Camshaft Timing Chain, Removing From Camshafts

Camshaft Timing Chain, Removing from Camshafts

Special tools, testers and auxiliary items required

• Camshaft bar (T10068 A)

• Adjustment tool (T10332) for vehicles without mechanical vacuum pump

• Adjustment tool (T10363) for vehicles with mechanical vacuum pump

• Sealant

Removing

• Engine installed.

- Remove intake manifold

- Remove cylinder head cover => [ Cylinder Head Cover ] Service and Repair.

- Remove timing chain upper cover => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.

- Adjust crankshaft at vibration damper bolt in direction of engine rotation to "TDC" marking.

• Markings on vibration damper and sealing flange must align - arrow -.

• Camshaft bar (T10068 A) must engage in grooves on both camshafts at the same time.

• Due to the camshaft adjuster function, the camshaft grooves may not be perfectly horizontal. Therefore, turn the camshaft back and forth slightly with an open end wrench - arrows - if necessary to insert camshaft bar (T10068 A).

• If the camshaft bar (T10068 A) does not engage, rotate crankshaft 1 rotation further in direction of engine rotation.

- Remove camshaft timing chain tensioner - arrow -.

- Remove guide rail bolt - arrow -.

- Remove camshaft bar (T10068 A).

• camshaft bar (T10068 A) must not be inserted when loosening or tightening camshaft adjuster bolts.

- Remove exhaust-side camshaft adjuster bolt while counter holding on camshaft wrench surface with open end wrench.

- Remove exhaust-side camshaft adjuster.

- Remove intake-side camshaft adjuster bolt while counter holding on camshaft wrench surface with open end wrench.

- Remove intake-side camshaft adjuster.

- Place camshaft timing chain over upper guide rail.

Installing (Adjusting Valve Timing)

• Tightening specifications => [ Camshaft Timing Chains, Assembly Overview ] Camshaft Timing Chains, Assembly Overview.

• Replace bolts which have been tightened to specifications.

- Check if crankshaft is in "TDC" position:

• Markings on vibration damper and sealing flange must align - arrow -.

- Check if camshaft is in "TDC" position:

• Camshaft bar (T10068 A) must be situated in grooves in both camshafts.

• Due to the camshaft adjuster function, the camshaft grooves may not be perfectly horizontal. Therefore, turn the camshaft back and forth slightly with an open end wrench - arrows - if necessary to insert camshaft bar (T10068 A).

- Check if fitting sleeve - 1 - for securing adjustment tool (T10332) is inserted.

• Ignore items - 2, 3 and arrows -.

Without Mechanical Vacuum Pump

- Secure high pressure drive chain position with adjustment tool (T10332).

- Lay camshaft timing chain tightly over drive chain sprocket.

With Mechanical Vacuum Pump

- Secure high pressure pump drive chain sprocket with adjustment tool (T10363).

- Lay camshaft timing chain tightly over drive chain sprocket.

Continuation for All

• Because of alignment pins - arrows -, both camshaft adjusters can only be installed in one position on front side of camshaft.

- First install intake-side camshaft adjuster by rotating sensor wheel - 1 - in adjuster clockwise as far as stop - ARROW - and holding in this position.

• On the front side of the camshaft adjuster, mark the location where the rear side of the alignment pin is located to aid in assembly.

- Place camshaft adjuster "24E" with camshaft timing chain placed on top on intake camshaft.

• It must be able to easily place camshaft adjuster with timing chain placed tightly on top on intake camshaft - note alignment pin.

• Camshaft timing chain must not hang through to high pressure pump drive chain sprocket.

• The "arrow" - 1 - on intake camshaft adjuster must align with notch - 2 - on far right of control housing.

• A small offset between notch - 2 - and arrow - 1 - is permitted.

• Ignore notch on camshaft adjuster.

- Install camshaft adjuster bolt in intake camshaft in this position and hand tighten.

• Contact surface of sensor wheel at screw head must be dry when installing.

• Do not use camshaft bar (T10068 A) as a counter hold.

- From marking "24E" on intake side of camshaft adjuster, count exactly 16 rollers on timing chain toward exhaust-side direction.

- Insert tooth at marking "32A" on exhaust side camshaft adjuster exactly behind 16th roller in chain.

• 16 chain rollers must now lie between the teeth.

• Because the exhaust side camshaft adjuster is locked in "rest state", the sensor wheel cannot rotate when adjusting the timing.

• If locking mechanism in "rest state" is not engaged, exhaust side camshaft adjuster must be replaced.

• When positioning exhaust side camshaft adjuster, ensure timing chain is lying on tensioning rail.

- Place camshaft adjuster "32A" with camshaft timing chain installed on exhaust camshaft.

• It must be able to easily place camshaft adjuster with timing chain placed tightly on top on exhaust camshaft - note alignment pin.

• Marking - 1 - on camshaft adjuster which "arrow" points to must align with notch - 2 - at far right on control housing.

• A small offset between the marking - 1 - and notch - 2 - is permitted.

- Install camshaft adjuster bolt in exhaust camshaft in this position and hand tighten.

• Contact surface of sensor wheel at bolt head must be dry when installing.

• Do not use camshaft bar (T10068 A) as a counter hold.

Without Mechanical Vacuum Pump

- Remove adjustment tool (T10332).

With Mechanical Vacuum Pump

- Remove adjustment tool (T10363).

Continuation for All

- Install guide rail bolt - arrow -.

- Install camshaft timing chain tensioner - arrow -.

- Remove camshaft bar (T10068 A).

- Install bolt on intake side camshaft adjuster while counter holding with open end wrench on camshaft wrench surface.

- Install bolt on exhaust side camshaft adjuster while counter holding with open end wrench on camshaft wrench surface.

- Rotate crankshaft 2 revolutions in direction of engine rotation at vibration damper bolt and place at "TDC" marking.

• Markings on vibration damper and sealing flange must align - arrow -.

• Camshaft bar (T10068 A) must engage in grooves on both camshafts at the same time.

• If camshaft bar cannot be engaged, adjust timing again.

- Replace timing chain upper cover sealing ring => [ Upper Timing Chain Cover Seal ] Upper Timing Chain Cover Seal.

- Install timing chain upper cover => [ Upper Timing Chain Cover ] Upper Timing Chain Cover.

- Install cylinder head cover => [ Cylinder Head Cover ] Service and Repair

- Install intake manifold