Drive Chain For Valve Gear and Camshaft Timing Chain, R&R

Drive chain for valve gear and camshaft timing chain, removing and installing

Special tools and equipment required





^ Camshaft plate T10068





^ Counterhold T10069

Removing
^ Engine removed.
^ Engine separated from transmission.
^ Dual-mass flywheel removed.
^ Intake manifold removed.
^ Cylinder head cover removed.
^ Thermostat housing removed
^ Sump removed.





^ Turn crankshaft to TDC marking (arrow) in normal direction of rotation via securing bolt on vibration damper...





^ ...camshaft plate must simultaneously be inserted in camshaft grooves. If necessary, turn crankshaft 1 rotation further.





^ Mark and disconnect electrical connectors:
1. Camshaft Position (CMP) sensor-G40
2. Camshaft Position (CMP) sensor 2 -G163
3. Valve -1- for camshaft adjustment -N205
4. Camshaft adjustment valve 1 (exhaust) -N318





^ Remove bolt for chain tensioner for camshaft timing chain (arrow).





^ Remove bolts -1...3- and remove upper cover for camshaft timing chain from cylinder head horizontally. Take care not to damage cylinder head gasket when removing.





^ Remove bolts and remove lower cover (arrow) for timing chains horizontally from cylinder block. Take care not to damage cylinder head gasket when removing.
^ Press out crankshaft oil seal (timing chain end) from timing chain cover.





^ Mark rotation direction of timing chains with colored arrows before removing (arrows).

Note: Do not mark the chains using a center punch, a notch or similar.





^ Remove bolts (arrows) and remove guide rail -1-.
^ Remove camshaft timing chain from sprocket for intermediate shaft.
^ Remove camshaft timing chain carefully from behind projection of cylinder head gasket.





^ Loosen bolt (arrow) for chain sprocket of intermediate shaft approximately 1 turn...





^ ...by counterholding with T10069 on vibration damper for support.





^ Unscrew chain tensioner for drive chain for valve gear (arrows).





^ Unscrew bolt (arrow) and remove drive chain together with gears for intermediate shaft.

Installing





Note marking for rotation direction (lower arrow) when reinstalling a used drive chain for valve gear.





^ Install drive chain together with large sprocket of intermediate shaft.
^ Note installation position of sprocket:
^ Sprocket can only be installed on intermediate shaft in one position. If necessary, turn intermediate shaft
lightly.
^ Check TDC position of crankshaft:
^ Ground-down tooth of drive chain sprocket must align with main bearing joint (arrow -A-).
^ Notch on sprocket for intermediate shaft must align with groove (arrow -B-) on thrust washer for intermediate shaft.
^ Install small sprocket for intermediate shaft:
^ Sprocket can only be installed in one position on intermediate shaft.





^ Replace securing bolt (arrow) for chain sprockets of intermediate shaft.
^ Tighten bolt finger-tight.





^ Release locking spline in chain tensioner with a small screwdriver (arrow) and press guide rail against chain tensioner.
^ Secure chain tensioner in this position.





^ Tighten securing bolt for chain sprockets (arrow)...





^ ...by counterholding at vibration damper with T10069 for support.





^ Install camshaft timing chain as follows:
^ Yellow chain link -1- must align with marking -2- on small chain sprocket for intermediate shaft.
^ Copper-colored chain links -4- must align with arrows -3- on camshaft adjusters and notches -5- on valve timing housing.
^ There must be 16 chain rollers between arrows.





^ Install guide rail -1- and tighten bolts (arrows).
^ Remove camshaft plate T10068.

Note:





When turning the crankshaft, it is necessary to press the guide rail firmly against the camshaft timing chain manually (instead of using the tensioning element) -arrow- to prevent the chain from slipping.





^ Turn crankshaft via securing bolt for vibration damper 2 revolutions in normal direction of rotation until marking is at TDC (arrow)...





^ ...and simultaneously be able to insert camshaft plate T10068 in both camshaft grooves.

Note: The marked chain links will now be in an undefined position.

If the camshaft plate cannot be inserted:
^ Repeat adjustment of valve timing.





^ Clean old sealing compound from 3 mm bores (arrows) in cylinder head gasket.

Note: With the cylinder head installed the holes in the cylinder head gasket are only half visible.

^ Clean sealing surfaces on engine and on both covers; they must be free of oil and grease.
^ Check whether dowel pins for lower cover for timing chains are inserted in cylinder block.





^ Thinly coat clean surface of lower cover for timing chains (hatched surface in illustration) with sealing paste AMV 188 001 02.

Note: The lower cover for the timing chains must be installed within 5 minutes after applying the sealing paste.





^ Tighten bolts securing lower cover (arrow) for timing chains in diagonal sequence and in stages.





^ Fill 3 mm bores (arrows) in cylinder head gasket with sealing compound (black) AMV 174 04 01.
^ Replace oil seals in upper cover for camshaft timing chain.





^ Check if dowel sleeves -2- and -3- are inserted in upper cover for camshaft timing chain.
^ Insert a new oil seal -1- and a new seal -4-.
^ Thinly coat clean surface of upper cover for camshaft timing chain (hatched surface in illustration) with sealing past AMV 188 001 02.





^ Install upper cover for camshaft timing chain and tighten bolts in following sequence:
1. Tighten bolts -1- and -2- to 5 Nm
2. Tighten bolts -3- to 23 Nm
3. Tighten bolts -1- and -2- to 10 Nm





^ Secure chain tensioner (arrow) for camshaft timing chain.
^ Turn crankshaft 2 revolutions in normal direction of rotation and recheck valve timing.
^ Install crankshaft oil seal (timing chain side) .
^ Install cylinder head cover.
^ Install intake manifold.
^ Install thermostat housing
^ Install sump.
^ Install dual-mass flywheel.
^ Install engine.
^ Fill engine with oil and check oil level.





Tightening torques