Camshaft Seal/Variable Valve Timing (VVT) Unit, Replacing
Camshaft seal/variable valve timing (VVT) unit, replacing
Special tools:
999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
999 5651 Extractor 999 5651 Extractor
999 5719 Drift 999 5719 Drift
999 5718 Drift 999 5718 Drift
999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection
999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool
999 5919 PULLER 999 5919 Puller
999 5450 PUNCH 999 5450 Punch
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.
First read Battery, disconnecting Battery Disconnecting.
- 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 wing 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 1/4 of a turn clockwise, then turn back counter-clockwise until the markings correspond.
The markings are illustrated.
Remove the upper timing belt cover.
Removing the timing belt
- Slacken off the belt tensioner
- Slacken off the centre screw for the belt tensioner slightly
- Hold the centre 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 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool 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 centre 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 Extractor 999 5651 Extractor 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.
Lubricate the new seal. Install the new seal for the exhaust camshaft. Use drift 999 5718 Drift 999 5718 Drift.
Installation
Checking and adjusting the variable valve timing unit
Check and adjust the variable valve timing unit.
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 gearbox 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 negative battery cable. First read Battery, disconnecting Battery Disconnecting.
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 PULLER 999 5919 Puller. 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 PUNCH 999 5450 Punch.
Note! The seal is normally pressed in so that it is level with the internal bevelled 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 motor bracket
Check the engine compartment. Wipe the engine compartment clean.