Hydraulic control unit - K16 VVC engines - assembling

Hydraulic control unit - K16 VVC engines - assembling

CAUTION: It is essential to ensure that absolute cleanliness is maintained during the following operations.

1. Thoroughly clean all components, dry with compressed air.
2. Lubricate new labyrinth seals and rack seal with engine oil.

3. Using the fingers only, fit labyrinth seals each side of hydraulic control unit seal plate.

CAUTION: Ensure seals are located beneath retaining lugs.

4. Fit new rack seal to plate.

5. Slide piston end of rack through seal.

CAUTION: Only insert rack through seal for a sufficient distance to enable piston to be fitted and take great care that teeth of rack do not contact seal.

6. Secure rack in a soft-jawed vice, fit new piston and seal assembly to rack, fit and tighten new screw supplied with seal kit to 9 Nm.
7. Lubricate piston bore with engine oil.
8. Position seal plate, piston and rack assembly to hydraulic control unit with rack teeth facing towards fixing hole adjacent to solenoid side of unit.

9. Insert piston and rack assembly into bore of housing at an angle as shown, taking care not to damage piston seal on machined edge of oil feed channel. Push piston to top of bore.