11 41 010 Removing and installing/replacing chain module for oil pump/vacuum pump (N55) from March 2012

Special tools required:

Attention!

Aluminum screws/bolts must be replaced each time they are released.

Aluminum screws/bolts are permitted with and without color coding (blue).

For reliable identification:

Aluminum screws/bolts are not magnetic.

Joining torque and angle of rotation must be observed without fail (risk of damage ).

Necessary preliminary tasks:

Remove CYLINDER HEAD COVER .
Remove all SPARK PLUGS .
Remove OIL SUMP .
Remove DRIVE BELT .
Remove TENSIONING DEVICE for drive belt.
Remove VIBRATION DAMPER .
Remove SEALING COVER for vacuum pump.
Remove SEALING CAP of chain tensioner for oil pump.
Remove TIMING CHAIN .
Remove CHAIN TENSIONER .

Screw in special tool 11 8 650 on belt tensioner screw connection on crankcase.

Turn camshaft sprocket with central bolt at crankshaft into position until special tool 11 0 290 can be secured.

Simultaneously secure special tool 11 0 290 to sprocket and special tool 11 8 650 .

Release screw (1) for sprocket.

Tightening torque 11 66 2AZ .

Fig 1: Releasing Sprocket Screw Using Special Tools

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NOTE: Before releasing the central bolt on the oil pump, the hydraulic chain tensioner must be drained.

Fig 2: Pressing Tensioning Rail Using Screwdriver

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Carefully press tensioning rail (1) with a suitable screwdriver (2) in direction of arrow.

As the oil pressure in the chain tensioner can only be drained pulsating, the tensioning rail (1) must be pressed several times.

Press the tensioning rail (1) and hold down.

Fix chain tensioner piston in position with a suitable lock pin (2).

Loosen screws (3).

Tightening torque: 11 41 7AZ .

Fig 3: Identifying Tensioning Rail And Lock Pin

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NOTE: Sprocket must be blocked in order to release central bolt (1).

Secure special tool 2 303 793 to crankcase.

Release oil pump central bolt (1).

Tightening torque 11 41 5AZ .

Fig 4: Releasing Oil Pump Central Bolt

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Remove fastener (1) in direction of arrow.

Fig 5: Installing Fastener

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Position flywheel (1) with special tool 11 0 300 in TDC setting.

Fig 6: Positioning Flywheel In TDC Setting Using Special Tool

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Press timing chain with chain tensioner (1) in direction of arrow.

Disconnect timing chain with special tool 11 4 120 .

Feed out sprocket (3) at hexagon head (4) of vacuum pump.

Installation note:

If the chain module is replaced, a mounting bar (2) is already pre-installed.

Fig 7: Disconnecting Timing Chain Using Special Tool (11 4 120)

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Release aluminum screws (1).

Remove oil pump drive gear from the drive shaft.

Fig 8: Locating Aluminum Screws

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Open screw plug (1).

Tightening torque: 11 11 9AZ .

Installation note:

Replace the sealing ring.

Fig 9: Identifying Screw Plug

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Lock flywheel (1) with special tool 11 9 260 .

Fig 10: Blocking Crankshaft With Special Tool (11 9 260)

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NOTE:

Do not remove special tools 11 0 300 and 11 4 280 to release central bolt (1).

Release central bolt (1).

Installation note:

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

Breakaway torque approx. 500 Nm.

Fig 11: Releasing Central Bolt With 3/4-Inch Tool

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

Installation note:

Replace front CRANKSHAFT SEAL .

Fig 12: Pulling Crankshaft Hub

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Release aluminum screw (1) with special tool 11 8 640 .

Fig 13: Identifying Aluminum Screw

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Remove chain module (1) in direction of arrow.

Fig 14: Removing Chain Module

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Installation note:

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

Fig 15: Identifying Oil Pump Drive Gear Welding Spots

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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.

Installation note:

Grip disc (1) must be mounted.

If grip disc (1) is not mounted, central bolt can come loose (engine damage).

Fig 16: Identifying Grip Disc

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IMPORTANT:

Note installation direction of sprocket (2).

Collar (see arrow) on sprocket (2) points to engine .

Incorrect assembly will result in engine damage .

Fig 17: Locating Collar On Camshaft Sprocket

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Insert chain module.

Secure aluminum screw (1) with special tool 11 8 640 .

Tightening torque: 11 41 3AZ .

Fig 18: Identifying Aluminum Screw

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Insert aluminum screws (1) for chain module.

Tightening torque 11 41 6AZ .

Installation note:

Replace aluminum screws.

Pay attention to mounting flats on oil pump drive.

Fig 19: Locating Aluminum Screws

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Position module (1) for oil pump drive.

Position module (2) for camshaft drive.

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

Fig 20: Inserting Vibration Absorber Hub With Grip Disc

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Insert central bolt (1).

Secure central bolt with special tool 1 00 9 140 .

Tightening torque 11 21 1AZ .

Installation note:

Replace front CRANKSHAFT SEAL .

Fig 21: Tightening Central Bolt With Special Tool (00 9 140)

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Assemble engine.