Contents: Removal ⬇ Installation ⬇
Note.
- Necessary special devices, control and measuring instruments, as well as auxiliary means:
- Camshaft position lock "T10171 A".
- Two studs (M6x80).
- Sealing agent "D 188 003 A1".
- Gasket Stripper (GST storage code, item No.34402). Manufacturer Retech sro.
- Cleaning and degreasing agent, eg. "0 000401 04".
Removal
Note.
- This engine has the camshafts housed in a camshaft housing. Before removing the camshaft housing, the timing gear cover must be removed.
- The sealing surface of the camshaft housing must not be treated.
- Observe safety regulations.
Caution: Pressure drop in high pressure part of fuel system.
1. Remove the upper decorative engine cover assembly.
2. Unscrew the fastening screws (2), remove the clamp (1), as 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 outwards (arrows) and remove the pressure pipe upwards.
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, which is shown in the figure below.
9. Unscrew the fastening screws (1) and 2() and move the cooling system pipes to the left.
10. Unscrew the fastening screws (arrows), remove the cover (1) and (2), as shown in the figure below.
11. Remove the turbocharger assembly.
12. Remove the timing chain cover.
13. Turn the crankshaft to the TDC position of the piston of the 1st cylinder, then turn it approximately 45° back against the direction of rotation of the engine shaft and remove the chain drive sprockets together with the camshaft drive chain.
14. Disconnect the wiring harness connector from the high pressure fuel pump.
15. Remove the ignition coils.
16. Remove the wire holder together with the wire harness from the camshaft housing.
17. Disconnect the fuel supply line (arrow to the right) from the high pressure pump as shown in the figure below.
18. Remove the pipeline (2), remove the clamp (4) from the high-pressure pipeline.
Note: When loosening the union nut, hold the threads on the high pressure pump and on the lower part of the fuel distributor with a wrench.
19. Loosen the union nuts (3) and (1) on the high pressure pipe as shown in the figure below.
20. Disconnect the wiring harness connector from the Hall sensor "G40".
21. Remove the oil level indicator.
22. Unscrew the left eye.
23. Unscrew the camshaft housing bolts in the sequence (15... 1), as shown in the figure below.
24. Carefully remove the camshaft housing.
Installation
Attention.
- Before installing the camshaft housing, studs (M6 x 80) must be screwed into the cylinder head.
- The studs guide the camshaft housing, preventing the rocker arms from slipping off the hydraulic tappets.
Note: Neither piston should be at TDC.
Caution: When working with the seal remover and degreaser, wear protective gloves and goggles.
1. Remove any remaining sealant from the cylinder head and camshaft housing using a chemical sealant remover.
2. Degrease the sealing surfaces. They must be free of oil and grease.
3. Prevent dirt and sealant residue from entering the cylinder head.
4. Turn the camshafts that operate the intake and exhaust valves until the camshaft position lock "T10171 A" can be inserted all the way into the holes in the camshafts.
5. To lock the camshaft position lock "T10171 A", manually screw the M6 screw into the corresponding hole (arrows), without tightening, as shown in the figure below.
Note: Please remember that the camshaft position lock "T10171 A" has different mounting points.
6. After replacing the mesh oil filter (1), insert it into the cylinder head as shown in the figure below.
7. Insert 4 new sealing rings (2) into the grooves of the cylinder head, as shown in the figure below.
8. Ensure that all rocker arms are correctly seated on the ends of the valve stems (1) and that they are correctly secured to the corresponding hydraulic compensators (2), as shown in the figure below.
9. Apply the sealing agent (sealant) evenly and in a thin layer to the clean sealing surface of the camshaft housing.
10. No sealing agent is applied to the areas marked with arrows A. The sealing rings inserted into the cylinder head are sealed here.
Note.
- No sealant should be applied to the arrow B location. The mesh oil filter seals here.
- The sealant must not be applied in an excessively thick layer, otherwise the sealant residue may enter the oil channels of the lubrication system, which may lead to failure of the entire engine.
11. Before installing the camshaft housing, screw two studs (M6x80) into the cylinder head.
12. Carefully place the camshaft housing vertically from above onto the studs (arrows) and onto the centering pins in the cylinder head, as shown in the figure below.
Note: Make sure that no oil residue drips onto the flange sealing gasket and that the camshaft housing does not become warped.
13. The new camshaft housing bolts must be tightened in sequence (1...15) in two steps:
- First approach: tighten to a torque of 10 Nm.
- Second approach: tighten all bolts by 90° (¼ turn).
14. Make sure that the camshaft housing does not jam.
Note: After installing the camshaft housing, allow the sealant to dry for at least 30 minutes.
15. Adjust the valve timing.
16. Further installation is carried out in the reverse order of actions than removal. In this case, it is necessary to observe the following instructions:
Install the timing gear cover.
Build in a turbocharger
Install the pulley onto the crankshaft.
Connect the fuel lines.