Removing and Installing/Replacing Right Inlet VANOS Gear (S85)

11 36 148 - Removing and installing / replacing right inlet VANOS gear (S85)





Special tools required:
- 11 5 100
- 11 5 291 11 5 290 Assembly Tool
- 11 5 292 11 5 290 Assembly Tool
- 11 5 301 11 5 300 Gauge
- 11 5 320 11 5 320 Plug mandrel
- 11 5 351 11 5 350 Retaining Fixture
- 11 5 370 11 5 370 Locating Tool
- 11 5 381 11 5 380 Gauge
- 11 5 410 11 5 410 Gauge





Necessary preliminary tasks:
- Remove right VANOS adjustment unit Removing and Installing / Replacing Right 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 inlet camshaft, cylinders 1-5.
Designation (E1) on dihedron points upwards.





Rotate exhaust camshaft with open-end wrench (1) at hexagon head in direction of arrow until special tool A 11 5 301 11 5 300 Gauge can be attached.
Designation (A1) on dihedron points upwards.

Note:
Exhaust VANOS gear (2) adjusted in direction of arrow (advance).





Disconnect inlet and exhaust camshafts.
Attach special tool A 11 5 301 11 5 300 Gauge.
Attach special tool E 11 5 301 11 5 300 Gauge and secure with bolts (2).

Important!
Screw in bolts (2) without fail, risk of damage to camshafts.





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

Insert M8x18 hexagon socket screw (2) into exhaust 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 exhaust VANOS gear (1) will result in rattling noises at idle.





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

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

Note:
Illustration shows cyl. 6-10.





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.





Remove right chain tensioner.

Installation:
Replace sealing ring.

Tightening torque: 11 31 1AZ 11 31 Camshaft.

Note:
Illustration shows cyl. 6-10.





Remove screw plug for chain rail on right cylinder head.

Installation:
Replace sealing ring.

Tightening torque: 11 12 9AZ 11 12 Cylinder Head with Cover.

Insert special tool 11 5 291 11 5 290 Assembly Tool.
Secure bearing pin against falling out with special tool 11 5 292 11 5 290 Assembly Tool.





Attach special tool 11 5 381 11 5 380 Gauge.
Fit special tool 11 5 410 11 5 410 Gauge with bolts (3).

Important!
Release central bolts (1 and 2) with special tools 11 5 410 11 5 410 Gauge and 11 5 381 11 5 380 Gauge only.
Risk of damage to VANOS gear.

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 (1 and 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 5 381 11 5 380 Gauge must not be removed.
VANOS gear is tensioned.

Tilt special tool 11 5 381 11 5 380 Gauge in direction of arrow.

If the VANOS gear is to be replaced by a new part, the special tool 11 5 381 11 5 380 Gauge can be removed.
Remove VANOS gear with special tool 11 5 381 11 5 380 Gauge.





Important!
Danger of injury!

Installation:
If the VANOS gear is to be reused, the special tool 11 5 381 11 5 380 Gauge must not be removed.
VANOS gear is tensioned.

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





Remove both VANOS gears.

Important!
Do not allow timing chain to fall into the engine compartment.
It is possible for the timing chain to become blocked on the VANOS high-pressure pump - risk of damage!

Insert special tool 11 5 351 11 5 350 Retaining Fixture into chain drive.

Press sliding rails (1) together.
Pretension timing chain with special tool 11 5 351 11 5 350 Retaining Fixture.





Installation:
If necessary, turn transportation lock on VANOS gear into a favourable position.
Position inlet VANOS gear (2) so that one of the three screws with washers points downwards.
Position exhaust VANOS gear (1) so that one of the three screws with washers points downwards.
M8x18 hexagon socket screw points upwards.
Check that timing chain is in correct installation position.
Insert central bolts (1 and 2) without play.

Installation:
Replace central bolts (1 and 2).





Insert bearing pin with special tool 11 5 291 11 5 290 Assembly Tool into sliding rail.
Tightening torque: 11 31 2AZ 11 31 Camshaft.
Remove special tools 11 5 291 11 5 290 Assembly Tool and 11 5 292 11 5 290 Assembly Tool.
Install screw plug for chain rail on right cylinder head.

Installation:
Replace sealing ring.

Tightening torque: 11 12 9AZ 11 12 Cylinder Head with Cover.





Insert chain tensioner with sealing ring.
Tightening torque: 11 31 1AZ 11 31 Camshaft.

Note:
Illustration shows cyl. 6-10.





If necessary, remove transportation lock from VANOS gear.
Insert special tool 11 5 381 11 5 380 Gauge between outer sleeve and gearwheel.
Fit special tool 11 5 410 11 5 410 Gauge.
Remove M8x18 hexagon socket screw or special tool 11 5 370 11 5 370 Locating Tool.

Important!
Secure central bolts (1 and 2) with special tools 11 5 381 11 5 380 Gauge and 11 5 410 11 5 410 Gauge only.

Tighten central bolts (1 and 2).

Tightening torque: 11 36 1AZ 11 36 Variable Camshaft Control VANOS.





Remove special tools 11 5 381 11 5 380 Gauge and 11 5 410 11 5 410 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.





Installation:
VANOS adjustment unit is 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.

Important!
Risk of mixing up parts!





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 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.





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

Important!
All 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.





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.