Work sequence

CAUTION: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:

Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
Ensure sufficient clearance to all moving or hot components.

NOTE:

The following work sequence is described for an engine after removal. Start with the adjustments at the relevant position depending on how far the engine has been disassembled.

Install roller chain and chain tensioner with tensioning plate for intermediate shaft drive:

Fig 1: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft

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Adjust position of crankshaft relative to intermediate shaft. To position: Align ground-down tooth of drive chain sprocket - B - with mounting joint (TDC cyl. 1).
Install both bolts without collar for guide rail - 2 - and tighten to 10 Nm.

NOTE:

Observe direction of rotation marks of used roller chain, Marking roller chains under Engine, disassembling and assembling

Install guide rail - 2 - with roller chain - 1 - and both chain sprockets - 3 - and - 4 -. Marking on sprocket - 4 - for roller chain must align with notch - C - or - D - on thrust washer of intermediate shaft.

During installation make sure that the roller chain runs completely straight in the guide plate from the crankshaft to the intermediate shaft.

Fig 2: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft

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Tighten chain sprockets - 3 - and - 4 - on the intermediate shaft by hand.

NOTE:

Please observe that all chain sprocket securing screws/bolts must be replaced.

Install chain tensioner on opposite side.
Release locking splines of chain tensioner - A - with a small screwdriver and tensioning plate pressed against chain tensioner.
Install chain tensioner in this position and tighten to 8 Nm.

Fig 3: Loosening/Tightening Securing Bolt, Using Counter-Holder T10069 To Hold Vibration Damper

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Lock vibration damper with Counter support T10069.

Fig 4: Identifying Guide Rail, Roller Chain, Both Chain Sprockets, And Marking On Roller Chain Sprocket Aligned With Notch On Thrust Washer Of Intermediate Shaft

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Tighten new securing bolts of chain sprocket - 3 - and - 4 - for intermediate shaft to 60 Nm + 90 ° (1/4 turn - turning further can be done in several stages).
Remove Counter support T10069.
Check position of crankshaft - B - to intermediate shaft - C - or - D - once again.
Set engine again to TDC cyl. 1.

Install roller chain for camshaft drive:

Position camshafts installed in cylinder head to TDC cylinder 1.

Fig 5: Camshaft Counter Support Area

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NOTE:

If necessary use 32 mm open end wrench to turn camshafts - arrows - to the correct position. Camshaft bar T10068 must not be installed when doing this.

Fig 6: Camshaft Bar T10068 Engaged In Both Shaft Grooves

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It must be possible to insert Camshaft bar T10068 into both shaft slots.

NOTE:

If the cylinder head is removed: → Cylinder head, removing and installing , Removing and installing cylinder head.

Place camshaft roller chain on intermediate shaft chain sprocket.
Guide chain between tensioning rail and guide rail toward control housing.
First install intake camshaft timing adjuster along with fitted camshaft roller chain.

Fig 7: Camshaft Timing Adjusters Positioned On The Camshaft Mountings

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Position both camshaft timing adjusters (identification: 24E on intake side and 32A on exhaust side) on the camshaft mountings - arrows -.

Fig 8: Exhaust Camshaft Timing Adjuster, Sensor Wheel And Turning Direction Of Installation

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NOTE:

The exhaust camshaft timing adjuster - 1 - can be turned in two directions. When installing, ensure that the sensor wheel - 2 - for the CMP sensor G163 is turned onto limit stop in direction of - arrow -. The distance between the two ground-down teeth of the intake and exhaust camshaft timing adjusters (markings 24E and 32A) must be exactly 16 rollers of the camshaft roller chain

Fig 9: Identifying Marks And Camshaft Adjusters Aligned With Notches On Control Housing

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Install exhaust camshaft timing adjuster with fitted camshaft roller chain. Marks - A - and - B - on camshaft timing adjusters must align with notches - arrows - on control housing - C -.
Tighten new securing bolts for camshaft timing adjuster hand tight.
Check distance between tooth - 1 - and tooth - 2 - of camshaft timing adjuster. It must be exactly 16 rollers of camshaft roller chain.
Remove Camshaft bar T10068.

Turn crankshaft two full turns in engine direction of rotation and check valve timing → Valve timing, checking .

NOTE:

When the crankshaft is turned, the tensioning rail must be pressed against the camshaft roller chain by hand instead of with the chain tensioner.

If the marks do not align:

Repeat timing adjustment.

If the marks align:

Fig 10: Camshaft Counter Support Area

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Hold camshaft to be tightened with a 32 mm open end wrench - arrow -.

NOTE:

The Camshaft bar T10068 must not be installed when doing this.

Fig 11: Identifying Intake And Exhaust Camshaft Adjusters And Securing Bolt

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Tighten new securing bolts - 3 - for intake and exhaust camshaft timing adjusters -4 and 2- to 60 Nm + 90 ° (1/4 turn - turning further can be done in several stages).
Coat sealing surfaces of flywheel/drive plate sealing flange with sealing compound AMV 188 001 02 and install. Tighten securing bolts to 8 Nm.
Replace flywheel/drive plate sealing flange, - -.

Fig 12: Locating 3 mm Holes In The Cylinder Head Gasket

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Remove old sealing compound from 3 mm holes in cylinder head gasket - arrows -.
Fill 3 mm holes in cylinder head gasket with sealing compound AMV 174 004 02 .

NOTE:

When the cylinder head is installed the holes in the cylinder head gasket are only half visible.

Coat sealing surface of cover with sealing compound AMV 188 001 02 .
Lubricate O-ring for oil channel seal and insert into cover together with seal ring.
Install cover, insert all securing bolts and tighten lightly.
First tighten M8 securing bolt to 23 Nm then M6 securing bolts to 8 Nm.

Install chain tensioner for camshaft roller chain and tighten to 40 Nm.
Turn crankshaft two full turns in engine direction of rotation and check valve timing → Valve timing, checking .
Install cylinder head cover and intake manifold → Cylinder head cover, removing and installing , Removing and installing cylinder head
Check camshaft adjustments → Camshaft adjustment, checking .