Removing Valve Tappets of the Cylinder Bank 1- 3 - Engine Installed

Removing and installing valve tappets - Engine installed








Tools

Preliminary work for valve tappet removal - Engine installed
1. Disconnect battery.
2. Remove the rear wheels.
3. Drain engine oil.

4. Remove the air cleaner assembly.








5. In vehicles with air conditioning, the following additional assembly operations must be performed:





Suck Pentosin fluid out of the reservoir until the level is just below the joint.
5.1. Turn bayonet lock in the direction indicated by the arrow and pull off the reservoir. Immediately seal the lower reservoir with a suitable plug (30 mm �).





Bayonett lock open








5.2. Remove drive belt. Mark belt travel direction with a colored pen. Slacken belt, turning the tensioning pulley (wrench size 24 mm) clockwise , hold still and simultaneously take the belt off the drive pulleys.





5.3. Undo front compressor fastening screws (2 ea.). Undo rear fastening screw between the intake pipes of cylinders 4 and 5. Disconnect the electrical plug connection.
5.4. Lift the compressor out, set it down with the hoses connected and secure it against being dropped.





6. Remove exhaust manifold.





7. Remove rear muffler. Undo three hexagon nuts.





7.1. Undo clamping sleeve and remove rear muffler.





8. Remove holder for rear muffler.





8.1. Undo upper hexagon-head bolts using a flexible-head socket wrench (wrench size 13). Detach holder.
9. Remove shield of cylinder head cover.

Removing valve tappets of the cylinder bank 1- 3 - Engine installed








1. Move camshafts of cylinder bank 1 - 3 to basic position. Turn crankshaft clockwise until the bore 1 OT (top dead centre) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595 or 9595/1.








2. Pull off closure caps of cylinder head 1 - 3 - flywheel side. Turn shop-made extractor into centre of piercing point of closure cap and pull off the cap.
3. Check basic camshaft adjustment of cylinder bank 1 -3. Ensure that the groove in the camshaft faces outward toward the cylinder head cover.





View from the flywheel side
4. If the position of the camshafts is incorrect or the groove in the inlet camshaft does not face outward , remove fixing pin of belt pulley and turn crankshaft a further 360° clockwise. Then position or fix the fixing pin in the bore (1 OT) and the fixing bore in the crankcase again.
5. Check the position of the groove again.
6. Remove ignition coils and spark plugs.
7. Pull off oil protection tubes.





8. Pull off closure caps (2 ea.) of cylinder head 1 - 3 - pulley side.
Diagram shows lower closure cap





9. Fit special tool, holding-down device 9634, on the cylinder head. Fasten holding-down device with a hexagon-head bolt M8 x 3.

Note;
- In order to prevent damage to the camshafts or saddle bearings, it is essential to fit the holding-down device before detaching the cylinder head cover.

10. Separate plug connection of the tensioning element (VarioCam).
11. Unscrew two hexagon-head bolts (M6 x 20) and remove closure cap from the tensioning element (VarioCam).
12. Undo the fastening screws of the oil extraction pump.





13. Remove cylinder head cover. Loosen the hexagon-head bolts from the outside to the inside. Detach the cylinder head cover by knocking it gently with a plastic hammer, and press off carefully.





14. Remove oil extraction pump.





15. To relieve the camshafts from strain, additionally fasten a holding-down device of special tool 9611 using M6 x 45 auxiliary screws.





16. Relieve camshaft tensioning element (VarioCam) with special tool, tensioning screw 9632. Screw in tensioning screw only so far as to slightly relieve the chain.
17. Unscrew and remove three fastening screws (M6 x 95) for tensioning element.
18. Undo four hexagon-head bolts (M6 x 15) on the chain sprocket.





Rear axle cross member removed for clearer illustration
19. Undo four hexagon-head bolts (M6 x 15) on the chain sprocket.





20. Relieve chain of tension. Unscrew chain tensioner of cylinder bank 1 - 3. ("2 rings" identification on chain tensioner and crankcase).
21. Take off drive plate of oil extraction pump. Remove sprocket wheel and chain and connect with a tie wrap (installation position).
22. Detach bearing saddles and lever out of the guide sleeves by hand. Do not use a tool.





23. Remove special tools (holding-down devices 9611 and 9634) and carefully lift the entire unit, consisting of camshafts with chain and tensioning element, out of the cylinder head. The chain must not jump over during this operation; reallocate if necessary. The groove or tab of the camshaft position sensor cover must face upward.
24. Pull out valve tappets by hand.

Note;
- Do not use a magnet.





25. Detach guide for valve tappet. Undo the pan-head screws (15 ea.) from the outside to the inside, and remove the guide.