Special tools and workshop equipment required
♦ Central Valve Assembly Tool - T10352-
♦ Counterhold - Vibration Damper - T10355-
♦ Chain Tensioner Lever - T40243-
♦ Tensioner Locking Tool - T40267-

♦ Camshaft Locks - T40271-
♦ Adapter - T40266-
♦ Sealant - D 154 103 A1-
Removing

Note

♦

The sealing surfaces of the lower cylinder head cover and on

the upper cylinder head must not be reworked.

♦

The camshaft bearings are integrated in the cylinder head or

cylinder head cover. Before removing the cylinder head cover,

release the tension on the camshaft timing chain.

♦

When installing, secure all cable ties back to same positions.

– Remove the air filter housing. Refer to

⇒ “3.2 Air Filter Housing, Removing and Installing”,

page 294

– Remove the upper coolant pipe. Refer to

⇒ “3.3 Upper Coolant Pipes, Removing and Installing”,

page 242

– Remove the ignition coils. Refer to

⇒ “1.3 Ignition Coils with Power Output Stages, Removing and

Installing”, page 357

– Disconnect the connectors:
1 - For Turbocharger Recirculation Valve - N249-
2 - For Camshaft Position Sensor 3 - G300-
3 - For Fuel Pressure Regulator Valve - N276-
– Disconnect the connectors -arrows- from the cam adjustment

actuator.

– Remove the bolt -5- and free up the ground cable.
– Free up the connector from the clip -4- and pivot it forward.
– Release the retainers in direction of -arrow-, remove the wiring

duct upward from the bracket and move it towards the front.

NOTICE

Risk of destroying the coolant pipes through deformation.
– Never change the coolant pipe bent shape.

– Remove bolts -1, 2 and 3-. Carefully swing coolant line back‐

ward slightly.

– Disconnect the connector -1- from the EVAP Canister Purge

Regulator Valve 1 - N80- .

– Press the release button on the crankcase ventilation hose

-2- and remove the hose.

– Remove the bolts -arrows- and the crankcase ventilation.
– Remove the high pressure pump. Refer to

⇒ “7.2 High Pressure Pump, Removing and Installing”,

page 328

– Remove the vacuum pump. Refer to

⇒ “1.4 Vacuum Pump, Removing and Installing”, page 100

– Support the engine in its installed position. Refer to

⇒ “2.5 Engine, Supporting in Installed Position”, page 33

– Remove the engine bracket. Refer to

⇒ “2.2 Engine Mount, Removing and Installing”, page 30

– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

Gr. 66 ; Noise Insulation; Overview - Noise Insulation .

– Remove the right wheel housing liner front section. Refer to ⇒

Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner; Front

Wheel Housing Liner, Removing and Installing .

– Remove engine support. Refer to

⇒ “1.6 Engine Support, Removing and Installing”, page 55

– Remove timing chain upper cover. Refer to

⇒ “2.2.1 Upper Timing Chain Cover, Removing and Installing”,

page 106

– Turn the vibration damper with the Counterhold - Vibration

Damper - T10355- to the “TDC point”.

• The markings -1- on the camshaft chain sprockets must be

opposite the markings -2 and 3-.

• The notch on the vibration damper and the marking on the

lower cover for timing chain -arrow- must be opposite one an‐

other.

– Remove the lower timing chain cover. Refer to

⇒ “2.2.2 Lower Timing Chain Cover, Removing and Installing”,

page 108

Note

The pilot valve has left-hand threads.

– Remove the left and right pilot valves using the Assembly Tool

- T10352/2- in the direction of -arrow-.

– Remove the bolts -arrows- and remove the bearing bracket.

– Remove the bolts -arrows-.

– Install the Chain Tensioner Lever - T40243- -arrows-.
– Press the chain tensioner locking ring -1- together and hold it.
– Slowly press and hold the Chain Tensioner Lever - T40243-

in the direction of -arrow-.

– Secure the chain tensioner with the Tensioner Locking Tool -

T40267- .

– Remove the Chain Tensioner Lever - T40243- .

Content .. 676 677 678 679 ..