Camshaft Adjuster with Camshaft Timing Chain, Installing

Camshaft Adjuster with Camshaft Timing Chain, Installing

• A revised camshaft adjuster is being installed as of 12.08. To recognize the new adjuster: starting in 12.08 the exhaust camshaft adjuster 32A has a plastic cover.

=> [ Vehicles through 11.08 ]

=> [ Vehicles from 12.08 ]

Vehicles through 11.08

- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the Top Dead Center (TDC) cylinder 1 mark - arrow -.





- The camshaft lobes - A - for cylinder 1 must face each other.





- Install the (T10068 A) into both camshaft grooves. If necessary, slightly rotate the camshaft back and forth using an open end wrench.





• Both camshaft adjusters (identification: "24E" on intake side and "32A" on exhaust side) can only installed in one position on the camshafts- arrows - by an alignment pin.





- Rotate the sensor wheel - 1 - on the intake camshaft adjuster clockwise in the - direction of the arrow - until it stops and hold the adjuster in this position.





• If the intake camshaft adjuster is attached to the camshaft, the adjuster must be rotated left accordingly with the chain sprocket and then the camshaft timing chain must be routed.

- Ensure the camshaft timing chain rests against the guide rail - 1 - tautly and does not hang through.





The adjuster must be able to be installed easily onto the intake camshaft with the camshaft timing chain installed tautly and the bolt be tightened hand tight.

• The "arrow" - 1 - on the camshaft adjuster for the intake camshaft must align with the left notch - 2 - on the control housing.





- Starting with the tooth that aligns with the "24E" mark, count exactly 16 rollers to the right on the timing chain. Mark this roller with a colored mark.





• The exhaust camshaft adjuster is locked in the rest position. Therefore the sensor wheel cannot be rotated when adjusting the valve timing. If the locking mechanism in the rest position is not engaged (locked) turn the adjuster in both directions by hand until it locks. If that is not possible, replaced the camshaft adjuster.

- Install the exhaust camshaft adjuster "32A" with the tooth at the arrow mark - 1 - into the camshaft timing chain so that the exact, previously counted 16 rollers lie between marks "24E" and "32A" and the marks - 1 - and - 2 - align.





- Exhaust camshaft adjuster must be able to be installed easily onto the exhaust camshaft and the bolt be tightened hand tight.

- Check the position of both camshaft adjusters one more time for correct adjustment.





- Remove the (T10068 A).

• When rotating the crankshaft, the tensioning rail must be pressed by hand against the camshaft timing chain at the chain tensioner, so that the camshaft timing chain does not jump over!





- Rotate the crankshaft twice in engine rotation direction and check the valve timing.

If the marks match:

- Secure the respective camshaft to be tightened using a 32 mm open end wrench on the recess - arrow -.





• (T10068 A) must not be installed during this process.

- Tighten the new camshaft adjuster bolts to 60 Nm + 90° (1/4) additional turn.

- Clean the sealing surfaces on the camshaft front cover and the cylinder head.

- Lubricate the oil passage seal O-ring - 1 - and install it in the cover.





- Make sure the alignment sleeves - 2 and 3 - are installed.

- Install the seal - 4 - in the cover.

- Clean the old sealing compound from the 3 mm holes in the cylinder head gasket - arrows -.





- Fill the 3 mm holes in the cylinder head gasket with sealant (D 176 501 A1). Apply sealant (D 176 501 A1) to the sealing surfaces on the cover and install the cover immediately.

- Install all camshaft front cover bolts - arrows - and tighten lightly.





- Tighten the M8 bolts - item 8 -=> [ Bolt ] to 23 Nm and tighten the M6 stud bolt to 8 Nm.

- Install the chain tensioner for the camshaft timing chain and tighten it to 40 Nm.

- Rotate the crankshaft twice in engine rotation direction and check the valve timing again.

- Install the cylinder head cover and the intake manifold.

Vehicles from 12.08

- Rotate the crankshaft at the vibration damper bolt in engine rotation direction to the Top Dead Center (TDC) cylinder 1 mark - arrow -.





- The camshaft lobes - A - for cylinder 1 must face each other.





- Install the (T10068 A) into both camshaft grooves. If necessary, slightly rotate the camshaft back and forth using an open end wrench.





The camshaft adjusters can be attached to the camshafts - arrows - in only one position. This is due to the alignment pin.





• The camshaft adjusters are locked in their rest position. Therefore the sensor wheels cannot be rotated when adjusting the valve timing. If the locking mechanism in its rest position is not engaged (locked) turn the adjuster in both directions by hand until it locks. If that is not possible, replaced the camshaft adjuster.

- Ensure the camshaft timing chain rests against the guide rail - 1 - tautly and does not hang through.





The adjuster must be able to be installed easily on the intake camshaft with camshaft timing chain installed tautly and the bolt be tightened hand tight.

• The "arrow" - 1 - on the camshaft adjuster for the intake camshaft must align with the left notch - 2 - on the control housing.





- Starting with the tooth that aligns with the "24E" mark, count exactly 16 rollers to the right on the timing chain. Mark this roller with a colored mark.





- Now install the exhaust camshaft adjuster "32A" positioned with the tooth at the mark - 1 - into the camshaft timing chain so that the exact, previously counted 16 rollers lie between marks "24E" and "32A".

- Install the camshaft adjuster 32A with the camshaft timing chain installed onto the exhaust camshaft. Note the following:

• The arrow - 1 - on the camshaft adjuster 32A must align with the notch - 2 - on the right side of the control housing.





• the exhaust camshaft adjuster must be able to be installed easily onto the exhaust camshaft and the bolt be tightened hand tight.

- Check the position of both camshaft adjusters one more time for correct adjustment.





- Remove the (T10068 A).

• When rotating the crankshaft, the tensioning rail must be pressed by hand against the camshaft timing chain at the chain tensioner, so that the camshaft timing chain does not jump over!





- Rotate the crankshaft twice in engine rotation direction and check the valve timing.

If the marks match:

- Secure the respective camshaft to be tightened using a 32 mm open end wrench on the recesses - arrow -.





• (T10068 A) must not be installed during this process.

- Tighten the new bolts for the camshaft adjusters to 60 Nm + 90° (1/4) additional turn.

- Clean the sealing surfaces on the cover and on the cylinder head.

- Lubricate the oil passage seal O-ring - 1 - and insert it in the cover.





- Make sure the alignment sleeves - 2 and 3 - are installed.

- Install the seal - 4 - in the cover.

- Clean the old sealing compound from the 3 mm holes in the cylinder head gasket - arrows -.





- Fill the 3 mm holes in the cylinder head gasket with sealant (D 176 501 A1). Apply sealant (D 176 501 A1) to the sealing surfaces on the cover and install the cover immediately.

- Install all the camshaft front cover bolts - arrows - and tighten lightly.





- Tighten the M8 bolts - item 8 -=> [ Bolt ] to 23 Nm and tighten the M6 stud bolt - item 2 -=> [ Stud Bolt ] to 8 Nm.

- Install the chain tensioner for the camshaft timing chain and tighten it to 40 Nm.

- Rotate the crankshaft twice in engine rotation direction and check the valve timing again.

- Install the cylinder head cover and the intake manifold.