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Camshaft Sprockets, Remove and Install
 Remove
| 2. |
Remove air cleaner housing
| • |
Disconnect mass air flow sensor wiring harness plug (2)
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| • |
Unclip tank vent line (3)
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| • |
Detach engine vent hose (4) from air intake hose
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| • |
Detach air intake hose (5) from throttle valve body
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| • |
Detach air cleaner housing
| – |
Unclip rubber mounting at the bottom
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| – |
Remove air intake pipe (6)
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| 3. |
Disconnect wiring harness plugs for camshaft sensor (1), hot
film mass air flow meter (2), oil pressure switch (3) and coolant
temperature sensor (4)
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| 4. |
Unclip wiring trough (5) from cylinder head cover
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| 5. |
Remove engine vent hoses (2) from cylinder head cover
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| 6. |
Remove ignition module
| • |
Disconnect cooling module wiring harness plug (4)
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| • |
Pull the cover of the ignition module (1) away from the
cylinder head cover in the direction of the arrow
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Important: Do not tilt
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| • |
Remove ignition module (5) from spark plugs with KM-6009 (3)
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| 7. |
Detach cylinder head cover (7) from cylinder head
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| 8. |
Remove gasket remnants and clean sealing surfaces
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| 9. |
Move crankshaft in direction of engine rotation to just before
"cylinder 1 TDC of combustion stroke"
| • |
The marking (3) on the crankshaft belt pulley is just before
the cast projection (2) on the timing case
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| • |
In this position, the cams (1) of cylinder 1 are at "TDC of
combustion stroke" (both cams point outwards)
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| 10. |
Remove closure bolt of chain tensioner (1) from timing case
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| 11. |
Lock chain tensioner with KM-955-1
(2)
| • |
Apply tension to intake camshaft in the direction of engine
rotation via hexagon (direction of arrow)
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| 12. |
Detach sliding rail (1) from cylinder head
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| 13. |
Remove camshaft sprockets
| • |
Unscrew 2x bolts (2)
| – |
Counterhold with open-ended wrench against the hexagon of the
camshafts (3)
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| • |
Take out camshaft sprockets
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Install
| 14. |
Tighten camshaft sprockets hand-tight with new bolts
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Screw in 2x bolts
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Tighten hand-tight
Note: It must still be
possible to turn the phase sensor disc on the intake camshaft by
hand
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| 15. |
Attach sliding rail to cylinder head
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| 16. |
Turn camshafts by the hexagon (short distance) until KM-953 (1) can be inserted in the grooves of
the camshafts
Note: Turn camshafts
carefully and evenly
| • |
KM-953 must engage as far as the stop
in the grooves of the camshafts
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| 17. |
Turn phase sensor disc (2) in such a way that KM-954 (1) can be inserted on the timing case
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| 18. |
Attach KM-954 to timing case
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| 19. |
Take KM-955-1 out of chain
tensioner
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| 20. |
Unscrew closure bolt, crankshaft bearing bridge (1)
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| 21. |
Adjust TDC of combustion stroke of cylinder 1
| • |
Insert KM-952 (2)
| – |
Turn crankshaft evenly until KM-952
engages
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| – |
Marking on the crankshaft belt pulley (4) must align with the
cast projection (3) on the timing case
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| 22. |
Remove locking pin of chain tensioner KM-955-1
| • |
Tighten chain tensioner closure bolt 50
Nm
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| 23. |
Fasten camshaft sprockets
Note: Tightening torque
10 Nm serves to fix the camshaft
sprockets and the phase sensor disc temporarily
| • |
Tighten 2x bolt (2) 10 Nm
Note: First of all
tighten bolt of intake camshaft sprocket
| – |
Counterhold the camshafts on the hexagon (1)
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| 24. |
Remove locking tools KM-954 , KM-953 and KM-952
Note: Locking tools may
not be used for counterholding
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| 25. |
Tighten camshaft sprockets
Note: Use a second
person
| • |
Tighten 2x bolt 50 Nm + 60°
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| 26. |
Timing, Check
| • |
Turn crankshaft through 720°
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| • |
Insert KM-953 into camshafts
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| • |
Attach KM-954 on phase sensor
disc
Note: if KM-954 cannot be inserted, the operation "Timing,
Adjust" must be repeated
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| 27. |
Remove KM-954 , KM-953 and KM-952
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| 28. |
Attach cylinder head cover (1)
Important: Complete assembly work
within 10 minutes
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| • |
Apply a bead of silicone sealing compound (dimension I) approx.
2 mm thick to the dividing joints of the cylinder head and timing
case
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Important: Bolts must be checked
visually to check whether the elastomer seal is damaged. If the
elastomer seal is damaged, the bolt must be replaced with a new
one.
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| • |
Tighten 13x bolt 8 Nm
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| 29. |
Install ignition module
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Connect ignition module to spark plugs
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| • |
Attach ignition module cover to cylinder head cover
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| • |
Connect ignition module wiring harness plug
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| 30. |
Clip wiring trough to cylinder head cover
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| 31. |
Connect wiring harness plugs for camshaft sensor, hot film mass
air flow meter, oil pressure switch and coolant temperature
sensor
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| 32. |
Install air cleaner housing
| • |
Connect air intake hose
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| • |
Attach engine vent hose
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| • |
Connect 2x wiring harness plugs
| – |
Hot film air mass flow meter, tank vent valve
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