounting bolt (2) has a left-hand thread.
16. Unscrew the screw (arrow), remove the camshaft position lock "T10171 A" from the camshaft housing, as shown in the figure below.
17. Check the valve timing.
If the valve timing is adjusted correctly
18. Hold the camshaft chain sprockets with the clamping device "T10172" and turn the mounting bolt (2) with a rigid wrench (left hand thread) and (4) ¼ turn (90°) as shown in the figure below.
Note.
- The camshaft phase shifter mounting bolt (2) has a left-hand thread.
- The camshaft timing chain sprockets must not rotate on the camshaft during tightening.
19. Install the oil pump housing (1) shown in the figure below.
20. Install the timing chain cover (for more details, see the relevant section in this chapter).
21. Install the pulley on the crankshaft.
22. Install the poly V-belt.
23. Replace the camshaft cover sealing rings and lubricate them with oil before installation.
24. Further installation is carried out in the reverse order of actions than removal.