11 31 505 Adjusting camshaft timing (S54)

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Special Tools Required:

11 2 300
11 5 100
11 7 160
11 7 200
11 7 342
11 9 130
11 9 140
11 9 170
12 6 050
12 6 410
12 6 411
(Refer to 11 31 005 CHECKING CAMSHAFT TIMING (S54) .)

When the engine is switched off, VANOS moves the camshafts to a position which is advantageous to engine starting.

CAUTION: The timing must "not" be adjusted in this position. The camshafts must be rotated back to their initial position beforehand and the timing checked.

Check camshaft timing. Refer to 11 31 005 CHECKING CAMSHAFT TIMING (S54) .

If the timing check reveals an impermissible deviation, the VANOS adjustment unit must be removed and the camshaft timing readjusted.

Release screws (1).
Remove sliding rail (2).
Release screws (3).
Remove holder (4).

Fig 1: Locating Sliding Rail
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Attach special tool 11 5 100 to four screws of crankshaft hub.

Fig 2: Attaching Adapter With Socket Wrench To Crankshaft Hub Screws

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Remove special tool 11 2 300. Rotate crankshaft in direction of rotation a further revolution up to overlap TDC position.

NOTE: TDC allocation above marking on vibration damper is sufficient.

Fig 3: Removing Plug Mandrel From Vibration Damper

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Slacken six accessible bolts two turns.

Fig 4: View Of Accessible Bolts

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Crank engine at central bolt in direction of rotation until 1st cylinder is at TDC firing position. Secure vibration damper in position with special tool 11 2 300.

Fig 5: Securing Vibration Damper

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Slacken remaining six bolts two turns.

Fig 6: Identifying Remaining Bolts

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Release screws on VANOS adjustment unit.

Fig 7: Releasing Screws On VANOS Adjustment Unit

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CAUTION: Do not damage VANOS adjustment unit.

Carefully detach VANOS adjustment unit.

Fig 8: Detaching VANOS Adjustment Unit

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CAUTION: Pay attention to installation direction of special tool 11 9 130.

(A) Exhaust side.
(E) Inlet side.

Fig 9: Identifying Setting Gauge

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Inlet side:

CAUTION: Pay attention to installation direction of special tool 11 9 130.

Attach special tool 11 9 130 to cylinder head. Align inlet camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head. Remove special tool 11 7 342.

Fig 10: Attaching Setting Gauge To Cylinder Head

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Exhaust side:

Align exhaust camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head. Remove special tool 11 9 130 and special tool 11 7 342.

Fig 11: Aligning Exhaust Camshaft

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Tighten all screws of spline hub (1) on inlet and outlet sides by hand until free from play.

Then slacken screws again until spline hubs (1) can be moved) with fingers.

Fig 12: Locating Screws Of Spline Hub On Inlet And Outlet Sides

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Detach control valve (1) from VANOS adjustment unit.

Fig 13: View Of Control Valve From VANOS Adjustment Unit

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NOTE: A filter is integrated in the control valve.

In the event of engine damage which suggests that the filter is contaminated with swarf/chips, it is essential to replace the control valve.

Replace sealing rings (1) and coat with oil as antiseize agent. Preassemble control valve in cylinder head.

Fig 14: Replacing Sealing Rings On Control Valve

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Oil is sprayed when splined shafts are pressed back. Cover bore (1) with a cloth.

Connect special tool 12 6 050 in conjunction with special tool 12 6 411 (from special tool kit 12 6 410) to solenoid valves of VANOS adjustment unit. Connect special tool 12 6 411 to correct terminals on car battery.

Press buttons 1 and 3 on special tool 12 6 050 simultaneously. Solenoid valves are actuated.

Press splined shafts by hand up to stop into initial position.

Fig 15: Identifying Switching Unit

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Check adapter sleeves (1) for damage and correct installation position.

Fig 16: View Of Adapter Sleeves

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Replace gasket (1).

CAUTION: Note direction of installation of gasket. Install gasket (1) in such a way that beading points to VANOS adjustment unit. Secure gasket (1) with sealing compound on adapter H sleeves.

Fig 17: Replacing VANOS Adjustment Unit Gasket

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Secure special tool 11 9 170 - as shown in illustration - by means of stud bolt.

NOTE: The special tool 11 9 170 serves to maintain a prespecified distance during the below-mentioned installation of the VANOS adjustment unit.

Fig 18: Securing Spacer For Installation Of VANOS Adjustment Unit

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Turn spline hubs (1) of inlet and exhaust camshafts to right limit position

Fig 19: Turning Spline Hubs To Right Limit Position

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NOTE: Special tool 11 9 170 remains as a spacer element between cylinder head and VANOS adjustment unit.

Attach VANOS adjustment unit.

Fig 20: Attaching VANOS Adjustment Unit

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CAUTION: Make sure both VANOS splined shafts remain in initial position during installation.

Rotate splined shafts of inlet and exhaust sides until spur toothing is engaged.

Push VANOS adjustment unit with splined shaft into VANOS gear until helical cut splines (2) are positioned shortly before meshing with spline hub (1).

Fig 21: Identifying Helical Cut Splines And Spline Hub

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Exhaust side:

If the helical cut splines cannot be pushed into the spline hub (1):

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

CAUTION: The "first" matching tooth must engage.

Fig 22: Placing Special Tool On Bore In Spline Hub (Exhaust)

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Inlet side:

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

CAUTION: The "first" matching tooth must engage.

Fig 23: Placing Special Tool On Bore In Spline Hub (Inlet)

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Exhaust side:

Align radial piston pump to driver on spline hub.

NOTE: Picture shows a schematic representation.

Fig 24: Aligning Radial Piston Pump To Driver On Spline Hub (Exhaust)

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Push on VANOS adjustment unit until it contacts special tool 11 9 170.

CAUTION: If this position is not reached, realign position of radial piston pump to driver.

Fig 25: Installing VANOS Adjustment Unit

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CAUTION: Do not tighten down screws.

NOTE: Screw on left and right serves to secure the VANOS adjustment unit.

Insert a screw on left and right and tighten by hand until free of play.

Fig 26: Securing VANOS Adjustment Unit

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NOTE: The procedure described below helps to provide compensation for play. Only with this compensation for play is the timing diagram correctly set.

NOTE: To tighten down screws on VANOS gear: Use special tool 11 7 200.

Tighten down the two opposing screws on the inlet and exhaust sides of the VANOS gear to 10 N.m.

Then slacken all four screws by a 1/4 turn.

Fig 27: Locating Screws On VANOS Gear

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Remove special tool 11 9 170 on left and right sides.

Fig 28: Removing Special Tool On Left And Right Sides

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CAUTION: Make sure that radial piston pump is aligned to driver on spline hub. When the left and right screws are tightened down alternately, the exhaust and inlet camshafts must not rotate. If the camshafts do rotate, this means that the screws on the VANOS gear were not previously released correctly.

Alternately tighten down bolts in 1/2 turn increments carefully and evenly until VANOS adjustment unit rests against timing case cover.

Fig 29: Installing VANOS Adjustment Unit To Timing Case Cover

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Insert remaining screws and tighten down.

Fig 30: Inserting Remaining Screws

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NOTE: Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Fig 31: Installing Bolts On VANOS Gear

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Tighten down six accessible screws (three on exhaust side and three on inlet side) on VANOS gear to 10 N.m.

Fig 32: Securing Accessible Screws On VANOS Gear

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Remove special tool 11 2 300. Rotate crankshaft in direction of rotation a further revolution up to overlap TDC position.

NOTE: TDC allocation above marking on vibration damper is sufficient.

Fig 33: Removing Plug Mandrel From Vibration Damper

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NOTE: Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Fig 34: Securing Remaining Screws On VANOS Gear

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Tighten down remaining six screws (three on exhaust side and three on inlet side) on VANOS gear to 10 N.m.

Fig 35: Tightening Down Six Accessible Screws On VANOS Gear

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Then crank engine again in direction of rotation until 1st cylinder is at TDC firing position.

Secure vibration damper in position with special tool 11 2 300.

Fig 36: Securing Vibration Damper

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Check camshaft setting:

Attach special tool 11 9 140 and join in inlet camshaft.

NOTE: The inlet camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

Fig 37: Attaching Gauge To Inlet Camshaft

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Join special tool 11 9 140 in exhaust camshaft.

NOTE: The exhaust camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

Fig 38: Attaching Gauge To Exhaust Camshaft

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NOTE: Check installed direction.

Install holder (4)

Fig 39: Installing Holder

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Insert screws (3) and secure holder (4) (do not tighten down screws (3) yet)
Install sliding rail (2).
Insert screws (1).
Tighten down screws (1) and screws (3).

Fig 40: Identifying Sliding Rail
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Replace sealing rings of banjo bolt.

Install banjo bolt do not tighten down yet

Fig 41: View Of Banjo Bolt

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Install bracket of oil line. Install screw and tighten down.

Fig 42: Locating Bracket Of Oil Line

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Tighten down banjo bolt of oil line.

Tightening torque, refer to 11 36 9AZ in ENGINE - TIGHTENING TORQUES .

Fig 43: Locating Banjo Bolt Of Oil Line

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Remove special tool 11 2 300.

Assemble engine

Fig 44: Removing Plug Mandrel From Vibration Damper

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CAUTION: There is air in the VANOS system once it is opened. In the first few seconds after startup this results in a clearly discernible "rattling noise". This rattling noise does "not" indicate incorrect assembly. The rattling noise will disappear as soon as the oil pressure has built up and the system has vented.