Remove the ignition coils and remove all spark plugs. Remove the cylinder head cover, freeing access to the camshafts. Loosen the nut (7, see fig. 3.13) and remove the chain tensioner piston cylinder which is under considerable spring pressure.
1 - crankshaft; 2,8,14,15 - asterisk; 3 - tensioner bar; 4 - piston; 5 - spring; 6 - sealing ring; 7 - cover bolt; 9.16 - chain; 10.12 - strap bolt; 13 - key; 17 - exhaust camshaft; 18 - intake camshaft; 19 - hydraulic pusher; 20 - valve cotters; 21 - top plate; 22 - spring; 23 - bottom plate; 24 - oil scraper cap; 25 - inlet valve; 26 - exhaust valve
Install fixture «11.4.220» (see fig. 3.117) and turning the adjusting screw only bring it to the tensioner bar.
Pretension the tensioner bar using the tool «11.4.220», screwing its adjusting bolt with a tool «00.9.250» or a conventional torque wrench, applying a torque of 0.7 Nm (0.07 kg m).
Disconnect the oil pressure line (30, see fig. 3.63) D-VANOS system and install the tool «11.3.450» (pic. 3.120) with a hollow bolt of a pressure oil pipeline.
1, 19 - plug; 2 - nut; 3 - protective cover; 4 - overlay; 5, 28, 31, 33, 39 - sealing ring; 6, 23 - locating pin; 7 - rubber-metal hinge; 8, 9 - cap nut; 10 - gasket washer; 11 - sealant; 12, 13, 14 - profile gasket; 15, 37 - sealing ring (17x3); 16, 35 - camshaft sensor; 17, 34 - bolt (M6x16); 18 - precision bolt; 20 - plug with a sealing ring; 21 - flange hook; 22 - mount; 24 - nut M6; 25 - jumper «masses»; 26 - bolt (M6x10); 27 - nut M8; 29, 32 - hollow bolt; 30 - oil pipeline; 36 - EMC; 37 - ring (17x3); 38 - piston; 39 - spring; 40 - cylinder head; 41 - metal seal; 42 - executive unit; 43 - oil filler cap; 44 - head cover
Attention! From above cover the executive unit of the system «D-VANOS», because when compressed air is supplied, a jet of oil will spray from the opening of the system.
Connect to fixture «11.3.450» compressed air source (2-8 bar). Turn the engine crankshaft at the central bolt in the direction of rotation until the piston of the first cylinder is at TDC at the end of the compression stroke (see fig. 3.106), while air pressure must be applied.
The tops of the camshafts of the first cylinder must face each other (dotted lines).
Remove dust plug (10, see fig. 3.3) from the hole in the crankcase and block the crankshaft at TDC at the end of the compression stroke of the first cylinder with a tool «11.2.300».
1 - cylinder block; 2 - screw plug (M14x1.5); 3 - sealing ring; 4 - centering sleeve (∅13,5); S - shield; 6, 30 - centering sleeve (∅10.5); 7, 8 - nozzle; 9 - bolt (M6x16); 10 - plug; 11 - cover; 12 - centering sleeve (∅14,5); 13 - sealant; 14 - stuffing box cover; 15.16 - bolt (М8x32); 17 - stuffing box; 18 - centering sleeve (∅10,5); 19 - bolt (М8x22); 20 - oil level damper; 21 - bolt (M6x12); 22 - O-ring (17x3); 23 - crankshaft sensor; 24 - bolt (M6x16); 25 - hairpin (M8x35); 26 - hairpin (М10x40); 27 - bolt (М8x22); 28 - intermediate insert; 29 - screw plug (M24x1.5); 30 - centering sleeve (∅13,5); 31 - knock sensor; 32 - bolt (M8x30); 33 - bolt (М10x92); 34 - screw plug (M14x1.5); 35, 36 - cover pin
Attention! At the end of the work and when turning the engine shaft, do not forget to unlock the crankshaft by removing the tool «11.2.300».
Unscrew the mounting pins (2 pcs., arrows, fig. 3.121).
Install fixture «11.3.240» (see fig. 3.119) to the camshafts.
Despite the correct adjustment of the camshafts, the tool «11.3.240» may protrude up to 1 mm in relation to the intake side due to the manufacturing tolerances of the D-VANOS system components and the gap in the gearing. fixture «11.3.240», must not protrude from the exhaust side, and the valve timing must be readjusted.
Disconnect the compressed air source and remove the tool «11.3.450» (see fig. 3.120).
Connect pressure oil line with new O-rings (28, see fig. 3.63), tightening torque of the hollow bolt M14x1.5 (29) - 32 Nm (3.2 kgf·m).
Remove tool «11.3.240» (see fig. 3.119), fixture «11.2.300» (stopper) and install the dust cap (10, see fig. 3.3) into the fixing hole.
Loosen the tension of the timing chain bar and remove the tool «11.4.220» (see fig. 3.117).
Replace o-ring (2, see fig. 3.123) and install the timing chain tensioner plunger cylinder. piston cylinder nut (M26x1.5) tighten torque 70 Nm (7.0 kgf·m).
Assemble the engine and check the unlocking of the crankshaft.