Removal & Installation
- Before servicing the vehicle, refer to the Precautions Section.
- Remove the oil pan.
- Set crankshaft to TDC of cylinder 1 by turning the vibration damper securing bolt in the direction of engine rotation. Align the mark on the vibration damper.
- Remove intake manifold and cylinder head cover.
- Remove the thermostat housing.
- Remove the upper timing chain tensioner.
Remove the upper timing chain cover. Note that the cover has a hidden bolt that can be removed only after the thermostat housing has been removed.
- Mark the position of the timing chain before removing with paint. Also mark an arrow pointing in the direction of rotation. Do not mark chain with a center punch or similar means!
- Remove the exhaust camshaft adjuster. Counter-hold the camshaft using a 32 mm open end wrench on the camshaft flats.
- Remove camshaft adjuster together with the timing chain from the intake camshaft. Place the chain aside.
- Remove the drive plate (refer to the Rear Main Seal procedure).
- Remove the bolts securing the lower timing chain cover.
The upper (camshaft) timing chain can now be removed.
NOTEBe careful not to damage the cylinder head gasket.
- Mark the position of the lower timing chain before removing with paint. Also mark an arrow pointing in the direction of rotation. Do not mark chain with a center punch or similar means!
- Remove the bolt securing the sprockets to the intermediate shaft.
- Release the lower timing chain tensioner, then remove the chain together with the intermediate shaft sprockets.
- Make sure the engine is at TDC of cylinder 1. Align the ground down tooth of the drive chain sprocket (B) with the mounting joint.
If the lower guide (2) was removed, install it and tighten the bolts to 7 ft. lbs. (10 Nm).
NOTEIf installing a used chain, note the direction of rotation and alignment marks made earlier.
Install the timing chain (1) and both chain sprockets (3) and (4). The marking on the timing chain sprocket (4) must align with notch (C) or (D) on the thrust washer of the intermediate shaft.
NOTEMake sure that the chain runs completely straight in the guide rail from the crankshaft to the intermediate shaft.
- Hand tighten the intermediate shaft bolt. Use a new bolt.
- Release the locking splines of the lower chain tensioner (A) with a small screwdriver while the tensioning rail is pressed against chain tensioner. If removed, the chain tensioner should be installed in this position and tightened to 71 inch lbs. (8 Nm).
- Lock the vibration damper with tool T10069 or equivalent.
- Tighten the new intermediate shaft sprockets securing bolt to 44 ft. lbs. (60 Nm), plus an additional 1 / 4 turn.
- Remove the vibration damper counter holder tool.
- Check the position of crankshaft (B) to intermediate shaft (C) and (D) once again. The engine must still be at TDC of cylinder 1.
- Position the camshafts to TDC of cylinder 1.
Install camshaft locking bar T10068 or similar. It must engage in both shaft grooves
- Place the camshaft timing chain on the intermediate shaft chain sprocket. Route the chain between the tensioning rail and guide rail towards the control housing.
- Install the intake camshaft adjuster first. Turn the sensor wheel (1) in the camshaft adjuster to the right onto its stop and bolt it on in this position. The marking 24E must align with the notch in the control housing.
Place the camshaft timing chain over the sprocket in this position.
NOTEIf the camshaft adjuster is to be fastened to the camshaft, the adjuster with the corresponding chain sprocket must be turned to the left. In any case, the marking 24E (intake) or 32A (exhaust) must be aligned to the notch in the control housing.
- Count exactly 16 rollers of the timing chain to the right from the 24E marking of the camshaft adjuster. Insert the tooth of the exhaust camshaft adjuster with the marking 32A at that point.
- There must now be exactly 16 rollers between those two teeth. Turn the sensor wheel (1) in the camshaft adjuster to the right onto its stop and bolt it on in this position.
Marks (A) and (B) on the camshaft adjusters must align with notches (arrows) on the control housing (C).
- Remove the camshaft locking bar.
- Using new bolts for the camshaft adjusters, tighten them by hand.
Check the timing adjustment:
- Press the tensioner plate of upper timing chain against the chain.
Turn the crankshaft over twice in direction of engine rotation and check the timing marks.
NOTEWhen turning the crankshaft, the tensioning plate must be pressed against the chain by hand at the chain tensioner, so that the chain does not jump over a tooth.
- If the marks do not align, repeat the valve timing adjustment.
- If the marks align, hold the respective camshaft tightly with a 32 mm open end wrench. Tighten the intake and exhaust camshaft adjusters to 44 ft. lbs. (60 Nm), plus and additional 1 / 4 turn.
- Remove the rear main seal from the lower timing cover.
- Coat the sealing surface of the lower timing with sealant AMV 176 501 or equivalent.
- Align the cover with the dowel pins in the cylinder block. Tighten the bolts to 71 inch lbs. (8 Nm).
- Install a new rear main seal.
- Lubricate a new oil channel seal and install it into the upper timing cover.
- Fill the 3mm holes in the cylinder head gasket with sealant AMV 174 004 01 (or equivalent). Coat the sealing surface on the upper timing cover with sealant AMV 176 501 (or equivalent). Install the cover immediately after applying the sealant.
- Insert all the securing bolts with corresponding brackets and tighten lightly. Then tighten the M8 bolts to 17 ft. lbs. (23 Nm) and the M6 bolts to 71 inch lbs. (8 Nm).
- Install the camshaft timing chain tensioner and tighten to 30 ft. lbs. (40 Nm).
- Turn the crankshaft over twice in direction of engine rotation and check the timing marks. If the marks do not align, repeat the valve timing adjustment.
- Install the thermostat housing. Tighten the bolts to 71 inch lbs. (8 Nm).
- The remaining installation is the reverse of removal.