Table of Contents
Print Text Only
Print Text and images
Bring lock carrier into service position as follows:
Remove radiator grille.
Remove upper bolts (2), Fig. 1.
Remove quick release screw (6) from below, Fig. 1.
Remove bolts (5 and 4) pointing upward in area of wheel housing liner, Fig. 1.
With aid from an assistant, pull cover parallel out of guides.
Disconnect harness connectors of installed electrical components and hoses.
Remove noise insulation.
Remove intake air duct between lock carrier (1) and air cleaner housing at lock carrier, Fig. 2.
Remove bolt (5) on bumper carrier (4) and install guide rods tool No. 3411, or equivalent, (6) on righthand and lefthand longitudinal member, Fig. 2.
Remove bolts (2 and 3), Fig. 2.
Lock carrier (1) can be pulled approximately .39 inch toward front onto guide rods tool No. 3411, (2), Fig. 3.
Remove upper toothed belt guard.
Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must be flush with marking on cylinder head cover, Fig. 4.
Loosen tensioner and remove toothed belt from camshaft sprocket.
Turn crankshaft back slightly.
Remove camshaft sprocket. To loosen bolt, counter hold camshaft gear using tool No. 3036, or equivalent.
Remove hall sensor housing.
Remove washer and cover for hall sensor.
Clean drive chain and camshaft chain sprockets across from both arrows on bearing caps and mark installed position with a color marking. Do not mark chain using a center punch or similar means. Distance between both arrows or colored markings consists of 16 rollers of drive chain, Fig. 5.
Secure camshaft adjuster or chain tensioner using bracket for chain adjustment tool No. 3366, or equivalent. If chain tensioner retainer is fastened too tightly, chain tensioner or camshaft adjuster can be damaged, Fig. 6.
First remove bearing caps 3 and 5 from intake and exhaust camshafts, Fig. 7.
Remove double bearing cap.
Remove both bearing caps from chain gears on intake and exhaust camshafts.
Remove securing bolts of camshaft adjuster/chain tensioner.
Alternating in diagonal sequence, loosen bearing caps 2 and 4 of intake and exhaust camshafts and remove.
Remove intake and exhaust camshaft, chain tensioner or camshaft adjuster and chain tensioner retainer tool No. 3366, or equivalent.
When installing the camshafts, cam lobes for cylinder 1 must point upward.
When installing bearing caps, verify marking on cap is readable from intake side of cylinder head.
When reusing old drive chain, mount drive chain according to color markings onto both camshafts. When using a new drive chain, distance between notches (A) and (B) must be 16 rollers on chain, Fig. 8.
Illustration shows where first and sixteenth drive chain rollers must be installed on chain gears.
Notch (A) is slightly offset inward toward chain roller (1), Fig. 8.
Replace rubber/metal seal for camshaft adjuster or chain tensioner and coat hatched surface with thin coat of sealant D 454 300 A2, or equivalent, Fig. 9.
Insert camshaft adjuster/chain tensioner between drive chain.
Oil running surfaces of both camshafts.
Insert camshafts with drive chain and camshaft adjuster/chain tensioner into cylinder head.
Tighten camshaft adjuster/chain tensioner to specification, pay attention to bushing.
Alternating in diagonal sequence, tighten bearing caps 2 and 4 of intake and exhaust camshafts and tighten to specification, pay attention to bushing, Fig. 7.
Install both bearing caps on gears on intake and exhaust camshafts. Inspect camshaft for proper adjustment (arrows) and tighten bearing cap to specification, pay attention to alignment bushing, Fig. 10.
Remove chain tensioner/camshaft adjuster tool No. 3366, or equivalent.
Coat hatched surfaces of double bearing cap lightly using sealant D 454 300 A2, or equivalent, install and tighten to specification, pay attention to bushing, Fig. 11.
Install remaining bearing caps and tighten to specification, pay attention to alignment bushing.
Install camshaft gear, thin rib toward outside (arrows) and TDC marking visible and tighten screw to specification, use retainer tool No. 3036, or equivalent, Fig. 12.
Inspect setting of camshafts to each other.
After installing camshafts, engine may not be started for approximately 30 minutes. Hydraulic adjusting elements must seat themselves, otherwise valves will seat themselves on pistons.
Pistons must not be positioned at TDC. Ensure that crankshaft is still positioned before cylinder 1 TDC.
Align marking on camshaft sprocket with marking on cylinder head cover.
Place toothed belt onto crankshaft sprocket, observe direction of rotation.
Install lower toothed belt guard.
Install vibration damper/belt pulley with new bolts. Tighten to specification.
Turn crankshaft to set cylinder 1 at TDC.
Place toothed belt on in this order coolant pump, tensioning roller and camshaft gear.
Tension toothed belt as follows:
If toothed belt tensioner is completely driven out, it must be pressed back by tensioner roller when installed. This procedure can last approximately five minutes. Pressing together with too much force can damage tensioner roller.
Turn eccentric pulley counterclockwise using tensioning device tool No. 3387, or equivalent, tab (A) of eccentric pulley must not be bent, until tensioning device locking tool No. T10008, or equivalent, can be pulled free of stress, Fig. 13.
Rotate eccentric pulley clockwise direction of (arrow) until a drill bit (2) with dimension (a) .31 inch, can be pulled through between tensioning lever and housing of tensioning device, Fig. 14.
Turn over crankshaft twice and inspect if markings on camshaft and crankshaft still align with their reference points.
Inspect dimension (a) .24-.39 inch between tensioning lever and housing of tensioning device using a drill bit (2), Fig. 14.
If dimension (a) is not obtained, release tension of toothed belt and tension it again.
Install upper and center toothed belt guards.
Install tensioner for serpentine belt. Tighten to specification.
Install serpentine belt. When installing serpentine belt, ensure that belt is seated correctly in belt pulleys.
Place torque wrench tool No. V.A.G 1331, or equivalent, in seven o'clock position and tighten A/C compressor belt tensioner to specification. Hold torque wrench securely and tighten bolts (A) to specification, Fig. 15.
Install lock carrier.
Install front bumper.
Tighten fasteners to specification.
Fill cooling system with coolant.
- Fig. 1 Front bumper removal
- Fig. 2 Lock carrier disconnection
- Fig. 3 Lock carrier service position
- Fig. 4 Camshaft sprocket alignment
- Fig. 5 Camshaft drive chain marking location
- Fig. 6 Camshaft drive chain tensioner securing location
- Fig. 7 Camshaft bearing cap removal
- Fig. 8 Camshaft installation
- Fig. 9 Camshaft chain tensioner seal installation
- Fig. 10 Camshaft installation mark alignment
- Fig. 11 Double bearing cap installation
- Fig. 12 Camshaft gear installation
- Fig. 13 Toothed belt tensioning device release
- Fig. 14 Toothed belt tensioning device
- Fig. 15 Air conditioning compressor belt installation
If you want a picture of one of the fig, let me know which one, there are several pictures. All I'm doing is copying out of my database.