AR05.20-P-7201A Remove/Install Camshaft Adjuster

Remove/Install Camshaft Adjuster

Camshaft Adjuster Replacement (Part 1 Of 2):

Camshaft Adjuster Replacement (Part 2 Of 2):

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

Removal
1. Remove cylinder head (Valve) cover (18).
2. Remove front cover (23) of cylinder head, refer to Upper Cover. Service and Repair
3. Position piston of cylinder 1 to 20° after ignition Top Dead Center (TDC)
- Rotate engine at crankshaft in direction of rotation.
4. Lock camshafts (75 and 78)
- Insert locating pins (01) from the rear through the camshaft bearing caps into the camshaft flanges (arrows).
5. Mark timing chain (73) and camshaft gears (76 and 13) with a cohered marking Arrows)
6. Remove chain tensioner (58). Service and Repair
7. Remove exhaust camshaft gear (76)
8. Take camshaft adjuster off the inlet camshaft as follows:





a. Unscrew collar bolt (1); counter-hold armature (2) at flats (arrow) when performing this step.
b. Pull off armature (2).
c. Unscrew nut (6); counter-hold camshaft (22) at hexagon with wrench (03) when performing this step.
d. Take off cover (12).
e. Screw on thrust nut (02)
f. Take off inlet camshaft sprocket (13); lift timing chain for this step.
g. Unscrew thrust nut (02), take off positioning piston (14) and conical spring (14a).
h. Unbolt flange shaft (16); counterhold camshaft (22) at hexagon with wrench (03) for this step.


Installation
1. Fit camshaft adjuster onto inlet camshaft as follows:





a. Bolt plunge shaft (16) to inlet camshaft (22); counterhold camshaft (22) at hexagon with wrench (03) for this step.
- Tighten collar bolts in two stages to:
1st Stage, tighten to: 20 Nm
2nd Stage, turn: An Additional 60°

NOTE: Replace collar bolts (15); use only once.

b. Insert conical spring (l4a) and push adjusting piston (14) onto flange shaft (16) in the fixed position (blocking tooth B).
c. Screw on thrust nut (02).
d. Push inlet camshaft gear (13) onto splines of adjusting piston (14) into the fixed position (blocking tooth B); hold timing chain up for this step.
e. Unscrew thrust nut (02); hold camshaft adjuster together for this step.
f. Push on cover (12).
g. Screw on nut (6) with the flat face pointing toward the camshaft adjuster flocking slot at front).
h. Tighten nut (6); counterhold camshaft (22) at hexagon with wrench (03) for this step to: 65 Nm.
i Push on armature (2) into the fixed position.
j Screw on collar bolt (1); counterhold armature (2) at the flats (arrow) for this step
- Tighten collar bolts in two stages to:
1st Stage, tighten to: 20 Nm
2nd Stage, turn: An Additional 60°
2. Install exhaust camshaft gear (76) with timing chain (73) installed on
- Replace collar bolts (15); use only once.
- Tighten in two stages to:
1st Stage, tighten to: 20 Nm
2nd Stage, turn: An Additional 60°
- Fit on timing chain so that the colored markings (arrows) on the timing chain and on the camshaft gears (13 and 76) are positioned one above the other.
3. Install chain tensioner (58)
- If the complete chain tensioner is slackened, it has to be removed, disassembled and re-assembled as described.
4. Remove locating pins (01)
5. Rotate engine Twice at crankshaft in direction of rotation
6. Check basic position of camshafts
7. Install front cover (23) at cylinder head
8. Install cylinder head cover (18)
- Run engine and inspect for leaks
- Inspect gasket of cylinder head cover to ensure correctly installed