Note. The sequence of operations for removing and installing the actuating units of the VANOS system is different.
The removal of the left-hand intake and exhaust VANOS control units on the bank of cylinders 5-8 must be carried out in the following order.
Prepare fixtures «11.9.190», «11.9.460», «11.9.461», «11.9.462» And «11.9.463». Read information from storage device (memory) faults and fix it (record). Remove the left eccentric shaft adjustment drive motor, the left engine cylinder head cover, unscrew the spark plugs of cylinders 5–8.
Remove the fan cover, left timing cover and unscrew the special bolt (M8) (15, see fig. 5.13), which cannot be replaced by an ordinary bolt. Release the oil line (12) from the clamps and remove it.
Turn the crankshaft at the central bolt in the direction of rotation to the TDC position of the end of the compression stroke in the 1st cylinder. At the same time, the cams (arrows, see fig. 5.121) the intake and exhaust valves of the 5th cylinder are tilted up and out, as shown in the figure.
Fix the vibration damper with the tool «11.9.190» (see fig. 5.130) when the piston of the 1st cylinder is at TDC at the end of the compression stroke. The hole for the fixture is located on the front timing cover.
Attention! When the engine is stopped normally, the intake and exhaust actuators are blocked in their original position.
In some cases, this initial position may not be reached and the camshaft rotates within the adjusting range of the adjustment unit. To avoid incorrect adjustment of the valve timing, it is necessary to check the locking of the actuating unit and, if necessary, block it by turning the camshaft.
Check blocking of the inlet control unit in the initial position:
- grab a hexagon (dark arrow, see fig. 5.122) intake camshaft and carefully try to turn the intake camshaft against the direction of rotation;
- if there is no reliable connection between the intake camshaft and the intake actuator (there is a backlash), it is necessary to turn the intake camshaft against the direction of rotation until it stops (light arrow);
- The intake actuator is considered to be locked in the home position if the intake camshaft is securely connected to the intake actuator.
Check the blocking of the release actuator in the initial position:
- grasp the hexagon of the exhaust camshaft and carefully try to turn the exhaust camshaft in the direction of rotation;
- if there is no reliable connection between the exhaust camshaft and the exhaust actuator (there is a backlash), it is necessary to turn the exhaust camshaft in the direction of rotation until it stops;
- The exhaust actuator is considered locked in its home position if the exhaust camshaft is securely connected to the exhaust actuator.
Attention. Very important! If the inlet or outlet control unit «does not allow» block the camshafts as described above, the actuator is defective and must be replaced.
Remove tool «11.9.190». Turn the crankshaft at the central bolt against the direction of rotation to a position of 45°before TDC (pic. 5.139).
Note. When loosening the bolts securing the actuator units, hold the camshafts against turning by the hexagon.
Loosen the bolts (M10) (arrows, see fig. 5.127) fixing the VANOS system actuating units. Unscrew bolt for VANOS exhaust adjustment unit. Press the chain tensioner bar firmly several times to remove oil from it. Remove actuator (2) release.
Release screw for VANOS inlet adjustment unit. Remove the intake control unit, taking care to prevent the drive chain from slipping by securing it with a wire clip on the engine head.
Installation of the left actuating units of the intake and exhaust VANOS system on the bank of cylinders 5-8 must be carried out in the following order.
Attention! The intake and exhaust actuators are different, changing the installation locations of the intake and exhaust actuators of the VANOS system leads to engine damage.
Executive intake unit (1, fig. 5.140) is marked «EIN» And «IN», release control unit (2) is marked «AUS» And «EX».
The position of the inlet actuating unit relative to the drive chain is arbitrary. Pull drive chain up. Hook the sprocket of the intake adjustment unit to the drive chain and slide the assembly onto the intake camshaft. Replace bolt (M10) fixing the actuating unit with a new one. Install the bolt of the inlet control unit and screw it in until the bolt head is in contact with the unit. Loosen the bolt half a turn.
Release control position (2, fig. 5.141) relative to the drive chain arbitrary.
Pull drive chain up. Hook the release adjustment sprocket onto the drive chain. Press the tensioner bar and slide the exhaust control unit onto the exhaust camshaft.
If the tensioner bar is not depressed enough to install the exhaust control unit, then it is necessary:
- remove the chain tensioner;
- set it on a flat pad and squeeze slowly and gently, repeat this process twice;
- when installing the tensioner, it is necessary to replace the sealing ring, insert the tensioner and tighten it with a torque of 65 Nm (6.5kgf·m).
Install release executive. Replace bolt (M10) fixing the executive assembly of the release with a new one. Install the bolt of the exhaust control unit and screw it in until the bolt head is in contact with the unit. Loosen the bolt half a turn.
Prepare a kit «11.9.460» for fixing the camshafts.
Install fixture «11.9.461» onto the intake camshaft and align the intake camshaft so that the tool «11.9.461» without gaps lay on the cylinder head.
Install fixture «11.9.463», by screwing it in (1, see fig. 5.128) threaded hole for the oil line and hand-tighten.
Attention! Check again that the intake and exhaust actuator bolts are loosened by half a turn.
Turn the crankshaft at the central bolt from position 450 before TDC of the end of the compression stroke, to the position of the piston of the 1st cylinder at TDC of the end of the compression stroke. Fix the vibration damper with the tool «11.9.190» (see fig. 5.130) when the piston of the 1st cylinder is at TDC at the end of the compression stroke.
Tighten the new inlet actuator bolt to 90 Nm (9.0 kgf·m), while holding the camshaft against turning by the hexagon.
Remove bolt (1, see fig. 5.128), remove fixtures «11.9.463» And «11.9.461» from the intake camshaft.
Install fixture «11.9.462» onto the exhaust camshaft and align the exhaust camshaft so that the tool «11.9.462» without gaps lay on the cylinder head.
Install fixture «11.9.463», by screwing its screw into the threaded hole for the oil line and hand-tighten it.
Tighten new bolt (2, see fig. 5.129) fastening of an actuating unit of release by the moment of 90,0 Nm (9.0 kgf·m), while holding the camshaft against turning by the hexagon.
Loosen the bolt and remove the tools «11.9.463» And «11.9.462» from the exhaust camshaft.
Remove tool «11.9.190» (see fig. 5.130). Turn the crankshaft at the central bolt in the direction of rotation two full turns (720°) until the piston of the 1st cylinder is reset to the TDC position of the end of the compression stroke. Install fixture «11.9.190», fixing the vibration damper at the position of the piston of the 1st cylinder at the TDC of the end of the compression stroke.
Install fixture «11.9.461» on the intake camshaft and check the valve timing.
Note. The valve timing is set correctly if the tool «11.9.461» adjacent to the cylinder head without play, or raised relative to the exhaust side by a maximum of 0.5 mm.
Remove tool «11.9.461» from the intake camshaft and install the tool «11.9.462» (pic. 4.142) on the exhaust camshaft and check the valve timing.
Note. The valve timing is set correctly if the tool «11.9.462» adjacent to the cylinder head without play, or raised relative to the exhaust side by a maximum of 0.5 mm.
Remove all fixtures. Clamp oil line (12, see fig. 5.13) staples (3). Bolt (15) is a special bolt and cannot be replaced with an ordinary M8 bolt. Insert and tighten it. Assemble the engine.