Removing and Installing/Replacing Left Exhaust VANOS Gear (S85)

11 36 144 - Removing and installing / replacing left exhaust VANOS gear (S85)





Special tools required:
- 11 5 100
- 11 5 302 11 5 300 Gauge
- 11 5 320 11 5 320 Plug mandrel
- 11 5 370 11 5 370 Locating Tool
- 11 5 382 11 5 380 Gauge
- 11 5 410 11 5 410 Gauge





Necessary preliminary tasks:
- Remove left VANOS adjustment unit Removing and Installing / Replacing Left VANOS Adjustment Unit (S85).





Important!
Both inlet and exhaust camshafts can be adjusted in the 1st cylinder firing TDC position.
The procedure for checking timing Testing and Inspection is different from that for adjusting.

Secure special tool 11 5 320 11 5 320 Plug mandrel to vibration damper in 1st cylinder firing TDC position.





Position of camshafts, cyl. 6-10, in 1st cylinder firing TDC position.
Dihedron of camshafts is vertical to cylinder axis, lettering of camshaft points upwards (E2).





Rotate exhaust camshaft at hexagon head with an open-end wrench (2) in direction of arrow until special tool A 11 5 302 can be attached.
Designation (A2) on dihedron points upwards.

Note:
Exhaust VANOS gear (1) adjusted in direction of arrow.





Disconnect inlet and exhaust camshafts.

Note:
Rotate exhaust camshaft at hexagon head, attach special tool A 11 5 302 11 5 300 Gauge.
Attach special tool E 11 5 302 11 5 300 Gauge and secure with bolts (1).

Important!
Screw in bolts (1) without fail, risk of damage to camshafts.





Important!
Removal/installation is not possible without hexagon socket screw (1).
Hexagon socket screw (1) with washer must not be longer than 18 mm.
Gearwheels (2 and 3) of exhaust VANOS gear are tensioned with a spring.

Insert M8x18 hexagon socket screw (1) into VANOS gear.





Installation:
If the hexagon socket screw is released or forgotten by mistake, the gear teeth can be readjusted with special tool 11 5 370 11 5 370 Locating Tool.
Screw in special tool 11 5 370 11 5 370 Locating Tool until gearwheel (1) lines up with bore (see arrow) on thread.
Failure to tension the VANOS gear will result in rattling noises at idle.





Release hexagon socket screws with washers (1 and 2).

Installation:
If reusing the VANOS gear, replace hexagon socket screws with washers (1 and 2).





Important!
Release central bolt only when inner sleeves (1 and 2) with elongated holes are at left stop.

Pull VANOS gear with outer sleeve forwards until inner sleeves (1 and 2) with elongated holes are at left stop.

Join hexagon socket screws with washers (3 and 4) to 10 Nm.





Attach special tool 11 5 382 11 5 380 Gauge.
Fit special tool 11 5 410 11 5 410 Gauge with bolts (3).

Important!
Release central bolt (2) with special tools 11 5 410 11 5 410 Gauge and 11 5 382 11 5 380 Gauge only.

Note:
- If the special tool 11 5 410 11 5 410 Gauge cannot be fitted due to the hexagon socket screws being unfavourably positioned, it is necessary to remove the two or if necessary four hexagon socket screws.

Release central bolts (2).

Remove special tool 11 5 410 11 5 410 Gauge.





Note:
- If the central bolt is released, the removed hexagon socket screws are reinstalled with a joining torque of 10 Nm.

Installation:
Replace central bolts (1 and 2).





Important!
Danger of injury!

Installation:
If the VANOS gear is to be reused, the special tool 11 5 382 11 5 380 Gauge must not be removed.
VANOS gear is tensioned.

Tilt special tool 11 5 382 11 5 380 Gauge in direction of arrow.

If the VANOS gear is to be replaced by a new part, the special tool 11 5 382 11 5 380 Gauge can be removed.
Remove VANOS gear with special tool 11 5 382 11 5 380 Gauge.





Important!
Danger of injury!

Installation:
If the VANOS gear is to be reused, the special tool 11 5 382 11 5 380 Gauge must not be removed.
VANOS gear is tensioned.

Set down VANOS gear (1) with special tool (2).





Installation:
If necessary, turn transportation lock on VANOS gear into a favourable position.

Install exhaust VANOS gear (2) in position.

Installation:
M8x18 hexagon socket screw points upwards.
One of the three screws points downwards.
Insert central bolt, join slightly and then release again through 90°.
Remove M8x18 hexagon socket screw or special tool 11 5 370 11 5 370 Locating Tool.





If necessary, remove transportation lock from VANOS gear.
Insert special tool 11 5 382 11 5 380 Gauge between outer sleeve and gearwheel.
Fit special tool 11 5 410 11 5 410 Gauge.

Important!
Secure and release central bolt (2) with special tools 11 5 410 11 5 410 Gauge and 11 5 382 11 5 380 Gauge only.
Risk of damage to VANOS gear.

Tighten central bolt (2).

Tightening torque: 11 36 1AZ 11 36 Variable Camshaft Control VANOS.
Remove special tools 11 5 410 11 5 410 Gauge and 11 5 382 11 5 380 Gauge.





Release hexagon socket screws with washers (1 and 2) through 90°.





Installation:
Both thrust bearing plates (1) on the VANOS adjustment unit can be rotated.
Both thrust bearing plates (1) must be retracted.
Clean sealing surface (2).
Replace seal.





Important!
Risk of mixing up

Installation:
VANOS adjustment units are marked to avoid being mixed up.
The lettering EIN (1) must point to the inlet camshaft.
Cylinder assignment (2), cyl. 1-5 or 6-10.





Insert seal.
Position VANOS adjustment unit (4) with both outer bolts (1).
Both VANOS gears (2) are extended.
Align thrust bearing plates (3).
Push VANOS adjustment unit (4) forwards until thrust bearing plates (3) rest against VANOS gears (2).

Installation:
There is a visible gap of approx. 8 mm between VANOS adjustment unit and cylinder head.

Note:
Illustration shows cyl. 1 to 5.





Insert hexagon socket screws (1) without washers and join to 5 Nm.
Release hexagon socket screws (1) without washers through 90° again.

Important!
All hexagon socket screws with and without washers must be released through 90°.

Screw in bolts (2) of VANOS adjustment unit uniformly in 1/2 turns.

Installation:
Both outer sleeves rotate clockwise and retract approx. 8 mm.
Both inner sleeves with elongated hole must rotate counterclockwise (see arrow).





Installation:
Check seal for correct seating.

Secure VANOS adjustment unit with screws (1 and 2).





Tighten down hexagon socket screws with and without washers to 10 Nm.

Installation:
Mark all screws which are already tightened down with a coloured dot.

Note:
Illustration shows cyl. 1-5.





Important!
Remove all special tools - risk of damage.

Continue cranking engine at hexagon head or with special tool 11 5 100 120° camshaft until further hexagon sockets screws can be inserted on the VANOS gear and tighten to 10 Nm.

Note:
First both the inlet camshafts are moved when the engine is cranked.
Both exhaust VANOS camshafts are moved in the direction of the arrow (retard stop).
Illustration shows cyl. 1 to 5.





Check timing Testing and Inspection.
Assemble engine.