Drive Chain For Valve Gear and Camshaft Timing Chain, Removing and Installing
Drive chain for valve gear and camshaft timing chain, removing and installing
Special tools and equipment required
^ Camshaft plate T10068
^ Counterhold T10069
Removing
^ 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 approx. 1 turn...
- ...by counter holding 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 slightly.
- 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 counter holding 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
