Note.
- Necessary special devices, control and measuring devices, as well as auxiliary means:
- Counterholder -T30004 (3415) -.
- Puller -T10094A-.
- Adapter for dial indicator -T10170- or -T10170A-.
- Camshaft position lock -T10171A-.
- Clamping tool -T10172-.
- Locking pin -T40011-.
- Dial indicator, standard.
Removing
1. Remove the top decorative engine cover assembly.
2. Unscrew the fastening screws (2), remove clamp (1), shown in the figure below.
3. Disconnect the wiring harness connector (3) from charge pressure sender -G31- with intake air temperature sender 2 -G299-.
4. Hang the hoses on the pressure pipe and open the cable guide.
5. Move clamps outward (arrows) and remove the pressure pipe upwards as shown in the figure below.
6. Then remove the pressure pipe from the turbocharger.
7. Disconnect the wiring harness connector (arrow) from the oil pressure drop sender -F1- as shown in the figure below.
8. Unscrew the fastening screw (1) wires «masses», as shown in the figure below.
9. Unscrew the fastening screws (1) And (2), move the cooling pipes to the left.
10. Unscrew the fastening screws (arrows), remove cover (1) And (2), shown in the figure below.
11. Remove the ignition coil of the 1st cylinder.
12. Screw dial indicator adapter -T10170- into the spark plug thread as far as it will go.
13. Wearing a dial indicator (A) with extension -T10170/1- up to the stop, tighten with clamping nut (arrow), as shown in the figure below.
14. Turn the crankshaft in the direction of the engine shaft until the piston of the 1st cylinder is at TDC.
15. Mark the position of the small dial indicator knob.
16. Holes (arrows) in the camshafts must be in the position shown in the figure. Turn the crankshaft one turn if necessary (360‘).
Note.
- If the crankshaft turns more than 0.01 mm past TDC, turn the crankshaft back by about 45°. Then turn it in the direction of rotation of the engine shaft to the TDC position of the 1st cylinder.
- Permissible deviation from the TDC of the piston of the 1st cylinder:±0.01 mm.
17. The camshaft position lock -T10171 A - must be inserted into the holes of the camshafts until it stops. Stop mandrels (arrows 1) should go into the holes (arrows 2). It is necessary that the inscription "TOR" (arrow 3) could 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 delay.
Note. It should be remembered that. that the camshaft positioner -T10171 A- has different attachment points.
19. Remove the timing chain cover (for details, see the relevant section in this chapter).
20. Remove cover (1) oil pump drive sprockets as shown in the figure below.
21. Move the tension rail (1) in the direction of the arrow and lock the plunger of the chain tensioner (2) stopper -T40011- as shown in the figure below.
22. Remove chain tensioner (2), as shown in the figure below.
23. Use a suitable felt-tip pen to mark the direction of movement of the camshaft drive chain (3).
Note. At the fixing screw of the camshaft phase shifter (2) has a left hand thread.
24. Unscrew the fastening screws (2) And (4), remove the camshaft phase shifter (1) with camshaft drive chain (3), as shown in the figure below. Use clamping tool -110172- for support.
25. Hold oil pump chain sprocket with clamping tool -T10172- and loosen fixing bolt (1), shown in the figure below.
26. Disconnect the tension spring (1) screw driver (2) remove tension spring (1), as shown in the figure below.
27. Unscrew the fixing screw -3-, remove the chain tensioner.
28. Use a suitable marker to mark the direction of movement of the oil pump drive chain (2), as shown in the figure below.
29. Unscrew the fixing screw of the chain sprocket (1), remove 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 on the 1st cylinder.
1. Install chain sprocket (1) in the direction of the arrow on the crankshaft journal until it stops.
Attention. high tide (2) on the chain sprocket (1) must be in slot (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. Put on the oil pump drive chain (3) on the chain gear (1). as shown in the picture below.
4. Inserting the oil pump chain sprocket (2) to the oil pump drive chain (3), put 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 mounted on the oil pump drive shaft (arrow) only in one single position.
5. Hold oil pump chain sprocket with holding tool -T10172-.
6. Tighten the fixing screw (1) with a tightening torque of 20 Nm, tighten it an additional 45° (¼ turn).
7. Putting the chain tensioner on the oil pump drive chain, tighten the fixing screw (3) with the application of a torque of 15 Nm.
8. Using a screwdriver, install the tension spring (1) on the screw (2), as shown in the figure below.
Note.
- Guided by labeling (arrows).
- The crankshaft must not be rotated.
9. Install and hand-tighten the new exhaust camshaft sprocket bolt (3), as shown in the figure below.
10. Put on the camshaft drive chain (1) on the chain sprocket on the crankshaft (4), on the chain drive gear of the exhaust camshaft (3), and install and hand-tighten the camshaft phase shifter bolt (2), as shown in the figure below.
Note.
- Observe the direction of travel marked on the camshaft timing chain (1).
- Ensure that a guide sleeve is fitted between the intake camshaft and the mechanical camshaft adjuster.
- At the fixing screw of the mechanical device for adjusting the camshaft (2) has a left hand thread.
11. The camshaft drive chain must be in contact with the guide bar (1) and to the chain sprocket on the crankshaft (arrow).
12. Install the chain tensioner (1), tighten the fixing screws (2) with the application of a torque of 9 Nm.
13. Tension the camshaft timing chain by pulling out 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 opposite each other.
15. Fixing bolt (2) must be tightened with a torque of 40 Nm and the bolt (4) — with application of torque 50 Nm (use clamping tool -T10172-).
Note.
- Mounting bolts (2) And (4) tightened by turning 90°only after checking the distribution over time.
- At the camshaft phase shifter fixing bolt (2) left thread.
16. Remove the screw (arrow), remove the camshaft positioner -T10171 A- from the camshaft housing as shown in the figure below.
17. Check the valve timing over time.
If the valve timing is adjusted correctly
18. Hold the camshaft chain sprockets with the clamping tool -T10172- and turn the fastening bolt with a hard wrench (2) (left hand thread) And (4) ¼ turn (90°), as shown in the figure below.
Note.
- At the camshaft phase shifter bolt (2) left thread.
- The chain sprockets on the camshafts must not be rotated on the camshaft during tightening.
19. Install the oil pump cover (1), shown in the figure below.
20. Install the timing chain cover (for details, see the relevant section in this chapter).
21. Install the pulley on the crankshaft.
22. Install poly V-belt.
23. Replace the O-rings of the camshaft covers and lubricate them with oil before proceeding with installation.
24. In the future, installation is carried out in the reverse order of actions than removal.