Variable Valve Timing Actuator: Service and Repair
VVT unit
Special tools:
999 5433 COUNTERHOLD 999 5433 Counterhold
999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool
999 5651 Extractor 999 5651 Extractor
999 5718 Drift 999 5718 Drift
999 7364 Drift 999 7364 Drift
999 7109 Wrench 999 7109 Wrench
999 7103 Lifting beam 999 7103 Lifting Beam
999 5185 HOOK 999 5185 Hook
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.
Preparatory work
Removing components
Note! Crankshaft and camshafts must not be turned more than is stated in the method description. If the shafts are turned in any other way the valves may be damaged.
Disconnect the battery negative lead. See: Battery Disconnecting.
Remove the air cleaner (ACL) module. See: Air filter module Service and Repair.
Removal
Removing upper intake manifold
Caution! Seal the openings in the lower part of the intake manifold. Use tape or similar.
Remove:
- the 6 screws for the upper intake manifold, closest to the front cover plate, and the 2 screws against the firewall
- the EVAP canister hose on the intake manifold
- the brake vacuum pipe. Press in the red catch. Pull out the pipe. Disconnect the throttle body (TB) connector and the pressure sensor on the intake manifold. Cut the tie strap. Lift up the intake manifold and put it to one side.
Removing components from the rear edge of the engine
Remove:
- the 2 screws for the lifting eyelet at the rear edge of the cylinder head
- the screw for the clamp for the fuel pressure pipe in the lifting eyelet. Unhook the evaporative emission system (EVAP) valve from the lifting eye. Disconnect the connector for the heated oxygen sensors (HO2S). Move the lifting eyelet to one side.
Removing the rotor on the camshaft
Note! Clear up any oil spillage using paper.
Remove:
- the covers in the rear edge of the camshaft. Using a screwdriver, press in the center of the cover. Pry off the cover
- the rotor screw
- the rotor.
Mounting the engine
Install lifting beam: 999 7103 Lifting beam 999 7103 Lifting Beam together with hook: 999 5185 HOOK 999 5185 Hook. Tension the tool. Lift the expansion tank and place on the engine.
Note! Ensure that no coolant escapes.
Marking the position of the engine pad
Mark the position of the engine pad on the frame member. Use a marker pen.
Removing components
Remove:
- the screws (1) for the limiter from the engine mounting in the right-hand frame member
- the limiter
- the screws (2) for the engine mounting in the cylinder head
- the engine mounting.
Removing the belt covers
Remove:
- the screw for the front belt cover
- the front belt covers.
Removing wheels
Raise the vehicle.
Remove:
- the right front wheel
- the right-hand fender liner. Slacken off the 6 screws. Fold back the fender liner
- the outer auxiliaries belt by turning the tensioner clockwise. Use: 999 7109 Wrench 999 7109 Wrench.
Lower the vehicle so that the timing belt pulley is visible and the lifting beam accessible.
Removing the power steering pump pressure line
Caution! Seal the openings.
Note! Clear up any oil spillage under the delivery line.
Disconnect the delivery line from the power steering pump.
Removing the vibration damper
Remove the 4 x screws. Use the crankshaft center nut as a counterhold. Install a counterhold. Use 999 5433 COUNTERHOLD 999 5433 Counterhold. Remove the center nut. Remove the counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold. Work the vibration damper loose.
Setting up the engine
Turn the crankshaft clockwise until the markings on the crankshaft and the camshaft pulley correspond. The markings are illustrated.
Remove the upper timing belt cover. Lower the engine using the lifting beam until the screw for the timing belt tensioner can be accessed from beneath.
Removing the timing belt
Slacken off the belt tensioner. Slacken off the center screw for the belt tensioner slightly. Hold the center screw still. Turn the tensioner eccentric clockwise to 10 o'clock. Use a 6 mm Allen key. Remove the timing belt from the camshaft pulleys.
Installing the camshaft adjustment tool
Use: 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool.
Install:
- the part of the tool intended for the exhaust camshaft (drilled hole)
- the adjustment tool belonging to the intake side camshaft (threaded hole). Screw the adjustment tool sections together into one unit.
Removing the timing belt pulley / variable valve timing unit
Remove:
- the plug at the front edge of the variable valve timing unit
Note! Use paper to collect any spilled oil under the variable valve timing units.
the center screw in the variable valve timing unit. Carefully pull out the timing gear pulley with the VVT unit
- the screws for the timing belt pulley
- the timing belt pulley.
Removing the front camshaft seal
Carefully press in tool 999 5651 Extractor 999 5651 Extractor between the sealing ring and the camshaft. Carefully pry out the seal. Discard the seal.
Installation
Note! For tightening torques, see Specifications. Tightening Torque
Note! The purpose of the section entitled " Installing the variable valve timing unit/timing gear pulley" is to reset the camshaft timing gear pulley to the correct position using the markings made at the factory. This is to ensure that the conditions are correct for any later fault-tracing.
Cleaning
Note! When cleaning work around the shaft journal, not in and out. It is essential that any residue from the emery cloth and any other contaminants are completely removed before the new sealing ring is installed
To clean the shaft journal and mating surface, use emery cloth P/N 951 1024.
Installing the front camshaft seal
Lubricate the surface of the seal that the camshaft rotates against. Install the camshaft seal.
For camshafts with variable valve timing:
Use: 999 5718 Drift 999 5718 Drift. Use the mounting screw for the variable valve timing unit. Tighten until the drift bottoms out.
For camshafts without variable valve timing:
Use: 999 7364 Drift 999 7364 Drift. Use the screws for the timing belt wheels to pull in the drift until it bottoms out.
Removing the starter motor
Lift the coolant hose out of the holder/bracket.
Remove:
- the nuts for the coolant hose bracket. Bend the bracket to one side to access the screws for the starter motor
- the flat pin contact and the positive cable from the starter motor
- the screws holding the starter motor against the transmission. Lift out the starter motor.
Installing the crankshaft adjustment tool
Caution! Ensure that the tool bottoms out against the cylinder block.
Remove the blind cover plug from the hole for the adjustment tool. Turn the crankshaft clockwise slightly. Use: 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool.
Aligning the crankshaft
Turn the crankshaft counter-clockwiseuntil 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 (VVT) unit on the intake camshaft
Press the timing gear pulley and variable valve timing (VVT) unit on to the camshaft. Set the variable valve time (VVT) unit according to the marking.
Install:
- the center screw that secures the VVT unit to the camshaft. Do not tighten the screw
- the upper timing belt cover.
Installing the timing gear pulley on the exhaust camshaft
Install:
- the timing gear pulley on the exhaust camshaft according to the marking
- the 3 screws. Do not tighten. Set the camshaft pulley according to the marking on the upper timing belt cover. Remove the upper timing belt cover.
Installing the timing belt
Caution! Ensure that the camshaft pulley is still positioned according to the marking on the upper timing belt cover. If not, repeat the exercise until the markings correspond.
Tighten the center screw in the timing belt tensioner. Tighten to 5 Nm in the 9 o'clock position.
Install the belt in the following order:
- crankshaft
- the idler pulley
- intake camshaft pulley
- exhaust camshaft pulley
- water pump
- tension pulley.
Adjusting the timing belt
This adjustment is to be made with a cold engine. A suitable temperature is approximately 20°C/68°F. At higher temperatures (with the engine at operating temperature or a high outside temperature for example) the indicator is further to the right. The illustration shows the position of the indicator when aligning the timing belt tensioner at different temperatures.
Hold the center screw secure and turn the belt tensioner eccentric clockwise until the tensioner indicator passes the marked position and reaches the limit position. Tighten.
Tighten the center screw holding the variable valve timing unit. Tighten. See: Tightening torque Tightening Torque.
Tighten the screws for the exhaust timing belt pulley. Ensure that the screws are not in a limit position. Tighten. See: Tightening torque Tightening Torque.
Install the plug for the VVT unit. Tighten. See: Tightening torque Tightening Torque
Adjusting belt tension
Slacken off the screw for the timing belt tensioner. Then turn the eccentric back so that the indicator reaches the marked position in the center of the window. Remember to hold the center screw secure at the same time. Hold the eccentric in place and tighten the center screw.
Tighten. See: Tightening torque Tightening Torque. Check that the indicator is in the correct position.
Removing the adjustment tools
Remove:
- the camshaft adjustment tools 999 5452 CAMSHAFT ADJUSTMENT TOOL 999 5452 Camshaft Adjustment Tool from the rear edge of the camshafts
- the crankshaft stop 999 5451 ADJUSTMENT TOOL 999 5451 Adjustment Tool. Install the plug with a new sealing washer. Tighten. See: Tightening torque Tightening Torque.
Checking the markings and belt tension
Press the belt to check that the indicator on the belt tensioner moves easily. Position the upper timing cover. Turn the crankshaft 2 rotations and check that the markings on the crankshaft and camshaft pulleys correspond.
Check that the indicator on the belt tensioner is within the marked position. Adjust if necessary. Remove the upper timing cover.
Installing components
Install:
- the vibration damper. Tighten. See: Tightening torque Tightening Torque. Use counterhold 999 5433 COUNTERHOLD 999 5433 Counterhold. Remove the counterhold and install new screws. Tighten. See: Tightening torque Tightening Torque.
- the auxiliaries belt. Turn the belt tensioner up clockwise and install the belt. Use: 999 7109 Wrench 999 7109 Wrench.
Installing components
Install:
- the front belt covers. Tighten the screw
- the upper belt cover
- the pressure line for the power steering pump. Remove the seals
- the fender liner on right-hand side
- the right front wheel. See: Wheels Service and Repair.
Installing the engine pad
Install the engine pad according to the markings.
Installing engine mounting
Install:
- the engine mounting on the cylinder head
- the limiter. Tighten screws 1 and 2. Tighten. See: Tightening torque Tightening Torque. Remove lifting beam: 999 7103 Lifting beam 999 7103 Lifting Beam and hook 999 5185 HOOK 999 5185 Hook.
- the expansion tank.
Installing components in the rear edge of the engine
Install:
- the lifting lug
- the 2 screws for the lifting eyelet at the rear edge of the cylinder head. Tighten
- the screw for the clamp for the fuel pressure pipe in the lifting eyelet. Tighten. Hook the evaporative emission system (EVAP) valve onto the lifting eyelet. Connect the connector to the heated oxygen sensors (HO2S).
Installing upper intake manifold
Install:
- new gaskets for the upper section of the intake manifold
Caution! Ensure that the guides for the lower section are in the correct position.
the upper intake manifold. Tighten the screws alternately. Tighten. See: Tightening torque Tightening Torque.
- the brake vacuum pipe
- EVAP canister hose
Connect the connector for the throttle body (TB) connector and the connector for the pressure sensor on the intake manifold. Install a new tie strap.
Installing the starter motor
Install:
- the starter motor
- the screws for the starter motor. Tighten. See: Tightening torque Tightening Torque
- the battery positive cable to the starter motor. Tighten the nut
- the protective cover over the positive terminal on the starter motor
- the flat pin contact to the starter motor solenoid
- the bracket for the coolant hose. Tighten the nuts. Insert the coolant hose in the bracket.
Finishing
Installing the air cleaner (ACL) module
Install:
- the air cleaner (ACL) module. See: Air filter module Service and Repair.
- the battery ground lead.
Final checks
Start the engine. Check for leakage. Check the engine function.