11 41 010 Removing and installing/replacing chain module for oil pump (PHEV)

Special tools required:

2 219 548 .
83 30 2 212 831
2 212 825 .
11 4 120 .
2 318 117 .
11 9 260 .
2 212 831 .
00 9 140 .

WARNING: High-voltage system - danger to life

Observe the SAFETY INFORMATION for working with electric vehicles.

Fig 1: Attaching Special Tool (2 318 117) To Crankcase

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IMPORTANT: The counterbalance shaft must be adjusted to the motor.

Necessary preliminary tasks:

Remove TRANSMISSION .
Remove CYLINDER HEAD COVER .
Remove all SPARK PLUGS .
Remove OIL SUMP .
Remove TOOTHED BELT for the starter motor.
Remove VIBRATION DAMPER .
Secure CAMSHAFTS with special tool.
Remove CHAIN TENSIONER PISTON .

Installation note:

Wet special tool 2 219 548 with oil for simpler removal and installation.

Secure crankshaft with special tool 2 219 548 above the dowel hole.

Secure camshafts with special tool 83 30 2 212 831 (see procedure in CHECKING TIMING ).

Fig 2: Identifying Special Tool (2 219 548)

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Release screw (1).

Detach intake snorkel (2) in direction of arrow.

Fig 3: Detaching Intake Snorkel

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Remove sealing cap using a screwdriver.

Fig 4: Loosening Sealing Cap Using Screwdriver

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IMPORTANT: Only open central bolt of oil pump with special tool.

Secure special tool 2 212 825 to oil pump with screw (1).

The counterbalance shaft is now secured.

Fig 5: Securing Special Tool (2 212 825) On Oil Pump Housing With Screw

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Push back chain tensioner with tensioning rail (1) and secure with special tool 11 4 120 .

NOTE: Sprocket must be blocked with special tool 2 318 117 in order to release central bolt (2).

Fig 6: Attaching Special Tool (2 318 117) To Crankcase

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Mount special tool 2 318 117 and secure with screws (3).

Release central bolt (2) for oil pump drive shaft.

Remove special tool 2 318 117 .

Installation note:

Replace central bolt (2).

Tightening torque 11 41 5AZ .

NOTE: Engine removed.

Block crankshaft with special tool 11 9 260 .

Fig 7: Securing Flywheel With Special Tool (11 9 260)

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IMPORTANT: Do not remove special tools 2 219 548 and 2 212 831 to release central bolt (1).

Fig 8: Releasing Central Bolt

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Release central bolt (1).

Breakaway torque greater than 500 Nm .

Installation note:

Release central bolt (1) with 3/4 inch tool (2).

Screw in two screws (1) and pull off hub (2) in direction of arrow.

Fig 9: Pulling Crankshaft Hub

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Release screws (1) and pull off chain module (2) off of oil pump drive shaft.

Tightening torque 11 41 3AZ .

Fig 10: Identifying Chain Module And Screws

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Installation note:

Observe mounting flats on camshaft sprocket (1).

Both grip discs (2) must be attached to drive gear for oil pump with welding spots.

Fig 11: Identifying Grip Disc, Mounting Flats On Camshaft Sprocket, And Special Tool (11 4 120)

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Grip discs are not individually available.

If grip discs are damaged, the drive gear for oil pump with grip discs must be replaced.

Before installation: Press back chain tensioner with tensioning rail and secure with special tool 11 4 120 .

Position module (1) for oil pump drive.

Position module (2) for camshaft drive.

Insert hub (3) for vibration absorber with grip disc.

Fig 12: Inserting Vibration Absorber Hub With Grip Disc

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Position chain module (2) for oil pump drive shaft on mounting flats.

Insert bolts (1).

Tightening torque: 11 41 3AZ .

Fig 13: Identifying Chain Module And Screws

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NOTE: Camshaft sprocket must be blocked with special tool 2 318 117 in order to tighten central bolt (2).

Mount special tool 2 318 117 and secure with screws (3).

Insert and tighten central bolt (2) for oil pump drive shaft.

Installation note:

Replace screw.

Tightening torque 11 41 5AZ .

Fig 14: Attaching Special Tool (2 318 117) To Crankcase

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Disassemble special tools 11 4 120 and 2 318 117 .

Insert central bolt.

Secure central bolt with special

tool 00 9 140 .

Tightening torque 11 21 1AZ . Position magnetic foot (1) in suitable location.

Installation note:

Replace front CRANKSHAFT SEAL .

Fig 15: Tightening Central Bolt

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Assemble engine.