Removing Valve Tappets of the Cylinder Bank 4 - 6 - 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 4 - 6 - Engine installed





1. Remove fixing pin. 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.





2. Check camshaft adjustment at cylinder bank 4 - 6: The groove in the camshaft must face inward toward the crankcase.
View from the belt pulley side
3. Turn engine by 90° on assembly support until cylinder bank 4 - 6 faces upwards.





4. Unscrew chain tensioner of cylinder bank 4 - 6.
5. Remove closure cap from tensioning element (VarioCam). Hexagon-head bolts M6 x 20 (2 ea.).
6. Remove cylinder head cover. Loosen hexagon-head bolts from the outside to the inside.





7. Fit holding-down device for camshafts, special tool 9611. Use auxiliary screws M6 x 45.





8. Detach and remove oil extraction pump at cylinder head 4 - 6 (pulley side).
9. Relieve camshaft tensioning element with tensioning screw, special tool 9632.

Note;
- Screw tensioning screw in only until the chain is slightly relieved.

10. Unscrew three fastening screws (M6 x 95) for tensioning element.
11. Affix auxiliary chain tensioner (screw in by approximately 3 turns). Undo four hexagon-head bolts (M6 x 15) on the chain sprocket. Remove auxiliary chain tensioner again.





12. Remove drive plate. Connect sprocket wheel and chain with a tie wrap (installation position). With a second tie wrap suspend the sprocket wheel and chain to the side under slight tension.
13. Detach two bearing saddles. Lever bearing saddles out of the guide sleeves.
14. Remove holding-down device (special tool 9611) from the camshafts.





15. Carefully lift the complete unit, camshafts with chain and tensioning element out of the cylinder head. The chain must not jump over. The groove or tab of the camshaft position sensor cover must face downward. If the allocation should be uncertain, e.g. chain jumped over, reallocation is necessary. Refer to: Completing camshafts.
16. Lift out valve tappets with a magnet.
17. Detach guide for valve tappet. Undo the pan-head screws (15 ea.) from the outside to the inside, and remove the guide.