Camshafts and hydraulic chain tensioner, removing and installing: Removing

• Remove ribbed belt and tensioning element for ribbed belt. Refer to Removing ribbed belt .

Fig 1: Remove Engine Cover Panel Above Cylinder Head.

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• Remove engine cover panel above cylinder head.
• Remove toothed belt guard (upper section). Refer to Toothed belt, removing and installing .

Fig 2: Setting Crankshaft To Markings For TDC Of No. 1 Cylinder

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• Set crankshaft to markings for TDC of No. 1 cylinder (arrows) by turning central bolt on crankshaft sprocket in direction of rotation.
• Remove cylinder head cover. Refer to Cylinder head, removing and installing .

Fig 3: Screwing Stud Into Toothed Belt Tensioning Element & Hex Nut Onto Stud Using Large Washer

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• Screw M5x55 stud -1- into toothed belt tensioning element. Screw hex nut -2- onto stud -1- using a large washer -3-.
• Only tension piston of tensioning element as far as necessary to secure it with a locking pin (e. g. from lifting appliance 2024 A) (arrow).

NOTE: If it is not possible to insert the locking pin, carefully tension the pressure piston of the tensioning element just enough to allow the toothed belt to be removed.

• Take toothed belt off camshaft sprocket.
• Loosen camshaft sprocket (using 3036).
• Remove camshaft sprocket using puller T40001.
• Remove Camshaft Position (CMP) Sensor housing.

• Remove rotor for Camshaft Position (CMP) Sensor.

Fig 4: Securing Camshaft Adjuster Or Chain Tensioner Using Bracket For Chain Adjustment 3366

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• Secure hydraulic chain tensioner with retainer for chain tensioner 3366.

NOTE: If the retainer for chain tensioner is tightened excessively, this can damage the hydraulic chain tensioner.

Fig 5: Positioning Camshafts To TDC Cyl. 3

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• Re-check TDC position of camshafts.

• The marks on the two camshafts must be in line with the (arrows) on the bearing caps.

• Clean chain and camshaft sprockets opposite the two (arrows) on the bearing caps and mark installation position with colored marks.

Fig 6: Checking Distance Between Markings Consists Of 16 Rollers Of Drive Chain

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• The distance between the two arrows (and thus between the colored markings) is 16 rollers on the chain.
• The notch on the exhaust camshaft is offset slightly toward the inside in relation to chain roller -1-.

NOTE: Do not mark chain with a center punch or by making a notch or similar.

Fig 7: Identifying Bearing Cap Positions

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• First remove bearing caps 3 and 5 on intake and exhaust camshafts.
• Remove double bearing cap.
• Remove both bearing caps next to intake and exhaust camshaft chain sprockets.
• Remove securing bolts of hydraulic chain tensioner.

• Slacken off bearing caps 2 and 4 of intake and exhaust camshafts alternately and diagonally, and remove.
• Remove intake and exhaust camshafts with hydraulic chain tensioner.