Installing the lock
Note. Screw in the screw until it takes.
Install the fuel rail.
Press in the secondary lock (2).
Screw the screw (1) right in.
Variable valve timing solenoid, replacing
Note. The illustrations in this service information are used for different model years and / or models. Therefore there may be some variation. However, the essential information in the illustrations is always correct.
Scheme 299
Applies only to B6xx4T
Remove the plastic pipes between the turbocharger (TC) and charge air cooler (CAC) and between the air cleaner (ACL) and the turbocharger (TC).
Put them to one side.
Slacken off the clamp for the intake manifold at the turbocharger (TC) for cylinders 1, 2 and 3. Turn the upper section of the manifold towards the firewall.
Scheme 300
Remove the upper timing belt cover.
Note. Clean the area around the variable valve timing (VVT) solenoid thoroughly to avoid contaminated oil entering the ducts / the variable valve timing (VVT) unit.
Remove
- the connector for the check valve
- the screws holding the valve
- the control valve and the gasket.
Installing the variable valve timing solenoid
Clean the gasket faces. Note the cleanliness requirements above.
Install a new gasket.
Install
- a new check valve Tighten the control valve crosswise. Tighten to 10 Nm
- the connector
- the upper timing belt cover.
Finishing
Applies only to B6xx4T
Turn back the intake manifold for the turbocharger (TC) for cylinders 1, 2, 3 and tighten the clamp.
Install the plastic hoses between the turbocharger (TC) and the charge air cooler and between the air cleaner (ACL) and the turbocharger (TC).
Tighten the hose clamps.
Variable valve timing unit, checking and adjusting (B5XX4TX; 1999-2001)
Special tools
9995451
9995452
Installing and adjusting the variable valve timing unit/timing gear pulley on the camshaft
Note. This procedure must be carried out with precision as any deviation could generate a fault symptom.
Scheme 301
Remove the starter motor mounting screws. Pull out the starter motor and put it aside. Remove the plug of the gauge hole. Rotate the crankshaft slightly clockwise. Install: 9995451 . Make sure that it bottoms against the engine block.
Scheme 302
Turn the crankshaft counterclockwise to its stop against the crankshaft adjustment tool. Check that the marking on the crankshaft timing gear pulley aligns with the marking on the oil pump.
Scheme 303
Note. Some engines have double VVT units/belt pulleys. If this is the case, the method is to be performed on both.
Note. Oil the center screw before installation.
Press the variable valve timing unit/timing gear pulley onto the camshaft. Install the center screw (1) that holds the variable valve timing unit to the camshaft. Do not tighten yet .
Slacken off, but do not remove the screws (2) which secure the timing gear pulley to the variable valve timing unit.
Position the upper timing cover.
Scheme 304
Turn the timing gear pulley so that the screws at the oval holes are in the limit position. Continue turning clockwise until the timing gear pulley's marking is 1 tooth before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw (1) in the VVT unit to 120 Nm .
Check that the variable valve timing unit does not rotate when tightening. Install the center plug and tighten to 35 Nm .
Install the belt pulley on the intake camshaft : Install the belt pulley on the intake camshaft with three screws; do not tighten yet .
Scheme 305
Turn the timing gear pulley to the marking. Check that the markings on the timing gear pulley/intake camshaft and upper timing cover correspond.
Installing the timing belt
Install the belt in the following order
- the belt pulley on the crankshaft
- the idler pulley
- cam wheel, intake camshaft
- water pump
- belt tensioner.
Scheme 306
Turn the variable valve timing unit clockwise to the stop.
Note. Hold the VVT unit fixed in the limit position clockwise when the belt if fitted.
Check that the markings on the belt pulley and the upper timing cover align.
Scheme 307
Fit the timing belt over the exhaust camshaft's cam wheel.
Variable valve timing unit, checking and adjusting (B5XX4TX; 2002-)
Special tools
9995451
9995452
Note. 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. This procedure must be carried out with precision as any deviation could generate a fault symptom.
Aligning the crankshaft
Turn the crankshaft counter-clockwise until it stops against the adjustment tool.
Check that the marking on the crankshaft timing gear pulley corresponds to the marking on the oil pump.
Installing the variable valve timing unit on the camshaft
Note. Oil the center screw before installation
Push on the variable valve timing unit/timing gear pulley on the camshaft.
Install the center screw (1) which secures the variable valve timing unit to the camshaft. Tighten slightly.
Slacken off, but do not remove the screws (2) which secure the timing gear pulley to the variable valve timing unit.
Turn the timing gear pulley until the screws at the oval holes are in the center position. Tighten the screws (2) slightly.
Turn the variable valve timing unit clockwise to its limit position so that the unit is in its end position.
Position the upper timing cover
Undo the center screw and continue turning clockwise until the timing gear pulley marking aligns with the marking on the upper timing cover.
Tighten the center screw in the variable valve timing unit. Tighten. See: Summary of specific components and tightening torques .
Note. Variable valve timing units do not have return springs and are easily thrown out of position when the camshaft belt is installed. Check that the markings align.
Install the belt in the following order
- the idler pulley
- intake cam
- exhaust cam
- water pump
- tension pulley.
Scheme 308
This adjustment is to be made with a cold engine.
A suitable temperature is approximately 20 °C/68 °F.
At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.
The illustration shows the position of the indicator when aligning the timing belt tensioner at approximately 20 °C/68 °F.
Note. There are two different tensioners depending on model year.
Fix the belt tensioner center screw in position and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position and reaches the end position. Then turn the eccentric back so the indicator reaches the marked position shown in the illustration. Tighten the center screw. See Summary of specific components and tightening torques .
Check that the indicator is in the correct position.
Scheme 309
Slacken off the 3 x screws for the timing gear pulley slightly (applies to both timing gear pulleys).
Install the center plug in the variable valve timing unit. Tighten. See: Summary of specific components and tightening torques .
Hold the center plug at 25 Nm at the same time as tightening the 3 x screws on the camshaft timing gear pulley to: Summary of specific components and tightening torques .
Tighten the 3 x screws on the timing gear pulley for the intake camshaft. See: Summary of specific components and tightening torques . This is to ensure that the variable valve timing (VVT) unit is in its end position when the timing gear pulley is tightened.
Scheme 310
Remove
- «9995452»(ref-403953-S02369714572011061000000) from the rear of the camshafts
- «9995451»(ref-403953-S26663901482011061000000) . Install new plugs with new sealing washers. Tighten. See: «Summary of specific components and tightening torques»(ref-430997-S07821985842011101900000) .
Checking the markings and belt tension.
Position the upper timing cover.
Turn the crankshaft 2 rotations. Check that the markings on the crankshaft and timing gear pulleys correspond.
Remove the upper timing cover.