Note! As the illustrations in this service information are used
for different model years and / or models, some variation may occur.
However, the essential information in the illustrations is always
correct.
Note! Make a note of the valve clearance in the inspection form!
Remove (B6284T)
the camshaft position (CMP) sensor housing. Place to one side
the trigger wheel
the screw holding the control pipe for the pressure regulator to the top of the cylinder head
the protective cover over the injector connectors.
Remove (B6294S)
the cover at the rear of the exhaust camshaft
the vacuum hoses from the intake manifold
the screws at the intake manifold junction.
Lift out the upper section of the intake manifold. Remove the gasket. Install guard 999 5723 .
Remove (common)
the ground strip from the firewall
the connector for the variable valve timing solenoid
the connector for the coolant temperature sensor
the screw holding the cable duct for the temperature sensor to the top of the cylinder head
the radiator breather tube from the expansion tank. Install lock grip pliers.
Lift up the brake fluid reservoir.
Disconnect the ABS sensor connector.
Place the brake fluid reservoir over the engine.
Warning! Ensure that no fluid is spilled on the engine. It is extremely flammable!
Disconnect the connector for the level sensor in the expansion tank.
Lift up and place the expansion tank on top of the engine.
Remove
the auxiliaries belt
the front timing cover. Position the upper timing cover.
Turn the crankshaft clockwise until the markings on the crankshaft belt pulley and the timing belt pulley are aligned with the markings on the oil pump and the upper timing cover.
Remove the upper timing cover.
Caution! Crankshaft and camshafts must not be turned more than
is stated in the method description. If the shafts are turned in any
other way the valves may be damaged.
Slacken off the center screw for the belt tensioner slightly.
Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock using a 6 mm Allen key.
Remove the timing belt from the camshaft pulleys.
Removing the timing gear pulley
Install camshaft adjustment tool 999 5452 at the rear of the camshafts.
Check that the screws securing the adjustment tool to the camshafts and the screw holding the tool together are well tightened
Remove (timing gear pulley with variable valve timing unit)
the plug at the front of the variable valve timing unit (Tx55)
the center screw in the variable valve timing unit (Tx55).
Carefully pull out the variable valve timing unit with the timing gear
pulley.
Remove (timing gear pulley without variable valve timing unit)
the screws securing the timing gear pulley on the camshaft
the timing gear pulley. Remove tool 999 5452.
Reinstall the expansion tank and the brake fluid reservoir at the fender liner.
Install 2 tools 999 5454 . Leave a 2-3 mm gap to the camshaft cover.
Ensure that the screw in the spark plug well is fully tightened.
Remove all the screws securing the camshaft cover to the cylinder head.
Use pliers 999 5670 to lift the cover from the cylinder head.
Install the pliers at the stop lugs. Start with cylinder 1 and work alternately backward.
Slacken off the wing nuts approximately 2 turns. Repeat the procedure with the pliers.
Carefully press the camshaft seals free.
Note! Take care not to damage the sealing surfaces on the camshafts.
Remove
tool 999 5454
the camshaft cover
the camshafts.
Lift out the valve lifters. Mark up the valve lifters so that the original positions can be established.
Cleaning
Use a razor blade or a gasket scraper and gasket solvent P/N 1161 440 on the camshaft cover.
Warning! Use a fume hood or extractor when using gasket solvent!
Use only a gasket scraper or razor blade on the cylinder head.
Caution! Take great care around the oil ducts for the variable
valve timing solenoid. This applies to both the camshaft cover and the
cylinder head. The solenoid is extremely sensitive to contaminants.
Dry and blow all surfaces clean.
Preparations
Carefully tap the end of the valve stem to ensure that the valve is correctly located in the seat.
Use a plastic, aluminum or brass drift to protect the valve and the surface of the valve lifter.
The sound made by tapping reveals if the valve is correctly seated.
Installing the camshaft and valve lifter
Install both the valve lifters for the inlet valves at cylinder 1.
Check the notes made earlier. Select new valve lifters if necessary.
Note! Only install two valve lifters. The valve lifters should
be placed at the same cylinder! Other valve lifters are available as
replacement pant / replacement part kits.
The valve clearance on a cold engine (approximately 20°C) should be:
Inlet valve:
0.20 ±0.03 mm.
Exhaust valve:
0.40 ±0.03 mm.
Note! The tolerances are less at setting! When checking the valve clearance through the plug hole the tolerances are larger.
Position the intake camshaft. Ensure that the lobes at cylinder 1 point upwards.
Apply a little oil to the cam lobe and the upper side of the valve lifter to facilitate later measurement.
Installing the camshaft press
Install the lower section of the camshaft press 999 5165 at the inlet valves for cylinder 1. Tighten the tool against the cylinder head. Tighten to 17 Nm.
Turn the camshaft until it stops against the camshaft press.
Install the upper section of the camshaft press.
Tighten the screw which tensions the camshaft. Tighten to 12 Nm.
Checking the valve clearance
Note! Measurements should only be taken on a cold engine. Suitable temperature is approximately 20°C / 68°F.
Use feeler gauge 999 5752.
Press with a finger so that the feeler gauge lies parallel to the upper side of the tappet (see illustration).
Move the feeler gauge sideways when taking the reading in order to obtain as accurate a measurement as possible.
The valve clearance measured on cold engines (approximately 20°C / 68°F) should be:
Inlet valve:
0.20 ±0.03 mm.
Exhaust valve:
0.40 ±0.03 mm.
Note! The tolerances are less at setting! When checking the valve clearance through the plug hole the tolerances are larger.
Differences in valve clearance for different engines / ambient temperatures:
-0.01 mm at 15°C
+0.01 mm at 25°C
+0.02 mm at 30°C
+0.03 mm at 35°C
+0.04 mm at 45°C
Correcting measured clearance Lift out the upper section of the press tool. Lift out the camshaft.
Adjust the play by replacing the valve lifters. Other valve lifters are available as replacement part / replacement part kits.
Reinstall the camshaft and the upper section of the press tool. Tighten to 12 Nm.
Take a new measurement
When the correct valve clearance is reached
Remove
the press tool 999 5765
the camshaft
the valve lifters.
Note! Carefully mark the valve lifters so that exact reinstallation can be carried out.
Lubricate the valve guide wells.
Install all the valve lifters.
Lubricate the camshaft bearing seats and the upper sides of the valve lifters.
Position the intake camshaft. Ensure that the groove at the rear edge of the camshaft is above an imaginary center line.
Position the exhaust camshaft. Ensure that the groove at the rear edge of the camshaft is below an imaginary center line.
Applying liquid gasket
Wipe the oil film off the mating surfaces on the camshaft cover and cylinder head. Install new 0-rings around the spark plug wells at the cylinder head.
Apply liquid gasket 1161 059 on the camshaft cover. Use roller 951 2767.
Note! The surface must be completely covered without any excess.
Caution! Ensure that no liquid gasket gets in to the oil ducts.
Installing the camshaft covers
Lubricate the camshaft lobes, the camshaft bearing surfaces and the valve lifters.
Install the camshaft cover. Install press too1 999 5454 (2x). Tighten the camshaft cover screws alternately, keeping it parallel to the cylinder head with the press tools.
Install the intake manifold and lifting eyes, tighten screws from the middle and outwards. Remove the press tool 999 5454
the variable valve timing (VVT) solenoid with a new gasket
the plugs for the test holes. Tighten to 20 Nm the ignition coils according to the earlier marking
the ignition coils according to the earlier marking
the ground terminals between the ignition coils
the upper engine stabilizer brace
the cable duct for the coolant temperature sensor.
Connect the connectors for the
the coolant temperature sensor
Variable valve timing solenoid.
Installing the rear camshaft seal
Use drift 999 5450.
Lubricate the surface of the seal that the camshaft rotates against.
Press in the seal until the drift bottoms out.
Note! If there are wear grooves on the camshaft, the seal can be pressed in a further 2 mm by reversing the sleeve.
B6284T: The seal at the rear edge of the exhaust camshaft.
B62946: The seal at the rear of the intake camshaft. Install the camshaft adjustment tool 999 5452 at the rear of the camshafts.
Check that the screws securing the adjustment tool to the camshafts and the screws holding the tool together are well tightened.
Installing the front camshaft seal
Lift up and position the brake fluid reservoir and the expansion tank on top of the engine.
Use drift 999 5718 on camshafts with variable valve timing units and drift 999 5719 on camshafts without variable valve timing.
Use new seals and lubricate the surface of the seal that the camshaft rotates against.
Use the variable valve timing unit / timing belt pulley mounting screws. Tighten the screws until the drift bottoms out.
Remove the drift.
Fixing the crankshaft position
Remove
the air cleaner (ACL) intake pipe
the mounting screws for the starter motor. Pull off the starter motor. Place the starter motor to one side
the blind cover plug and the seal washer. Turn the crankshaft clockwise. Install the crankshaft stop 999 5451
Ensure that it bottoms out against the cylinder block. Turn the
crankshaft counter-clockwise until it stops against the crankshaft stop.
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Installing the camshafts timing gear pulleys (B6284T)
Timing gear pulleys with variable valve timing units
Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit / timing gear onto the camshaft.
Install the center screw which secures the variable valve timing unit to the camshaft. Tighten slightly.
Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.
Continue turning clockwise until the timing gear pulley marking is 1 1/2 tooth before the marking on the upper timing cover.
Check that the timing gear pulley is still in its limit position at the oval holes.
Tighten the center screw for the variable valve timing (VVT) unit. Tighten to 120 Nm. Check that the variable valve timing unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm.
Timing gear pulleys without variable valve timing units
Install the timing gear pulley with two screws but do not tighten.
Check that the markings on the timing gear pulley and the upper timing cover correspond.
Installing the camshafts timing gear pulleys (B6294S)
Timing gear pulleys with variable valve timing units
Slacken off, but do not remove the screws which secure the timing gear pulley to the variable valve timing unit.
Press the variable valve timing unit / timing gear onto the camshaft.
Install the center screw which secures the variable valve timing unit
to the camshaft. Tighten slightly. Turn the variable valve timing unit
anti-clockwise as far as it will go.
Slacken off the center screw Position the upper timing cover.
Turn the timing gear pulley clockwise until the screws at the oval
holes are in the limit position. Continue turning clockwise until the
timing gear pulley marking is 11A tooth before the marking on the upper
timing cover.
Check that the timing gear pulley is still in its limit position at the oval holes.
Tighten the center screw for the variable valve timing (VVT) unit. Tighten to 120 Nm. Check that the variable valve timing unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm.
Timing gear pulleys without variable valve timing units
Install the timing gear pulley with two screws but do not tighten.
Check that the markings on the timing gear pulley and the upper timing cover correspond.
Tighten the center screw on the belt tensioner. Tighten to 5 Nm.
Turn the variable valve timing unit clockwise until stop.
Hold it secure in the limit position.
Install the belt in the following order:
crankshaft
the idler pulley
intake cam
exhaust cam
water pump
belt tensioner.
Note! Adjust
the timing gear pulleys so that the screws are not at a limit position
in the oval holes. Also check that the markings correspond.
This adjustment is always carried out on a cold engine. A suitable temperature is approximately 20°C.
At higher temperatures (with the engine at operating temperature or a
high outside temperature for example) the indicator is further to the
right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Hold the center screw secure and turn the belt tensioner eccentric
counter-clockwise until the tensioner indicator passes the marked
position.
Note! Check that the variable valve timing unit is in its limit position.
Tighten the three screws at the timing gear pulley for the intake camshaft. Tighten to 10 Nm.
Tighten the three screws at the timing gear pulley for the exhaust camshaft. Tighten to 20 Nm .
Turn the eccentric on the belt tensioner back so that the indicator
reaches the marked position in the center of the window. Remember to
hold the center screw secure at the same time.
Hold the eccentric secure and tighten the center screw to 20 Nm.
Check that the indicator is in the correct position. Remove camshaft adjustment tool 999 5451 and crankshaft stop 999 5452.
Install the plug with a new blind cover plug. Tighten to 40 Nm.
Checking the markings and belt tension
Press the timing belt to check that the indicator on the tensioner moves easily.
Turn the crankshaft two turns. Check that the markings on the
crankshaft timing gear pulley and the camshaft timing gear pulley match
up with the markings on the oil pump and upper timing cover
respectively.
Check that the indicator on the belt tensioner is within the marked position.
Remove the upper timing cover.
Finishing
Install
front timing cover
the auxiliaries belt
the expansion tank
the servo oil reservoir
the bleed hose for the expansion tank.
Close the clamp and check that the hoses lie correctly.
Connect the connectors for the
The ABS sensor by the right suspension turret
the coolant level sensor in the expansion tank.
Install
the starter motor
the air cleaner (ACL) intake pipe
the trigger wheel.
Note! Ensure that the trigger wheel is correctly positioned against the camshaft.
the camshaft position (CMP) sensor housing
the cover at the rear edge of the camshaft
the screws holding both the ground strips from the firewall to the cylinder head
the cover over the ignition coils
the upper timing cover.
Install (B6284T)
the protective cover over the injector connectors
plastic charge air / intake pipe over the engine. Tighten the clamps
the crankcase ventilation hose to the PTC valve. Use a new clamp
the connector for the PTC valve
the cover over the PTC valve
EVAP, "bypass"hoses and control hoses for boost pressure.
Install (B6294S)
the upper section of the intake manifold. Use a new gasket
vacuum hoses to the intake manifold.
Install (common)
the engine stabilizer brace between the suspension turrets Clamp
the servo hose to the right mounting for the engine stabilizer brace in
the bodywork
the plastic nuts for the cover in fender liner the right front wheel according to Installing wheels
the cable to the battery negative terminal.
Check
Check the level in the expansion tank and the brake fluid reservoir.
Top up if necessary.
Test drive the engine until the thermostat opens and check for any leakage.
