Camshaft Timing Chain, Removing From Camshafts
Camshaft timing chain, removing from camshafts
Special tools, equipment, and material required
^ Camshaft plate T10068
^ Gasket sealant, black, Part No AMV 174 04 01
^ Gasket paste, Part No. AMV 188 001 02
Removing
^ Engine in vehicle
^ Drain coolant.
^ Remove intake manifold.
^ Disconnect electrical connector for Mass Air Flow (MAP) sensor-G70-.
^ Remove bolts -1- and -3-.
^ Take out air cleaner housing.
^ Unclip protective cover -1- for electrical wiring.
^ Fold bracket box upward (arrows).
^ Remove fuse box by releasing retaining tabs (arrow).
Note: The wires remain connected.
^ Remove carrier (arrows).
^ Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor -G62-.
^ Disconnect coolant hoses at connections indicated (arrows).
^ Remove bolts (arrows).
^ Swing bracket for secondary air injection hose forward.
^ Remove bolt (arrow) on bracket for wiring harness.
CAUTION: When removing the thermostat housing, push the coolant pipe toward the coolant pump with an assembly lever to prevent it from also being removed.
^ Remove thermostat housing -2-. To do so, press coolant pipe -1 toward coolant pump with an assembly lever.
^ Disconnect air hose -4- and vacuum hose -1- at combination valve for secondary air injection system.
^ Disconnect Ground cable -2-.
^ Disconnect coolant hoses -3- and -5-.
^ Place Throttle valve control module -J338- on bulkhead.
^ 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
^ Disconnect electrical connector (left side) on cylinder head and move connector clear.
CAUTION: The fuel system is pressurized. Before opening the system place a clean cloth around the connection. Then dissipate the pressure by carefully loosening the connection.
^ Disconnect fuel supply line -1- and fuel return line -2- by pressing release tabs.
^ Unscrew and move clear all electrical connectors on cylinder head and lay them back together with fuel rail.
^ Unscrew cylinder head cover bolts in sequence -11...1-.
^ Turn crankshaft to TDC marking (arrow) in normal direction of rotation via securing bolt on vibration damper...
^ Simultaneously insert camshaft plate T10068 into grooves on both camshafts. If necessary, turn crankshaft 1 rotation further.
^ Remove bolt for camshaft timing chain tensioner (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 (arrows) and remove guide rail -1-.
^ Remove camshaft plate T1068.
Note: The camshaft plate T10068 must not be inserted when loosening and tightening the securing bolts for the camshaft adjuster.
^ Unscrew securing bolt at camshaft adjuster (intake side). Counterhold with open end wrench (32 mm) on hex flats of camshaft.
^ Remove camshaft adjuster (intake side).
^ Unscrew securing bolt at camshaft adjuster (exhaust side). Counterhold with open end wrench (32 mm) on hex flats of camshaft.
^ Remove camshaft adjuster (exhaust side).
^ Remove camshaft timing chain over valves for camshaft adjustment and set aside.
Installing
^ Install guide rail -1- and tighten bolts (arrows).
^ Recheck TDC position of crankshaft (arrow)
.
^ Check TDC position of camshafts:
It must be possible to insert camshaft plate T10068 into both camshaft grooves...
^ ...If necessary, turn camshafts to correct position at hex flats (arrows) using an open end wrench (32 mm).
Note: The crankshaft must not be at TDC at any cylinder when the camshafts are turned. Otherwise, there is a risk of damage to the valves and piston crowns.
^ First install camshaft adjuster for intake side.
^ Turn sender wheel -1- clockwise (arrow) in camshaft adjuster as far as stop.
Note: The camshaft plate must not be used as a counterhold.
^ Tighten camshaft adjuster (intake side) in this position to intake camshaft finger-tight.
^ Contact surface of sender wheel at bolt head must be dry when installing Inscription "24E" item -1- and tooth just behind it -2- must align with notch -3- in valve timing housing.
^ Lay camshaft timing chain in this position tautly onto sprocket of camshaft adjusts (intake side).
^ Count exactly 16 rollers of timing chain starting from inscription "24E" on camshaft adjuster (intake side) moving toward exhaust side.
^ Place tooth at inscription "32A" on camshaft adjuster (exhaust side) exactly behind 16th roller of chain.
^ There should be now 16 chain rollers between teeth.
^ Inscription "32A" and tooth just behind it must also align with notch in valve timing housing.
^ Turn sender wheel -2- clockwise (arrow) in camshaft adjuster -1(exhaust side) as far as stop.
^ Tighten camshaft adjuster (exhaust side) in this position to exhaust camshaft finger-tight.
^ Contact surface of sender wheel at bolt head must be dry when installing.
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.
If the camshaft plate cannot be inserted:
^ Repeat adjustment of valve timing.
^ Clean any old sealing compound from 3 mm bores (arrows) in cylinder head gasket.
^ Fill 3 mm bores in cylinder head gasket with sealing compound (black) AMV1740401.
Note: With the cylinder head installed the holes in the cylinder head gasket are only half visible.
^ Replace oil seals in upper cover for camshaft timing chain.
^ Clean sealing surfaces.
^ Sealing surfaces must be free of grease and oil.
^ 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 AMV188 001 02.
Note:
^ Also apply a thin coat of sealing paste to the surface beneath the cylinder head gasket (do not kink gasket).
^ The upper cover for the camshaft timing chain must be installed within 5 minutes after applying the sealing paste.
^ 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 cylinder head cover.
^ Install intake manifold.
^ Install thermostat housing.
Tightening torques