Variable Valve Timing Solenoid: Service and Repair

Camshafts and camshaft adjuster, removing and installing

Special tools and workshop equipment required
^ Counterhold 3036
^ Chain tensioner holder 3366

Removing
^ Cylinder head installed
^ Lock carrier in service position.
- Remove toothed belt from camshaft sprocket.





- Remove engine cover (arrows).
- Remove secondary air combination valve.





- Disconnect connector (arrow) at camshaft adjuster.
- Remove cylinder head cover.
- Loosen camshaft sprocket (counterhold with 3036).
- Pull off camshaft sprocket.
- Remove entire camshaft position sensor.

Note: Excessive tightening of chain tensioner holder can damage camshaft adjuster.





- Secure camshaft adjuster with chain tensioner holder 3366.





- Re-check TDC position of camshafts:
^ Mark on two camshafts must be in line with arrows on bearing caps.
- Clean chain and camshaft sprockets opposite two arrows on bearing caps and mark installed position using colored markings.





^ Distance between two arrows or between colored markings is 16 rollers on drive chain.
^ Notch on exhaust camshaft is offset slightly toward inside in relation to chain roller -1-.

Note: Do not mark chain with a center punch or by making a notch, etc.





- First remove bearing caps 3 and 5 on intake and exhaust camshafts.
- Remove double bearing cap.
- Remove both bearing caps on intake and exhaust camshaft chain sprockets.
- Remove bolts securing camshaft adjuster.





- Loosen bearing caps 2 and 4 of intake and exhaust camshafts alternately in diagonal sequence and remove.
- Remove intake and exhaust camshafts together with camshaft adjuster.

Installing





- Replace rubber/metal gasket for camshaft adjuster and apply a thin coat of sealant AMV 188 001 02 to shaded areas.
- Install drive chain on camshaft sprockets as follows:





^ If old chain is re-installed, install chain so that colored markings are in line (arrows).





^ If new chain is installed, distance between notches -A- and -B- on camshafts must be 16 rollers on chain. Illustration shows exact positions of 1st and 16th rollers on sprockets.
^ Notch -A- is offset slightly toward inside in relation to chain roller -1-
- Insert camshaft adjuster between drive chain (2 technicians needed).
- Locate camshafts together with drive chain and camshaft adjuster in cylinder head.
- Oil running surfaces of both camshafts.

Note:
^ Dowel sleeves for bearing caps and camshaft adjuster must be installed in cylinder head.
^ When installing bearing caps ensure that identification mark is readable from intake side of cylinder head.

- Tighten mountings of camshaft adjuster (watch position of dowel sleeves).





- Tighten bearing caps 2 and 4 of intake and exhaust camshafts alternately in diagonal sequence (watch position of dowel sleeves).
- Install both bearing caps on intake and exhaust camshaft chain sprockets.
- Check correct setting of camshafts:





^ Two markings on camshafts must be in line with two arrows on bearing caps (arrows).





^ Distance between two arrows on bearing caps or between colored markings is 16 rollers on drive chain.
^ Notch on exhaust camshaft is offset slightly toward inside in relation to chain roller -1-
- Remove chain tensioner holder 3366.





- Apply thin coat of sealant AMV 188 001 02 to shaded area on double bearing cap and install bearing cap (watch position of dowel sleeves).
- Install remaining bearing caps (watch position of dowel sleeves).
- Replace oil seals for intake and exhaust camshafts.





- Install camshaft sprocket.
^ Note installed position:

Narrow web of camshaft sprocket must face outward (arrows) and marking for TDC No. 1 cylinder must be visible from front.
- Install securing bolt for camshaft sprocket (use counterhold 3036).
- Install camshaft position sensor.
- Install cylinder head cover





- Align marking on camshaft sprocket with marking on cylinder head cover.
- Align marking on vibration damper with marking on bottom section of toothed belt guard.

Note: The crankshaft must not be at TDC when camshaft is turned. Otherwise there is a risk of damage to valves and piston crowns.

- Install toothed belt (adjust valve timing).

Note:
^ After installing camshafts, engine must not be started for approximately 30 minutes. Hydraulic valve compensation elements have to settle (otherwise valves will strike pistons).
^ After working on valve gear, turn engine carefully at least 2 rotations to ensure that none of the valves make contact when starter is operated.

Tightening torques

Tightening torques: