Procedures

PRECEDING WORK
Poly-V belt removed.
Radiator removed.

OVERVIEW

Right Cylinder Head Shown:

CHECKING SETTING OF TDC SENSOR
Tensioning roller, tensioning device:
Remove.
Install (step 1).
Spark plugs on cylinder 1 and 7:
Remove.
Install.
TDC sensors (L1/1 and L1/2):
Remove.
Install (step 3).
Piston of cylinder 1 and 7:
Set to 10° before TDC (step 4).
Dial gauge holder (02) 363 689 02 21 00 with threaded sleeve (04):
Fit on valve cover of cylinder 1 and 7 (step 5).
Dial gauge (01) with extension (03) (300 mm):
Clamp in dial gauge holder (02) 363 589 02 21 00 with 4 mm preload (step 6).
Crankshaft:
Rotate in direction of rotation of engine with wrench socket 001 589 65 09 00 and set TDC at cylinder 1 and 7 with dial gauge (01).
Large pointer of dial gauge (01):
Set to "0".
Crankshaft:
Rotate with wrench socket 001 589 65 09 00 in direction of rotation of engine until dial gauge has moved back by the value in table "piston travel" (20° after TDC cylinder 1 and 7).
Fixing device 119 589 00 21 00:
Insert into adjusting slide (step 10).
Fixing device 119 589 00 21 00:
Must engage in measuring pin on vibration damper.

CORRECTING SETTING OF TDC SENSORS
Nuts of adjusting slide:
Slacken (step 11).
Adjusting slide:
Move until fixing device 119 589 00 21 00 engages at vibration damper (step 11).
Nuts of adjusting slide:
Tighten (step 12).

NOTES:





The TDC sensors (L1/2) and (L1/1) with adjusting slides (3) and (7) are attached to the timing case cover.

The measuring pin (arrow) on the vibration damper must be centered below the TDC sensors (L1/2) and (0/1) at 200 after TDC at cylinder 1° and at 20° after TDC at cylinder 7 (TDC pointer reading 80°).

The setting of the TDC sensors must be chocked and corrected:
^ if the crankshaft or the vibration damper is replaced.
^ if the timing case cover is replaced.
^ if parts are added to part engines.

With the cylinder heads removed, attach a dial gauge holder to the crankcase and position dial gauge pin on the piston crown.

PROCEDURES
CHECKING SETTING OF TDC SENSORS (L1/1) AND (L1/2)





1 Unscrew bolt (1), remove tensioning pulley (8) of poly V-belt.
Tightening torque 38 Nm.
2 Unscrew spark plugs at cylinder 1 and 7. Tightening torque 25 Nm.





3 Unscrew TDC sensors (L1/2) and L1/1) and remove from adjusting slides (3) and (7).





4 Set pistons of cylinders 1 and 7 to 10° before TDC (reading 50° CKA on vibration damper for cylinder 7).
5 Attach dial gauge holder (02) 363 589 02 21 00 with threaded sleeve (04) (shop-made) to cylinder head cover of cylinders 1 and 7.
Unscrew cylinder head cover bolt for this stop and install dial gauge holder (02) with threaded sleeve (04).





6 Clamp dial gauge (01) with extension (03) (30° mm) into dial gauge holder (02) with 4 mm preload.
7 Rotate crankshaft in direction of rotation of engine with socket wrench 001 589 65 09 00 and set TDC at cylinders 1 and 7 with dial gauge (01).
8 Turn scale of dial gauge until the large pointer of gauge (01) is at "0".





9 Turn on crankshaft in direction of rotation of engine until the dial gauge has moved back by the respective amount (piston travel).
10 Insert fixing device (4) 119 589 00 21 00 into the adjusting slide (3) (right bank of cylinders) or (7) (left bank of cylinders).
The slot of the fixing device (4) must engage in the measuring pin (arrow) on the vibration damper (6).
If the fixing device (4) does not engage at the vibration damper (6), correct the setting of the TDC sensors.

CORRECTING SETTING OF TDC SENSORS (L1/1) AND (L1/2)





11 Slacken nut (5) or (9) and move adjusting slide (3) or (7) until fixing device (4) engages in the measuring pin (arrow) at the vibration damper (6).
12 Tighten nut (5) or (9).
13 Install in the reverse order, beginning at step 3.


DATA






SPECIAL TOOLS


















SHOP-MADE TOOL





Threaded sleeve (M8 to M6 reduction) for attaching dial gauge holder 363 589 02 21 00 to cylinder head cover.