Procedures

Camshaft Seal/Variable Valve Timing (VVT) Unit, Replacing

Special Tools: 999 5452, 999 5651, 999 5719, 999 5718, 999 5474, 999 5451, 999 5919, 999 5450.

NOTE: As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information is always correct.

Removal

CAUTION: There are a number of versions of the variable valve timing unit. Therefore it is extremely important to always read the information referring to the engine variant/model year to be remedied.

Removing The Camshaft Seal

NOTE: Crankshaft and camshafts must not be turned more than is stated in the method description.

If the shafts are turned in any other way the valves may be damaged.

Remove:







- the cable from the battery negative terminal.
- the cross stay between the suspension turrets
- the air intake hose for the turbocharger (TC) from the air cleaner (ACL) cover. Put to one side
- the upper timing belt cover
- the cover over the ignition coils
- the upper engine stabilizer brace
- the camshaft position (CMP) sensor housing
- the trigger wheel
- the servo reservoir and the expansion tank. Lift up and place on top of the engine.

WARNING: Ensure that no power steering fluid is spilled. Extremely flammable.

- the auxiliaries belt
- the front timing belt cover.

Aligning The Engine According To The Marking
Raise the car.

Remove:







- the right front wheel
- the nuts for the cover in the fender liner.

Install the upper timing belt cover.

Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.

Turn the crankshaft a further one-quarter of a turn clockwise, then turn back counterclockwise until the markings correspond.

The markings are illustrated. Remove the upper timing belt cover.

Removing The Timing Belt







- Slacken off the center screw for the belt tensioner slightly
- Hold the center screw still. Turn the tensioner eccentric clockwise to 10 O'clock using a 6 mm Allen key
- Remove the timing belt from the camshaft pulleys.

Removing The Timing Gear Pulley With The Variable Valve Timing Unit







Use Camshaft Adjustment Tool:
- Install camshaft adjustment tool 999 5452 at the rear of the camshafts
- First screw in the part of the tool intended for the exhaust camshaft (drilled hole)
- Then carefully turn the exhaust camshaft clockwise with the camshaft adjustment tool until the intake camshaft tool can be applied (threaded hole)
- Install the intake camshaft adjustment tool.
Screw the camshaft adjustment tools together.

Remove:







- the plug at the front edge of the variable valve timing unit (TORX 55)
- the center screw in the variable valve timing unit (TORX 55). Carefully pull out the timing gear pulley with the variable valve timing (VVT) unit.

NOTE: Use paper to collect any spilled oil under the variable valve timing units.

Replacing The Camshaft Seal







Carefully press in tool 999 5651 between the sealing ring and the camshaft.

Carefully pry out the seal.

Cleaning
To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.

NOTE: When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.







Oil the new seal. Install the new seal for the exhaust camshaft. Use drift 999 5718.

Installation

NOTE: The purpose of the procedure, "Installing the VVT unit/timing gear pulley", described here is to ensure that the VVT unit is correctly positioned and to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.

Setting The Crankshaft Position







- Install camshaft adjustment tool
- Remove the charge air pipe between the throttle body (TB) and the charge air cooler
- Remove the 3 mounting screws for the starter motor. Place the starter motor to one side
- Remove the blind cover plug and the sealing washer
- Turn the crankshaft clockwise slightly to avoid the adjustment tool being in the wrong position
- Install adjustment tool: 999 5451. Ensure that the camshaft adjustment tool bottoms out against the cylinder block
- Turn the crankshaft counter-clockwise as far as it will go against the camshaft adjustment tool
- Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.

Installing The Variable Valve Timing (VVT) Unit On The Exhaust Camshaft







- Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.
- Press the timing gear pulley and variable valve timing (VVT) unit on to the camshaft -Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
- Turn the variable valve timing unit counter clockwise as far as it will go.
- Slacken off the center screw
- Position the upper timing cover.
- Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.
- Continue turning clockwise until the timing gear pulley marking is 1 tooth before the marking on the upper timing cover.

NOTE: Do not turn counter clockwise during this procedure.

- Check that the timing gear pulley is still in the limit position in the oval holes.
- Tighten the center screw in the variable valve timing unit.
- Check that the variable valve timing unit does not rotate when tightening.
- Tighten the center plug.







Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond.

Installing The Variable Valve Timing (VVT) Unit On The Intake Camshaft







NOTE: Do not turn counter clockwise during this procedure.

- Slacken off, but do not remove the screws which secure the timing gear pulley to the VVT unit.
- Press the variable valve timing unit/timing gear onto the camshaft.
- Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
- Turn the variable valve timing unit counter-clockwise as far as it will go. Slacken off the center screw.
- Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley marking is 2 cogs before the marking on the upper timing cover.

Check that the timing gear pulley is still in the limit position in the oval holes. Tighten the center screw in the VVT unit.

Check that the variable valve timing unit does not rotate when tightening. Install and tighten the center plug.







Turn the variable valve timing unit clockwise to the limit position.

Turn the timing gear pulley so that the markings correspond.

Remove the upper timing belt cover.

Installing The Timing Belt







Tighten the center screw in the timing belt tensioner. Tighten to 5 Nm in the 10 O'clock position.

Install The Belt In The Following Order:
- crankshaft
- the idler pulley
- intake cam pulley
- exhaust cam pulley
- water pump
- tension pulley.

Install the upper belt guard. The variable valve timing units do not have a return spring and are easily dislodged when reinstalling the timing belt. Check that the markings correspond.

NOTE: Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.

Adjusting The Timing Belt







This adjustment is always carried out on a cold engine. A suitable temperature is approximately 20 degree C / 68 degree F.

At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right.

The above inage shows the position of the indicator when aligning the timing belt tensioner at different temperatures.

Hold the center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.

Tighten the screws on the exhaust camshaft timing gear pulley to 10 Nm.







Turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time.

Install the screw missing on the intake camshaft timing belt pulley.

Hold the eccentric secure and tighten the center screw. Tighten to 25 Nm. Check that the indicator is in the correct position.

Remove:
- the camshaft adjustment tools
- the crankshaft stop. Install the plug with a new sealing washer. Tighten.

Checking The Markings And Belt Tension

Check:







- Press the toothed belt to check that the indicator on the tensioner moves easily.
- Install the upper timing belt cover.
- Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond.
- Check that the indicator on the belt tensioner is within the marked position.

Installing Components

Install:
- the front timing belt cover
- the torque rod bracket
- the cover over the ignition coils
- the upper timing belt cover
- the auxiliaries belt
- the expansion tank
- the servo reservoir. Check that the hoses are correctly positioned
- the starter motor. Tighten the screws at the transmission to 40 Nm. Tighten the support bracket screw to 25 Nm
- the charge air pipe between the throttle body (TB) and the charge air cooler (CAC).

Install:







- the trigger wheel
- the camshaft position (CMP) sensor housing and a new cover
- the intake air hose between the turbocharger (TC) and the air cleaner (ACL) cover
- the engine stabilizer brace. Tighten the screws at the suspension turrets and the screw for motor bracket
- the cable to the battery negative terminal.

Checking The Engine
Test drive the car to check the function of the engine.

Replacing The Rear Seal

The Following Components Must Be Removed When Replacing The Rear Seal:







- the cross stay between the suspension turrets
- the air hose from the air cleaner (ACL) to the turbocharger (TC). Place to one side. Seal the openings
- place the air cleaner (ACL) cover to one side
- the charge air pipe over the engine. Seal the openings
- the cover over the ignition coils -the upper torque rod bracket
- the camshaft position sensor (CMP) housing and trigger wheel.

Replacing The Rear Camshaft Seal







Pull out the seal. Use puller 999 5919. Use emery cloth 951 1024 to clean the shaft journal and mating surface.

NOTE: When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed.

Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal. Use drift 999 5450.

NOTE: The seal is normally pressed in so that it is level with the internal beveled edge. If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm deeper by turning the drift socket.

Installing Components

Install:







- the trigger wheel.
- the camshaft position (CMP) sensor housing and a new cover.
- the torque rod bracket. Tighten.
- the cover over the ignition coils.
- the charge air pipe over the engine. Remove the seals.
- the air cleaner (ACL) cover and the intake air hose.
- the engine stabilizer brace. Tighten the screws at the suspension turrets and the screw for the engine bracket.

Check the engine compartment. Wipe the engine compartment clean.