Attention! The sequence of operations for removing and installing the actuating unit of the D-VANOS system is different.
The removal of the VANOS adjustment unit must be carried out in the following order. Prepare fixtures «00.9.250», «11.2.300», «11.3.240», «11.3.450», «11.4.220» And «11.6.170» and remove the engine cover. Remove the air filter housing together with the air flow meter.
Remove the fan impeller with viscous fan drive clutch and fan shroud. Remove the cylinder head cover. Remove all spark plugs. Remove plastic cover (pic. 3.130) intake camshaft.
Disconnect the oil pressure line (30, see fig. 3.63).
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
Install fixture «11.3.450» (see fig. 3.120) with a hollow bolt of a pressure oil pipeline.
Attention! Cover the executive node of the system «D-VANOS», because when compressed air is supplied, a jet of oil will spray out of the hole.
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 on the compression stroke (pic. 3.106), while air pressure is applied.
The tops of the camshafts of the first cylinder must face each other (see fig. 3.106). Remove the plug from the hole for fixing the flywheel and block the crankshaft at TDC of the end of the compression stroke of the 1st cylinder, using a tool «11.2.300» (see fig. 3.122).
Attention! At the end of work and before turning the engine shaft, do not forget to unlock the crankshaft, remove the tool «11.2.300».
Unscrew the mounting pins (see fig. 3.121) and install fixture «11.3.240» on camshafts in the region of the 6th cylinder (see fig. 3.119).
Disconnect the compressed air source by closing the tap and removing the hose. fixture «11.3.450» until you take it off.
Attention! After turning out the screw plugs, oil flows out of the holes of the actuating unit of the system. Prevent oil from getting into engine parts.
Prepare rags and a container for collecting oil. Take out the plugs (20, see fig. 3.63) using a device «11.6.170» or use narrow-nosed pliers.
Loosen threaded bolts (18) with left-hand thread, on the intake side and exhaust side, and catch any escaping oil.
Disconnect the camshaft position sensor (35) and AL of electromagnetic valves (36) on the exhaust and intake sides. Loosen the bolts (see fig. 3.61) and remove the engine lifting eye.
Loosen the nuts (7 pcs., arrows, fig. 3.131) and remove the actuating unit of the DVANOS system.
Attention! When the actuating unit of the D-VANOS system is removed, the rotation of the engine shaft is strictly prohibited due to the possibility of its failure of the engine when the valves and the piston come into contact.
The D-VANOS control unit must be installed in the following order. Check centering sleeves (2 and 7. see fig. 3.4) for damage and correct installation.
1 - cylinder head; 2.7 - centering sleeve; 3.8 - screw plug (M8x1); 4 - cover (∅28); 5 - hairpin (M6x30); 6 - hairpin (M6x60); 9 - hairpin (M6x28); 10 - bolt (M8x28); 11 - harness holder; 12 - spacer; 13 - sealant; 14.30 - cover; 15 - self-blocking nut; 16 - nut (M7); 17 - hairpin (М7x95); 18, 20 - center, sleeve (∅9,5); 19 - support bar; 21 - bolt T (M6x50); 22 - bolt T (M6x70); 23 - bolt 7 (M6x100); 24 - screw plug with sealing ring (М12x1.5x26); 25 - bolt; 26.35 - sealing ring; 27 - hairpin (М7x39); 28 - hairpin (M7/6x29.5); 29 - screw plug (M18x1.5); 31 - guide sleeve; 32 - head bolt (M10x110); 33 - gasket washer; 34 - cover (∅22); 36 - screw plug (M10x1.0); 37 - cover (∅18); 38 - hairpin (M7x55); 39 - sensor; 40 - saddle issue. valve; 41 - saddle vp. valve; 42 - hairpin (M6x25); 43 - sealing gasket; 44 - check valve
Sealing surfaces must be clean and dry from dirt and traces of oil. Use a hardwood scraper and hydrolysis alcohol for cleaning. Apply a thin layer of Drei Bond 1209 type sealant evenly to the corner joints of the end plane of the cylinder head connector with the D-VANOS control unit.
Replace seal. Install the D-VANOS adjustment unit and fix it with screws (arrows, fig. 3.131).
Connect the camshaft position sensor loop and the exhaust and intake side solenoid loops.
Insert and tighten precision bolts with left-hand thread (18, 2 pieces, see fig. 3.63) fastening the piston to the splined shaft on the intake side and exhaust side.
Bolt (M6) tighten torque 10 Nm (1.0 kgf·m). Install new plugs (19, see fig. 3.63) using a device «11.6.170» or use narrow-nosed pliers. Insert screw plugs (M22x1.5) with new sealing rings (20) and tighten them to 50 Nm (5.0 kgf·m). Install the engine lifting eye and tighten the engine mounting bolts.
Note. After replacing the control unit, the valve timing must be checked and, if necessary, adjusted.
Remove the chain tensioner plunger cylinder (1, see fig. 3.123), which is under spring pressure and remove it.
1 - cylinder; 2 - sealing ring; 3 - spring; 4 - plunger
Install fixture «11.4.220» (see fig. 3.117) into the hole on the cylinder head and turning the adjusting screw only bring it to the chain tensioner bar.
Pretension the tensioner bar using the tool «11.4.220», screwing the adjusting bolt with a tool «00.9.250» or a conventional torque wrench, applying a torque of 0.7 Nm (0.07 kgf·m).
Pull back fixture «11.2.300» (see fig. 3.122), to unlock the flywheel.
Remove tool «11.3.240» (see fig. 3.119).
Attention! Cover the executive node of the system «D-VANOS» when compressed air is supplied from the hole.
Connect to fixture «11.3.450» (see 3.120) compressed air source (2-8 bar).
crank twice (at 720°) engine shaft in the direction of rotation with compressed air supplied so that the tops of the camshaft camshafts of the intake and exhaust valves of the first cylinder face each other symmetrically «11.3.240» (see fig. 3.106).
Install fixture «112.300» (see fig. 3.122) and lock the crankshaft to the TDC position of the compression stroke of the 1st cylinder.
Check the adjustment of the camshafts by installing the tool «11.3240» (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 from the intake side due to D-VANOS tolerances and tooth play. fixture «11.2.240» must not protrude in relation to the exhaust side; in this case, the valve timing must be readjusted. Disconnect the compressed air source and remove the tool «11.3.450» (see fig. 3.120).
Connect the pressure oil line (30. see fig. 3.63) with new sealing rings (28), by screwing in a hollow bolt M14x1.5 (29) with tightening torque 32 Nm (3.2 kgf·m).
Loosen the bar tension and remove the fixture «11.4.220» (see fig. 3.117).
Replace o-ring (2, see fig. 3.123) and install the timing chain tensioner plunger cylinder.
1 - cylinder; 2 - sealing ring; 3 - spring; 4 - plunger
cylinder nut (M26x1.5) tighten torque 70 Nm (7.0 kgf·m).
Remove tool «11.3.240» (see fig. 3.119).
Remove tool «11.2.300» (see fig. 3.122) and install the dust plug into the fixing hole.
Assemble the engine and check the unlocking of the crankshaft.