Oil check valves, replacing: Removing

Remove bolts -arrows- and remove engine cover panels C-.
Remove cover above air cleaner.

Fig 1: Removing Engine Cover Panels
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Remove noise insulation -arrows-.
Drain coolant. See COOLING SYSTEM, DRAINING AND FILLING .
Remove bumper.
See FRONT BUMPER .
Move lock carrier to service position.
See LOCK CARRIER, SERVICE POSITION .

Fig 2: Removing Noise Insulation
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Remove viscous fan (counter-hold with pin wrench 3212).
NOTE: Viscous fan has LEFT-HAND thread.

Fig 3: Removing Viscous Fan With Pin Wrench 3212
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Mark direction of rotation of ribbed belt.
Loosen ribbed belt by turning to right using a 17 mm box wrench until two holes are aligned with each other -arrow- and hold in position with mandrel 3204.
NOTE: Mark direction of rotation of ribbed belt. The belt can break if it runs in the opposite direction when reinstalled.
Remove ribbed belt.

Fig 4: Turning Ribbed Belt Tensioner Using A 17 mm Box Wrench
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Disconnect water hoses -1- and -2-.
Remove coolant reservoir (arrows).
Disconnect connector for coolant level monitor.
Remove cover panel from cylinder head cover (cylinder bank 4 through 6).

Fig 5: Disconnecting Water Hoses From Coolant Reservoir
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Disconnect hose -1- from vacuum reservoir.

Fig 6: Disconnecting Vacuum Reservoir
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Remove air duct -arrows-.

Fig 7: Removing Air Duct
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WARNING: Fuel system is under pressure. Before opening the system, place a cloth around the connection. Then release pressure by carefully loosening the connection.
Disconnect fuel supply line and fuel return line -1- and -2-, and move fuel lines clear. See Fig 8.
Disconnect hose from EVAP valve -3-.

Fig 8: Disconnecting Fuel Lines And Hose From EVAP Valve
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Install clamp (special tool 3094) on hose from power steering reservoir to power steering pump.
Disconnect power steering hose -arrow-.

Fig 9: Disconnecting Power Steering Hose
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Release hose clamp -arrow-.
Remove intake line -1-.

Fig 10: Removing Hose Clamp And Intake Line
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NOTE:
- All hose connections are secured with clips.
- Charge air system must be free of leaks.
- Replace all seals and gaskets.
Disconnect connector from air recirculation valve -2-.

Fig 11: Disconnecting Connector From Air Recirculation Valve
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Disconnect connector from camshaft timing control -1- (cylinder bank 4 through 6).
Disconnect connectors from injectors -2- (cylinder bank 4 through 6).
Disconnect crankcase breather -4- from cylinder head cover (cylinder bank 4 through 6).

Fig 12: Disconnecting Electrial Connectors On Cylinder Bank 4 Through 6
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Disconnect connectors from injectors -2- (cylinder bank 1 through 3).
Disconnect hose -5- going from turbocharger intake side. See Fig 13.

Fig 13: Disconnecting Electrial Connectors On Cylinder Bank 1 Through 3
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Unclip solenoid valve for charge air pressure control -1-.
Disconnect connector from EVAP valve -2-.

Fig 14: Disconnecting Solenoid Valve For Charge Air Pressure Control
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Disconnect connector from throttle unit -1-. See Fig 15.
Disconnect connector from charge air pressure sensor -2-.
Disconnect crankcase breather -3-.
Disconnect connector from intake air temperature sensor -4-.

Fig 15: Disconnecting Connectors On Engine
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Remove pressure lines -1-.
NOTE: Observe position of retaining strips -2-.

Fig 16: Removing Pressure Lines
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Remove tensioner -1- for ribbed belt.
Remove toothed belt guards -2- (left and right).
Remove toothed belt guard -3- (center).

Fig 17: Removing Ribbed Belt Tensioner And Toothed Guards
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Turn crankshaft to TDC by hand. Marks -A- and -B- must be alignened.
NOTE: Turn over the engine at the central bolt on the crankshaft.
Check position of camshafts: larger holes in securing plates on camshaft sprockets must align opposite one another on inside. If not, turn crankshaft one revolution further.

Fig 18: Aligning Match Marks -A- And -B- On Crankshaft
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Remove sealing plug from cylinder block, left.
TDC drilling in crankshaft must be visible (or able to be felt) in line with sealing plug hole.
Screw clamping bolt 3242 for crankshaft into sealing plug hole and tighten.

Fig 19: Removing Sealing Plug 3242 From Cylinder Block
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NOTE:
- Mark the direction of rotation of the toothed belt with chalk or felt pen before removing. A used belt can break if it rotates in the wrong direction when reinstalled.
- The toothed belt tensioning element is oil-damped and can therefore only be compressed slowly by applying constant pressure.
Using a hex key, turn toothed belt tensioning roller -1- clockwise 8 mm in direction of arrow until tensioning lever 2- compresses tensioning element -3- sufficiently to enable special tool T 400 11 to be installed in drilling and in plunger.

Fig 20: Using A Hex Key To Turn Toothed Belt Tensioning Roller
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Insert special tool T 400 11 and release toothed belt tensioning roller.
Insert camshaft clamp 3391 in securing plates of two camshafts.
Loosen both camshaft bolts and remove approx. 5 turns.
Remove camshaft clamp 3391.
Disconnect both camshaft sprockets with special tool T40001.

Fig 21: Disconnecting Camshaft Sprockets
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Unbolt rear left toothed belt guard -arrows-.
Detach intake manifold using special tool 3249.

Fig 22: Removing Rear Left Toothed Belt Guard
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Unbolt cylinder head lifting bracket with coolant line -arrows- from cylinder head.

Fig 23: Removing Cylinder Head Lifting Bracket With Coolant Line
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Unbolt coolant line at front of cylinder head -arrows- and remove.
Remove water line and auxiliary water pump.
Remove cover on oil check valves.

Fig 24: Removing Coolant Line At Front Of Cylinder Head
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Replace oil check valves -1- (25 Nm).
NOTE: The oil distribution line -2- for the spray jets for piston cooling is also located in the opening.

Fig 25: Locating Oil Check Valves And Oil Distribution Line

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