Adjusting Timing, Side 4 - 6

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Align camshafts. On both camshafts, the smaller circular cutout -arrows- must lie at the top. See Fig 1.

Fig 1: Locating Camshaft Circular Cutout
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Fix the camshafts with special tool (adjustment gauge) 9686 and fasten the gauge with 1 M8 auxiliary screw (e.g. M8 x 16 hexagon-head bolt) (flat tool surface should face upwards). Only tighten the screw slightly.

Fig 2: Installing Special Tool (Adjustment Gauge) 9686
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Screw the bearing cover screws of the inlet and exhaust camshafts and the auxiliary screw of the adjustment gauge alternately by another approx. 90° until the specified tightening torque of 10 Nm (7.5 ft.lb.) is reached.
Tightening torque 10 Nm (7.5 ft.lb)
Insert the guide rail screw with a new O-ring and tighten (M6 hexagon socket a/f 5).
Tightening torque 10 Nm (7.5 ft.lb)
Fit the chain tensioner, side 4-6 (hexagon socket a/f 14) -arrow- . See Fig 3. Replace sealing ring. Position the chain tensioner with new sealing ring and tighten to the specified torque.

Fig 3: Locating Chain Tensioner, Side 4-6
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Tightening torque 80 Nm (59 ft.lb)
NOTE:
- Move the engine at the belt pulley of the crankshaft to the TDC marking without fail.
Turn the engine at the belt pulley of the crankshaft clockwise (engine direction of rotation) to the TDC marking (the TDC bore in the belt pulley is flush with the fixing bore in the crankcase). Fix with special tool (fixing pins) 9595/1, use short fixing pin.

Fig 4: Fixing belt pulley With Special Tool (Fixing Pins) 9595/1
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Position the 4 M6 x 12 hexagon-head bolts for the chain sprocket of the exhaust camshaft and tighten crosswise to the specified torque.

Fig 5: Identifying 4 M6 X 12 Hexagon-Head Bolts For Chain Sprocket
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Tightening torque 14 Nm (10.5 ft.lb.)
NOTE:
- Replace central screw for camshaft adjustment device.
Tighten the central screw of the camshaft adjusting device. Position the special tool (retaining tool) 9685 on the adapter of the central screw and place the loose contact block at the fitting bore of the oil extraction pump. Tighten the hexagon-head bolt on the contact block.

Fig 6: Installing Special Tool (Retaining Tool) 9685 On The Adapter Of The Central Screw
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Tighten the new central screw in two stages.
1st stage: pre-tightening torque 50 Nm (37 ft.lb.)

Fig 7: Tightening New Central Screw
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NOTE:
- Before the final tightening of the central screw, remove the special tool (adjustment gauge) 9686 without fail.
Remove special tool adjustment gauge 9686. Unscrew the M8 auxiliary screw and pull off the gauge.
2nd stage: final tightening of central screw with torque angle wrench 110° turn.
NOTE:
- Replace the seals for the spark plug recesses.
Insert 3 seals for the spark-plug recesses -arrow- . See Fig 8.

Fig 8: Locating Seals For The Spark-Plug Recesses
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NOTE:
- Only if the camshaft adjustment valve was removed:
- Replace oil strainer -arrow-. See Fig 9.
  
  Fig 9: Replacing Oil Strainer
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- Insert camshaft adjustment valve with a new O-ring again (installation position: ensure that dowel pin is in the cylinder head bore).
Install cylinder head cover. See REMOVING AND INSTALLING CYLINDER HEAD COVER - ENGINE REMOVED, AS OF MY 2003 .
NOTE:
- Replace O-ring in the oil extraction pumps.
- Do not tilt oil extraction pump when inserting it. Otherwise, the fitting bore on the cylinder head/cylinder head cover could be damaged.
- Pay attention to the installation position!
Fit oil extraction pump with new O-ring. Insert oil extraction pump carefully in the fitting bore on the cylinder head (installation position: Identification 4-6- faces crankcase). Position 4 M6 x 20 hexagon-head bolts on cylinder head and cylinder head cover and tighten to the specified torque.

Fig 10: Locating Identification Mark On Oil Extraction Pump
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Tightening torque 13 Nm (9.5 ft.lb.)
NOTE:
- Replace all plastic closure caps on the cylinder head/cylinder head cover.
Place a new, brown, dry closure cap (45 mm) on the large bore for the exhaust camshaft and tap it in gently with a plastic hammer.
Insert 2 new, green, dry closure caps into the small bores on the cylinder head and tap them in gently with a plastic hammer.
NOTE:
- Replace cover with integral seal for camshaft adjustment valve.
Slide the new cover over the camshaft adjustment valve, place holder with 2 M6 x 20 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to valve.
Tightening torque 10 Nm (7.5 ft.lb)
Install ignition coils. Insert 3 ignition coils into the spark-plug recesses, position 2 M6 x 25 pan-head screws (hexagon socket a/f 5) on cylinder head cover and tighten. Connect cable plug to ignition coils.
Tightening torque 10 Nm (7.5 ft.lb)
Fit the holder for the servo line.
Install air conditioning compressor. Refer to REMOVING AND INSTALLING THE COMPRESSOR .