Check timing of cylinder bank 2

Preliminary work 

• Refer to SUCTIONING THE AIR CONDITIONING .
• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to REMOVING THE COVER PANEL OF THE MASTER DME CONTROL UNIT .
• Refer to REMOVING THE COVER PANEL OF THE SLAVE DME CONTROL DEVICE .
• Refer to REMOVING THE ACOUSTIC COVER .
• Refer to REMOVING HOLDER OF DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
• Refer to REMOVING COOLANT EXPANSION TANK .
• Refer to REMOVING IGNITION COIL OF CYLINDER BANK 2 .
• Refer to REMOVING RAIL FROM BANK 2 .
• Refer to DISCONNECTING PLUG CONNECTIONS OF THE INJECTORS OF CYLINDER BANK 2 .
• Refer to REMOVING INJECTORS .
• Refer to REMOVING THE COVER OF THE ENGINE COMPARTMENT AT THE REAR LEFT .
• Removing the cover of the rear right engine compartment.

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  • Loosen the lock (1)
  • Remove the cover (2).

  Covering the vehicle battery 

  WARNING: Unprotected battery terminals. Risk of short circuits! Risk of fire!

  • Cover the vehicle battery

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  NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
  • Cover the vehicle battery with the special tool 2 452 007  as shown.
• Refer to REMOVING LEFT AND RIGHT WIPER ARM .
• Refer to REMOVING THE COWL COVER .
• Refer to REMOVING TRAILING LINK AT SPRING BOLT .
• Refer to REMOVING THE COWL UPPER PART IN THE CENTER .
• Refer to DISCONNECTING THE REFRIGERANT LINE FROM THE EXPANSION VALVE .
• Refer to REMOVING THE REFRIGERANT LINE BETWEEN THE AIR CONDITIONING CONDENSER AND THE EVAPORATOR .
• Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to REMOVING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
• Refer to REMOVING LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
• Refer to REMOVING HOLDER OF DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
• Refer to REMOVING LEFT HIGH PRESSURE PUMP .
• Refer to REMOVING COOLANT EXPANSION TANK .
• Refer to REMOVING EXPANSION TANKS FOR THE CHARGE AIR COOLERS .
• Refer to LIFTING THE HEAT SHIELD AT THE SIDE .
• Refer to REMOVING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
• Removing the tank ventilation line of cylinder bank 1 partially.

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  • Press the tank vent line (2) on the catch (1) and unlock.
  • Disconnect the tank vent line (2).
  • Fold the tank vent line (2) to the side
• Refer to REMOVING ENGINE VENTILATION LINE OF CYLINDER BANK 2 .
• Refer to REMOVING UPPER HEAT SHIELD .
• Refer to REMOVING THE STIFFENING PLATE .
• Refer to DISCONNECTING THE EXHAUST SYSTEM .
• Refer to REMOVING NEAR-ENGINE CATALYTIC CONVERTER AT THE BOTTOM OF THE CYLINDER BANK 2 .
• Refer to REMOVING THE CATALYTIC CONVERTER NEAR THE ENGINE AT TOPPING OF CYLINDER BANK 2 .
• Refer to REMOVING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
• Refer to REMOVING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
• Refer to RELEASING LEFT FRONT-END STRUT .
• Refer to RELEASING THE RIGHT FRONT-END STRUT .
• Refer to REMOVING FRONT CROSS CONNECTION .
• Refer to REMOVING LEFT INTAKE SILENCER HOUSING .
• Refer to REMOVING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to REMOVING RIGHT INTAKE SILENCER HOUSING .
• Refer to REMOVING THE CLEAN AIR PIPE OF CYLINDER BANK 1 .
• Refer to REMOVING THE REAR TOP CROSS CONNECTION .
• Refer to REMOVING FAN COWL WITH ELECTRIC MOTOR .
• Refer to REMOVING DRIVE BELT .
• Refer to REMOVING THE BELT TENSIONER .
• Refer to REMOVING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
• Refer to REMOVING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
• Refer to DRAINING THE COOLANT FROM THE COOLANT PUMPS .
• Refer to DRAINING THE HIGH-TEMPERATURE COOLANT CIRCUIT .
• Refer to REMOVING OIL FILLER NECK .
• Refer to REMOVING RIGHT CHARGE AIR COOLER .
• Refer to REMOVING LEFT CHARGE AIR COOLER .
• Refer to REMOVING THE INTAKE PIPE .
• Refer to REMOVING LEFT THROTTLE VALVE ASSEMBLY .
• Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to REMOVING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 2 .
• Refer to REMOVING FUEL DELIVERY LINE .
• Refer to REMOVING LEFT CYLINDER HEAD COVER .
• Refer to REMOVING THE COOLANT PUMP .

Remove the sealing cap on the cylinder head of the cylinder bank 2 

• Loosen screws (1)  .
• Remove the sealing cap (2)  on the cylinder head.

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Bring the crankshaft into the installation position of cylinder bank 2 

• Turn the engine at the central bolt in clockwise direction until the installation position (MP) (1)  of the vibration absorber (1)  is positioned flush with the marks of the engine block.

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• Check the camshaft position of cylinder bank 2.

  The cams (1)  should be in the position shown.

• Make sure that the increment wheels (2)  are aligned with the camshaft bearing caps.

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• Ensure that the polished surfaces of the camshafts (1)  point upward.
• Ensure that the rounded surfaces (1)  are pointing down at the cylinder head.
• Check timing again and assess.

Relaxing chain tensioner on bank 2 for checking or setting timing 

• Make sure that the chain drive is loaded at the same time on the central bolt of the engine and on the VANOS exhaust central valve. 

  The movement of the chain tensioner piston must be observed in this process.

• To do this, carry out the following steps at the same time:
• Keep the VANOS central valve on the exhaust side under tension in clockwise direction with a support person.

  The VANOS central valve on the exhaust side must not be twisted.

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• Rotate the engine counterclockwise at the central bolt.

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Slackening the hydraulic chain tensioner of cylinder bank 2 

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• Position the special tool 0 491 012 (11 4 120) (3)  in the bore and fasten the chain tensioner piston.

• Make sure that the chain drive is relieved at the same time on the central bolt of the engine and on the VANOS central valve on the exhaust side. 

  To do this, carry out the following steps at the same time:

• Relieve the chain drive clockwise at the central bolt.

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• Relieve the chain drive counterclockwise at the VANOS central valve on the exhaust side.

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Removing hydraulic chain tensioner of cylinder bank 2 

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• Loosen screws (1)  .
• Feed out and remove hydraulic chain tensioner (2)  .

Preloading the timing chain of cylinder bank 2 

• Position the special tool 2 249 162 on the cylinder head and apply the screws (1)  hand-tight.
• Exchange the screw (2) on the special tool  2 249 162  with an (M8x15) hexagon screw. 

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• Pretension special tool 2 249 162 using special tool 0 496 778 (00 9 460) at 0.6 Nm.

  The flexible shaft on the special tool  0 496 778 (00 9 460)  must not touch any other components, as the torque value will be falsified. 

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Secure the engine in the installation position at the 5th cylinder. 

• Position special tool 0 496 366 (11 8 570) (3)  on the vibration absorber.
• Position special tool 0 493 882 (11 9 190) (1)  in special tool 0 496 366 (11 8 570) .
  NOTE: Do not slide the special tool 0 493 882 (11 9 190) (2) too far in; otherwise, it will collide with  other components when the crankshaft is turning.
• Position reversible ratchet.
• Rotate the engine on the central bolt clockwise until the special tool lines up with the engine block marks.
• Attach the special tool 0 496 366 (11 8 570) (3)  to the vibration absorber with a screw from the belt pulley (2)  and hand-tighten.

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• With the crankshaft in the installation position, use the special tool 0 493 882 (11 9 190) (1)  to insert it onto the marks and fasten.

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• Ensure that the polished surfaces of the camshafts (1)  point upward.
• Ensure that the rounded surfaces (1)  are pointing down at the cylinder head.

Check 

• Check the camshaft position of cylinder bank 2.

  The cams (1)  should be in the position shown.

  The increment wheels (2)  must be flush with the exhaust camshaft bearing cap and the intake camshaft bearing cap.

  The ground surfaces of the camshaft must face up.

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Result 

» Camshaft position is correct.

Measure

• Continue the repair with the next step.

Result 

» Camshaft position is not correct.

Measure

• Disassemble special tools 0 496 366 (11 8 570) and 0 493 882 (11 9 190) and remove.

Measure

• Turn engine at the central bolt of the crankshaft by 360° until the installation position (MP) of the vibration absorber is positioned flush with the marks of the engine block.

Measure

• Re-secure the engine in TDC setting with special tools  0 496 366 (11 8 570)  and  0 493 882 (11 9 190)  .

Installing the special tool to secure the camshafts of cylinder bank 2 

Check 

• Position the special tool 2 249 117 (1)  on the camshafts of cylinder bank 2.
• Check if the camshafts can be fastened with the special tool 2 249 117 (1)  .
• Check if the special tool 2 249 117 can be brought in contact with the cylinder head using the two screws of the cylinder head cover (2)  .

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Result 

» The camshafts can be fastened.

Measure

• Loosen screws (2)  .

  Remove the special tool 2 249 117 (1)  .

  Continue the repair in the next step.

Result 

» The camshafts cannot be fastened.

Measure

• Adjust the timings of cylinder bank 2.

Remove the special tools to disconnect the crankshaft 

• Remove special tool 0 493 882 (11 9 190) (1)  .
• Release the screw (2)  of the belt pulley.
• Remove special tool 0 496 366 (11 8 570) (3)  .

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Removing special tool to pretension timing chain on cylinder bank 2 

• Release timing chain on the special tool  2 249 162  by turning the hexagon screw (2). 
• Release special tool 2 249 162 in area (1)  and remove.

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Installing the hydraulic chain tensioner of cylinder bank 2 

• Feed in and position the hydraulic chain tensioner (2)  .
• Tighten the screws (1)  .

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• Remove the special tool 0 491 012 (11 4 120) or transportation retainer (3)  from the bore.

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Installing the sealing cap on the cylinder head of cylinder bank 2 

• Replace the seal (1)  .

  Parts:  Seal

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• Position the sealing cap (2)  on the cylinder head.
• Tighten down screws (1)  .

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Follow-up work 

• Refer to INSTALLING THE LEFT CYLINDER HEAD COVER .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Installing holder with the wiring harness for the sensor system of cylinder bank 2.

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  • Position the holder with the wiring harness for the sensor system.
  • Tighten screws (2).
    TIGHTENING TORQUES
    
    

    Holder of sensor system
    M6x16 screw	Tightening torque	10Nm

  • Connect plug connection (3) and lock.
  • Engage the coolant ventilation line in area (1) at the holder.
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE LEFT THROTTLE BODY .
• Refer to INSTALLING THE INTAKE PIPE .
• Refer to INSTALLING THE LEFT-HAND CHARGE AIR COOLER .
• Refer to INSTALLING THE RIGHT-HAND CHARGE AIR COOLER .
• Refer to INSTALLING OIL FILLER NECK .
• Refer to CLOSING THE COOLANT PUMPS .
• Refer to INSTALLING THE WHEEL ARCH COVER ON THE FRONT LEFT AND BOTTOM RIGHT .
• Refer to INSTALLING THE BELT PULLEY ON THE TORSIONAL VIBRATION DAMPER .
• Refer to INSTALLING THE BELT TENSIONER .
• Refer to INSTALLING DRIVE BELT .
• Refer to INSTALLING FAN COWL WITH ELECTRIC MOTOR .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING THE CLEAN AIR PIPE OF CYLINDER BANK 2 .
• Refer to INSTALLING RIGHT INTAKE SILENCER HOUSING .
• Refer to INSTALLING LEFT INTAKE SILENCER HOUSING .
• Refer to INSTALLING FRONT CROSS CONNECTION .
• Refer to TIGHTENING THE LEFT FRONT-END STRUT .
• Refer to TIGHTENING THE FRONT-END STRUT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE RIGHT .
• Refer to INSTALLING THE COVER IN THE ENGINE COMPARTMENT ON THE LEFT .
• Refer to INSTALLING UPPER CATALYTIC CONVERTER NEAR ENGINE FOR BANK 2 .
• Refer to INSTALLING THE CATALYTIC CONVERTER NEAR ENGINE, BOTTOM AT BANK 2 .
• Refer to CONNECTING THE EXHAUST SYSTEM .
• Refer to INSTALLING THE STIFFENING PLATE .
• Refer to INSTALLING HEAT SHIELD, TOP .
• Refer to INSTALLING ENGINE VENTILATION LINE OF CYLINDER BANK 1 .
• Refer to INSTALLING THE TANK VENTILATION LINE OF CYLINDER BANK 1 PARTIALLY .
• Refer to INSTALLING THE ENGINE VENTILATION LINE OF CYLINDER BANK 2 .
• Refer to INSTALLING THE OXYGEN SENSOR MONITOR OF CYLINDER BANK 2 .
• Refer to CHECKING THE POSITION OF THE HEAT SHIELD .
• Refer to INSTALLING HOLDER OF THE DME CONTROL UNIT FOR CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE EXPANSION TANK FOR THE CHARGE AIR COOLER .
• Refer to INSTALLING COOLANT EXPANSION TANK .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 5 TO 8 .
• Refer to INSTALLING THE LAMBDA OXYGEN SENSOR FOR THE CYLINDERS 1 TO 4 .
• Refer to INSTALLING THE LEFT HIGH PRESSURE PUMP .
• Refer to INSTALLING THE HOLDER WITH THE VEHICLE WIRING HARNESS FOR THE SENSOR SYSTEM OF CYLINDER BANK 1 .
• Refer to INSTALLING THE CENTER COWL UPPER PART .
• Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Installing the rear right engine compartment cover.

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  Remove the battery cover  .

  NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
  • Remove the special tool 2 452 007  from the battery.

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  • Install the cover (2).
  • Lock the lock (1).
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to INSTALLING INJECTORS .
• Refer to CONNECTING THE CONNECTOR OF THE INJECTORS OF CYLINDER BANK 2 .
• Refer to INSTALLING RAIL ON BANK 2 .
• Refer to INSTALLING THE IGNITION COILS OF CYLINDER BANK 2 .
• Refer to INSTALLING CONTROL UNIT HOLDER FOR CYLINDERS 1 TO 4 .
• Installing the cover panel of the master DME control unit.

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  • Position the cover of the master DME control unit (1)
  • Engage the cover panel of the master DME control unit (1) downwards with the clamps (2) and the guide pins (3) in the carrier plate of the DME.
• Refer to INSTALLING THE COVER PANEL OF THE SLAVE DME CONTROL UNIT .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to CONNECTING BATTERY GROUND LEAD .
• Refer to FILLING THE HIGH-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE HIGH-TEMPERATURE COOLANT SYSTEM .
• Refer to FILLING THE LOW-TEMPERATURE COOLING SYSTEM WITH THE VACUUM FILLING EQUIPMENT .
• Refer to VENTING THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to EVACUATE AND CHARGE CONDITIONING .