Camshaft Seal/Variable Valve Timing (VVT) Unit, Replacing

Camshaft seal/variable valve timing (VVT) unit, replacing

Special tools:
999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
999 5651 Extractor 999 5651 Extractor
999 5719 Drift 999 5719 Drift
999 5718 Drift 999 5718 Drift
999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection
999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
999 5919 PULLER 999 5919 Puller
999 5450 PUNCH 999 5450 Punch

Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information in the illustrations is always correct.

Removal

Caution! There are a number of versions of the variable valve timing unit. Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied.

Removing the camshaft seal





Note! Crankshaft and camshafts must not be turned more than is stated in the method description!If the shafts are turned in any other way the valves may be damaged.

Remove:
- the cable from the battery negative terminal.
First read Battery, disconnecting Battery Disconnecting.
- the cross stay between the suspension turrets
- the upper timing belt cover
- the cover over the ignition coils
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the crankcase ventilation hose from the inlet hose
- place the inlet hose to one side
- the upper engine stabilizer brace
- the camshaft position (CMP) sensor housing
- the trigger wheel
- the rear cover for the intake camshaft
- the servo reservoir and the expansion tank. Lift them up and place them on top of the engine

Warning! Ensure that no power steering fluid is spilled. Extremely flammable.

- the auxiliaries belt
- the front timing belt cover

Position the engine according to the marking




Raise the car.

Remove:
- the right front wheel
- the nuts for the cover in the fender liner.
Install the upper timing belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.
Remove the upper timing belt cover.

Removing the timing belt




Slacken off the belt tensioner.
Slacken off the centre screw for the belt tensioner slightly.
Hold the center screw in place. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key.
Remove the timing belt from the camshaft pulleys.

Removing the timing gear pulley with the variable valve timing unit





Use camshaft adjustment tool:
- Install camshaft adjustment tool 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool at the rear of the camshafts.

Remove:
- the plug at the front edge of the variable valve timing unit (TORX 55)
- the center screw in the variable valve timing unit (TORX 55).
Carefully pull out the timing gear pulley with the VVT unit
- timing gear pulley without VVT
- the screws and the timing gear pulley.

Replacing the camshaft seal




Carefully press in tool 999 5651 Extractor 999 5651 Extractor between the sealing ring and the camshaft.
Carefully pry out the seal.

Cleaning
To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

Note! When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.




Oil the new seal.
Install the new seal for the exhaust camshaft. Use drift 999 5719 Drift 999 5719 Drift.
Install the new seal for the intake camshaft. Use drift 999 5718 Drift 999 5718 Drift.

Remove the engine cooling fan (FC)





Remove:
- slacken off the brake vacuum hose from the intake
- the air cleaner (ACL) housing intake pipe from the connection above the radiator. Twist the pipe up
- the manifold absolute pressure (MAP) sensor from the front cover plate
- the evaporative emission system (EVAP) valve from the engine cooling fan (FC) shroud
- release the wiring from the fan shroud.
Lift out the hose for the expansion tank from the holders on top of the fan shroud.
Disconnect both the engine cooling fan (FC) connectors.
- both screws holding the fan shroud.
Carefully lift up the engine cooling fan (FC).
Install radiator protection 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection.

Installation

Checking and adjusting the variable valve timing unit
Check and adjust the variable valve timing unit. See: Variable valve timing unit, checking and adjusting Testing and Inspection

Reinstall





Install:
- the front timing belt cover. Tighten to 12 Nm
- the cover over the ignition coils
- the upper timing belt cover
- the auxiliaries belt
- the expansion tank
- the servo reservoir.
Check that the hoses are correctly positioned
- the starter motor. Tighten the screws at the transmission to 40 Nm. Tighten the screw for the support bracket. Tighten to 25 Nm.
Remove the radiator protector.




Carefully lower the fan shroud. Align it with the holders at the sides of the radiator.
Tighten both the mounting screws.
Connect the engine cooling fan (FC) connectors.
Press the hose down from the expansion tank into the holder on the fan shroud.
Secure the wiring with tie straps as before.
Press the manifold absolute pressure (MAP) sensor onto the holder at the front cover plate.
Press the evaporative emission system (EVAP) valve into the holder on the fan shroud.
Turn down the air cleaner (ACL) intake manifold and locate against the sleeve connector above the air conditioning aggregate.

Install
- the brake vacuum hose
- the trigger wheel.
Tighten to 17 Nm
- the camshaft position (CMP) sensor housing and a new cover.
Tighten to 17 Nm
- the torque rod bracket.
Tighten to 50 Nm
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the crankcase ventilation hose on the inlet hose
- the plastic nuts for the cover in fender liner
- the wheel. See Installing wheels Service and Repair
- the engine stabilizer brace. Tighten the screws at the suspension turrets. Tighten to 50 Nm. Tighten the engine bracket screw. Tighten to 80 Nm
- the negative battery cable. First read Battery, disconnecting Battery Disconnecting.

Checking the engine
Test drive the car to check the function of the engine.

Rear camshaft seal





The following components must be removed when replacing the rear camshaft seal:
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the crankcase ventilation hose from the inlet hose
- place the air cleaner (ACL) cover to one side
- the cover over the ignition coils
- the upper torque rod bracket
- the camshaft position sensor (CMP) housing and trigger wheel.

Replacing the rear camshaft seal




Pull out the seal. Use puller 999 5919 PULLER 999 5919 Puller. Use emery cloth 951 1024 to clean the shaft journal and mating surface.

Note! When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 999 5450 PUNCH 999 5450 Punch.

Note! The seal is normally pressed in so that it is level with the internal beveled edge.If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm deeper by turning the drift socket.

Reinstall





Install:
- the trigger wheel.
Tighten to 17 Nm
- the camshaft position (CMP) sensor housing and a new cover.
Tighten to 17 Nm
- the torque rod bracket.
Tighten to 50 Nm
- the cover over the ignition coils
- air cleaner (ACL) cover
- the inlet hose between the air cleaner (ACL) and throttle body (TB)
- the crankcase ventilation hose on the inlet hose
Check the engine compartment. Wipe the engine compartment clean.

Checking the engine
Test drive the car to check the function of the engine.