Remove/install valve tappets - AR05.00-P-2310MCU
ENGINE 132.910 in MODEL 451.3/4
Scheme 148
Remove/install 1 Remove intake camshaft (2) or exhaust camshaft (3) over the relevant valve tappet (1) AR05.20-P-6992MCU 2 Remove valve tappet (1) from basic bore in cylinder head Do not use magnets. Magnetization of the valve tappet (1) can lead to gathering of the smallest metal chips which can lead to damage to the valve tappet (1) and intake camshaft (2) or exhaust camshaft (3) Installation: When recycling the valve tappet (1), it must be reinstalled at the same location. The valve tappets (1) are designed in various thicknesses to compensate for the valve clearance. The dimension for the thickness of the valve tappet (1) is located on its underside. Checking 3 Check basic bores in cylinder head In case of damage to the basic bore in the cylinder head, the cylinder head must be replaced, see: ↓ Remove/install cylinder head AR01.30-P-5800MCU 4 Install in the reverse order
Scheme 149
Replace timing chain - AR05.10-P-7601MCU
ENGINE 132.910 in MODEL 451.3/4
Scheme 150
Remove/install 1 Check basic position of camshafts AR05.20-P-6010MCU 2 Remove timing case cover AR01.40-P-8000MCU 3 Turn back ratchet (9) on chain tensioner (8) using a suitable screwdriver and lock chain tensioner (8) via the bore (arrow A) In order to lock the chain tensioner (8), place a pin with a diameter of 1.5 mm into the bore (arrow A) in the chain tensioner (8). Installation: Attach adapter to crankshaft, remove retaining lock on starter ring gear and turn engine in direction of engine rotation through about two revolutions until the markings on the crankshaft sprocket and on the cylinder crankcase stand opposite each other. Then check whether the marking (arrow B) on the camshaft sprocket (2) and the marking (arrow C) on the camshaft adjuster (3) stand opposite each other; remove timing chain (1) if necessary and mount again anew. Attach/disassemble retaining lock for engine AR03.30-P-1600-06MCE see scheme 4 see scheme 5 4 Unscrew bolts (5) and remove slide rail (6) Installation: Check slide rail (6) for wear; replace if necessary. *BA05.10-P-1002-01P *BA05.10-P-1003-01P 5 Unscrew bolt (4) and remove tensioning rail (7) Installation: Check tensioning rail (7) for wear; replace if necessary. *BA05.10-P-1001-01P 6 Take off timing chain (1) Installation: Before mounting the timing chain (1), check whether the marking (arrow B) on the camshaft sprocket (2) and the marking (arrow C) on the camshaft adjuster (3) are standing opposite each other. The intake camshaft and exhaust camshaft must be turned appropriately otherwise. 7 Install in the reverse order
Scheme 151
Scheme 152
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.10-P-1001-01P | Bolt, timing chain tensioning rail to cylinder head | Nm | 23 |
| BA05.10-P-1002-01P | Bolt, timing chain slide rail to cylinder head | Nm | 10 |
| BA05.10-P-1003-01P | Bolt, timing chain slide rail to crankcase | Nm | 10 |
TIMING CHAIN DRIVE
Scheme 153
Scheme 154
Remove/install chain tensioner - AR05.10-P-7800MCU
ENGINE 132.910 in MODEL 451.3/4
Scheme 155
Remove/install 1 Remove timing case cover (2) AR01.40-P-8000MCU 2 Push back ratchet (3) using a suitable screwdriver, press together chain tensioner (1) and secure using a pin with a diameter of 1.5 mm via the bore (arrow) 3 Remove bolts (4) and chain tensioner (1) *BA05.10-P-1004-01P 4 Install in the reverse order
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.10-P-1004-01P | Bolt, cam chain tensioner to crankcase | Nm | 9 |
TIMING CHAIN DRIVE
Remove, install tensioning rail - AR05.10-P-8127MCU
ENGINE 132.910 in MODEL 451.3/4
Scheme 156
Remove/install 1 Remove timing case cover AR01.40-P-8000MCU 2 Mark position of timing chain (2) relative to intake and exhaust camshaft and crankshaft. Mark position of intake and exhaust camshaft relative to cylinder head Installation: Check markings and correct settings if necessary. 3 Push back ratchet (5) using a suitable screwdriver, press together chain tensioner (3) and secure using a pin with a diameter of 1.5 mm via the bore (arrow) 4 Unscrew bolt (4) *BA05.10-P-1001-01P 5 Pull out tensioning rail (1) between timing chain (2) and chain tensioner (3) 6 Install in the reverse order
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.10-P-1001-01P | Bolt, timing chain tensioning rail to cylinder head | Nm | 23 |
TIMING CHAIN DRIVE
Remove/install slide rail of timing chain - AR05.10-P-8128MCU
ENGINE 132.910 in MODEL 451.3/4
Scheme 157
Remove/install 1 Remove timing case cover AR01.40-P-8000MCU 2 Mark position of timing chain (2) relative to intake and exhaust camshaft and crankshaft. Mark position of intake and exhaust camshaft relative to cylinder head Installation: Check markings and correct settings if necessary. 3 Push back ratchet (9) using a suitable screwdriver, press together chain tensioner (3) and secure using a pin with a diameter of 1.5 mm via the bore (arrow) 4 Loosen bolt (4), remove bolt (5) and turn chain tensioner (3) to the side Installation: Lead chain tensioner (3) into tensioning rail (6) guide. *BA05.10-P-1004-01P 5 Remove bolts (7) *BA05.10-P-1002-01P *BA05.10-P-1003-01P 6 Relieve timing chain (2) through careful turning at the camshaft and remove slide rail (1) from bearing pin (8) 7 Install in the reverse order
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.10-P-1002-01P | Bolt, timing chain slide rail to cylinder head | Nm | 10 |
| BA05.10-P-1003-01P | Bolt, timing chain slide rail to crankcase | Nm | 10 |
| BA05.10-P-1004-01P | Bolt, cam chain tensioner to crankcase | Nm | 9 |
TIMING CHAIN DRIVE
Remove/install camshaft sprocket - AR05.20-P-6040MCU
ENGINE 132.910 in MODEL 451.3 /4
Scheme 158
Remove/install 1 Remove spark plugs Replace spark plugs AP15.10-P-1580MCU 2 Remove cylinder head cover AR01.20-P-5014MCU 3 Counterhold exhaust camshaft (2) at hexagon (arrow A) and loosen bolt (3) on camshaft sprocket (1) see scheme 15 see scheme 16 *BA05.20-P-1005-01M 4 Detach right rear wheel AR40.10-P-1100MCU 5 Check basic position of intake camshaft and exhaust camshaft (2) Installation: Turn engine in direction of engine rotation through two revolutions and check basic position of intake camshaft and exhaust camshaft (2). AR05.20-P-6010MCU 6 Remove screw plug (4) on timing case cover (5) *BA01.40-P-1008-01M 7 Lower vehicle with lifting platform 8 Mark position of timing chain (6) relative to camshaft sprocket (1) 9 Mark position of camshaft sprocket (1) and camshaft adjuster (7) relative to each other and to the upper edge of the timing case cover (5) 10 Press timing chain (6) downwards using a suitable tool in the area between the camshaft sprocket (1) and the camshaft adjuster (7), push back ratchet (8) on chain tensioner (9) using a suitable screwdriver and lock chain tensioner (9) An aid for pressing down the timing chain (6) is required. In order to lock the chain tensioner (9) place a pin with a diameter of 1.5 mm into the bore (arrow B) in the chain tensioner (9). 11 Remove bolt (3) and detach camshaft sprocket (1) from exhaust camshaft (2) and remove from timing chain (6) Installation: Ensure correct installation position of camshaft sprocket (1) on the exhaust camshaft (2). Align camshaft sprocket (1) according to markings and insert in the timing chain (6). 12 Install in the reverse order
Scheme 159
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA01.40-P-1008-01M | Screw plug on timing case cover | Nm | 50 |
CRANKCASE, TIMING CASE COVER, END COVER
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.20-P-1005-01M | Bolt connecting camshaft sprocket to exhaust camshaft | Nm | 90 |
CAMSHAFT
Scheme 160
Scheme 161
Remove/install camshaft bearing caps - AR05.20-P-6992-04MCU
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.20-P-1001-01M | Bolt, camshaft bearing bridge to cylinder head | Nm | 20 |
| BA05.20-P-1002-01M | Bolt connecting camshaft bearing cap to cylinder head | Nm | 11 |
CAMSHAFT
When removing the exhaust camshaft
Scheme 162
Scheme 163
- Loosen bolts (1 to 3) for bearing bridge (4) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (1 to 3) in the reverse order in a number of stages all the way and tighten using the prescribed torque.
- Remove bolts (1 to 3) and take off bearing bridge (4). Installation: Clean running surface of bearing bridge (4) and wet with engine oil.
- Loosen bolts (5 to 10) for bearing cap (11) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (5 to 10) in the reverse order in a number of stages all the way and tighten using the prescribed torque.
- Remove bolts (5 to 10) and take off bearing cap (11). Installation: Clean contact surfaces of bearing cap (11) and wet with engine oil. Pay attention to installation position. The arrows on the bearing caps (11) must be aligned straight to the control side. The bearing caps (11) are numbered in ascending order starting from the control side.
- Install in the reverse order. When removing the intake camshaft
- Loosen bolts (1 to 3) for bearing bridge (4) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (1 to 3) in the reverse order in a number of stages all the way and tighten using the prescribed torque.
- Remove bolts (1 to 3) and take off bearing bridge (4). Installation: Clean running surface of bearing bridge (4) and wet with engine oil.
- Loosen bolts (12 to 17) for bearing cap (18) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (12 to 17) in the reverse order in a number of stages all the way and tighten using the prescribed torque.
- Remove bolts (12 to 17) and take off bearing cap (18). Installation: Clean contact surfaces of bearing cap (18) and wet with engine oil. Pay attention to installation position. The arrows on the bearing caps (18) must be aligned straight to the control side. The bearing caps (18) are numbered in ascending order starting from the control side.
- Install in the reverse order.
Remove/install camshafts - AR05.20-P-6992MCU
ENGINE 132.910 in MODEL 451.3 /4
Scheme 164
Remove/install The intake camshaft (1) and exhaust camshaft (2) can be removed separately 1 Check basic position of intake camshaft (1) and exhaust camshaft (2) and mark position of camshaft adjuster (3) relative to timing chain (4) AR05.20-P-6010MCU 2 Remove camshaft sprocket (5) on exhaust camshaft (2) Only the exhaust camshaft (2) is removed and adjusting of the basic setting is not required; fix camshaft sprocket (5) with cable tie to timing chain (4). AR05.20-P-6040MCU 3 Remove bearing bridge (6) Observe loosening and tightening sequence otherwise the bearing bridge (6) can be damaged. AR05.20-P-6992-04MCU *BA05.20-P-1001-01M Exhaust camshaft (2) 4 Remove camshaft bearing cap (7) for exhaust camshaft (2) Observe loosening and tightening sequence otherwise the exhaust camshaft (2) can be damaged. Installation: Insert camshaft sprocket (5) into timing chain (4), position on exhaust camshaft (2) and check whether the marking (arrow C) on camshaft sprocket (5) and marking (arrow D) on camshaft adjuster (3) are standing opposite to each other at the height of the upper edge of the timing case cover (9). Ensure that the crankshaft is not turned. AR05.20-P-6992-04MCU *BA05.20-P-1002-01M 5 Detach and remove exhaust camshaft (2) from the bearing seat by turning at hexagon (arrow A) Intake camshaft (1) 6 Remove camshaft bearing cap (8) for intake camshaft (1) Observe loosening and tightening sequence otherwise the intake camshaft (1) can be damaged. AR05.20-P-6992-04MCU *BA05.20-P-1002-01M 7 Detach and remove intake camshaft (1) from the bearing seat by turning at hexagon (arrow A) 8 Lift timing chain (4) and remove intake camshaft (1) Installation: Insert intake camshaft (1) in the timing chain (4) using the camshaft adjuster (3) in such a way that the marking (arrow D) on the camshaft adjuster (3) is at the upper edge of the timing case cover (9). Ensure that the crankshaft is not turned. 9 Remove camshaft adjuster (3) on inlet camshaft (1) When replacing the intake camshaft (1). AR05.20-P-7201MCU Checking 10 Check cam on intake camshaft (1) or exhaust camshaft (2) for wear; replace intake camshaft (1) or exhaust camshaft (2) if necessary 11 Install in the reverse order
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.20-P-1001-01M | Bolt, camshaft bearing bridge to cylinder head | Nm | 20 |
| BA05.20-P-1002-01M | Bolt connecting camshaft bearing cap to cylinder head | Nm | 11 |
CAMSHAFT
Remove/install camshafts - AR05.20-P-7201MCU
ENGINE 132.910 in MODEL 451.3/4
Scheme 165
Remove/install 1 Remove inlet camshaft (2) AR05.20-P-6992MCU 2 Clamp intake camshaft (2) on hexagon into a vise Use protective jaws otherwise the intake camshaft (2) can be damaged. 3 Remove bolt (3) and camshaft adjuster (1) from intake camshaft (2) Installation: Place camshaft adjuster (1) in such a way that the pin on the intake camshaft (2) coincides with the respective bore in the camshaft adjuster (1). *BA05.20-P-1004-01M 4 Install in the reverse order
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.20-P-1004-01M | Bolt connecting camshaft adjuster to intake camshaft | Nm | 90 |
CAMSHAFT
Remove/install solenoid chamshaft - AR05.20-P-7295MCU
ENGINE 132.910 in MODEL 451.3/4
Scheme 166
Remove/install 1 Remove interior flap above engine AR88.40-P-1100-03MCC 2 Disconnect electrical connector (1) on adjustable camshaft timing solenoid (Y49) 3 Unscrew bolt (2) *BA05.20-P-1006-01M 4 Pull adjustable camshaft timing solenoid (Y49) out of cylinder head Ensure that no dirt can find its way into oil holes on the adjustable camshaft timing solenoid (Y49) or in the bore in the cylinder head otherwise damage can occur on the engine. Installation: Check sealing ring on the adjustable camshaft timing solenoid (Y49); replace if necessary. 5 Install in the reverse order 6 Read out fault memory, erase if necessary When replacing the adjustable camshaft timing solenoid (Y49). Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A 7 Conduct engine test run and check leaktightness of adjustable camshaft timing solenoid (Y49)
Scheme 167
Scheme 168
| Number | Designation | Engine 132.9 | |
|---|---|---|---|
| BA05.20-P-1006-01M | Bolt, camshaft solenoid to cylinder head | Nm | 11 |
CAMSHAFT
Replace valve stem seals. - AR05.30-P-3510MCC
ENGINES 132.9 in MODEL 451.3 /4
Scheme 169
Scheme 170
Remove 1 Remove cylinder head * Not for USA AR01.30-P-5800MCC * For USA only AR01.30-P-5800MCU 2 Cut fuel hose with an inside diameter of 6 mm to a length of about 5 cm 3 Lay cylinder head on the wooden plate and lay the cut to length fuel hose in the combustion chamber under the valves 4 Screw in thread extension (1) and counter stay (2) in the area of the respective valves into a threaded hole on the cylinder head Valve assembly tool case see scheme 27 Thread extension for retaining fork (Scheme 157) 5 Attach lever handle and depressor (4) to the thrust fork (3) and hook into the counter stay (2) Valve assembly tool case see scheme 27 Depressor see scheme 29 6 Position depressor (4) in the middle on the upper valve spring retainer (6) and press valve spring (7) together through pressing together the lever handle Valve assembly tool case see scheme 27 Depressor see scheme 29 7 Remove valve collets (5) using suitable magnets and also remove thrust fork (3) using a depressor (4) and lever handle Valve assembly tool case see scheme 27 Depressor see scheme 29 8 Remove valve spring retainer (6) and valve spring (7) Observe installation position of valve spring (7). The valve spring retainer (8) can remain in the cylinder head. 9 Detach valve stem seal (9), using pliers out of the valves repair tool, from the valve guide Valve assembly tool case see scheme 27 Install 10 Lubricate new valve shaft seal (11) with engine oil 11 Insert new valve stem seal (11) on the valve stem (10) and press on using drift (12). The new valve stem seal (11) must not removed again from the valve stem (10). The valve stem seal (11) is damaged during removal and is therefore unusable. Drift see scheme 28 12 Insert valve spring (7) and valve spring retainer (6) Observe installation position of valve spring (7). 13 Hook thrust fork (3) with depressor (4) and lever handle into the counter stay (2) Valve assembly tool case see scheme 27 Depressor see scheme 29 14 Position depressor (4) in the middle on the valve spring retainer (6) and press together valve spring (7) through pressing down the lever handle, insert the valve conical pieces (5) on the valve stem (10) in the cutout and then relieve the valve spring retainer (6) Check for correct seating of the valve conical pieces (5); repeat the operation step if necessary. Valve assembly tool case see scheme 27 Depressor see scheme 29 15 Remove thrust fork (3) with depressor (4) and lever handle Valve assembly tool case see scheme 27 Depressor see scheme 29 16 Remove thread extension (1) and counter stays (2) on the cylinder head Valve assembly tool case see scheme 27 Thread extension for retaining fork (Scheme 157) 17 Repeat operation steps 3 to 16 until all valve stem seals (9) have been replaced by new valve stem seals (11) 18 Install cylinder head * Not for USA AR01.30-P-5800MCC * For USA only AR01.30-P-5800MCU
Scheme 171
Scheme 172
Scheme 173
Scheme 174
Remove/install valves - AR05.30-P-3511MCC
ENGINES 132.9 in MODEL 451.3 /4
Scheme 175
Remove 1 Remove valve stem seals (5) AR05.30-P-3510MCC 2 Remove valve spring retainer (4) from cylinder head (1) 3 Turn over cylinder head (1) and remove intake valves (2) and exhaust valves (3) with the valve grinding tool (6) out of the cylinder head (1) Check surfaces of valve stems, valve seats and valve guides by means of a visual inspection for roughness and ridging, replace intake valves (2), exhaust valves (3) or cylinder head (1) if necessary. Mark installation position if the removed intake valves (2) and exhaust valves (3) are reinstalled. Repair tools for valves see scheme 32 Install 4 Insert intake valves (2) and exhaust valve (3) into cylinder head (1) If removed intake valves (2) and exhaust valves (3) are used again then these should be reinserted in the same position. 5 Turn over the cylinder head (1) and insert valve spring retainer (4) in the cylinder head 6 Replace valve stem seals (5). AR05.30-P-3510MCC
