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fig.14
3.6.3
Attach a suitable torque wrench to the adjusting screw of
VS4803 (fig.14). Turn to apply a pre-load to the tensioner rail
of 0.6Nm.
fig.15
3.6.4
Tighten the bolt of the exhaust camshaft VANOS unit to the
specified torque, followed by the bolt of the inlet VANOS Unit,
again, to the specified torque – Torque 20Nm. + 90°+ 90°
(fig.15).
3.6.5
remove the VS4869 VANOS Alignment Tool.
3.6.6
unscrew the adjusting screw of VS4803 and remove the Pre-
Load Tool.
IMPORTANT: Install the chain tensioner.
3.6.7
remove all timing tools and turn the crankshaft twice (at the
crankshaft pulley centre bolt), in normal direction of engine
rotation, returning to TDC engine timing position, No.1 cylinder.
3.6.8
Insert the Flywheel TDC Locking Pin and Camshaft Setting
Plates to check timing position, follow the procedure as
described in "Checking valve timing".
Removing, Installing and Replacing VANOS Units.
If either of the VANOS units, on inlet or exhaust camshafts,
cannot be 'locked' and are faulty, they must be replaced.
3.7
Removal
fig.16
3.7.1
Slacken the bolts of the VANOS units on the inlet and exhaust
camshafts (fig.16).
WARNING: These bolts are likely to be tight. It will be
necessary to counter-hold against engine rotation at the
crankshaft pulley centre bolt. Do NOT rely on the Flywheel
Pin to counter-hold when loosening these bolts.
3.7.2 Screw in the bolts to finger-tight only, sufficient so there is no
play or tilt on the units.
3.7.3 Ensure that the VS4801 Flywheel TDC Locking Pin is fitted into
the timing hole in the flywheel.
fig.17
3.7.4
Place VS4868-1 Camshaft Setting Plate on to the rectangular
section at the rear of the INLET camshaft, ensuring that the
curved edge of the rectangular plate is uppermost. Align the
camshaft so the Setting Plate rests fully on the surface of the
cylinder head. (Do not insert fixing bolt) (fig.17).
fig.18
3.7.5
Place VS4868-2 Camshaft Setting Plate on to the rectangular
section at the rear of the EXHAuST camshaft, ensuring that the
curved edge of the rectangular plate is uppermost. Align the
camshaft so the Plate rests fully on the surface of the cylinder
head (fig.18).
3.7.6
Screw in the two fixing bolts and tighten to secure the
Setting Plate VS4868-2 to the cylinder head.
fig.19
3.7.7
Screw in VS4805-3 Securing Screw into Setting Plate VS4868-2
until it presses on Setting Plate VS4868-1 (fig.19).
3.7.8
Screw in the fixing bolt for VS4868-1 and tighten to secure
this Setting Plate to the cylinder head.
3.7.9
remove the timing chain tensioner.
3.7.10 Fully remove the bolt of the VANOS unit on the exhaust
camshaft. Lift chain off the sprocket and feed out and remove
the complete VANOS unit.
3.7.11 repeat this procedure on the VANOS unit on the inlet
camshaft.
3.8
Replacement
fig.20a
WARNING: It is important to note that the Inlet and exhaust
VANOS Units are different. It is essential to keep the parts
of Inlet Unit separate from the Exhaust Unit. Under no
circumstances should the parts be mixed or parts from any
other engine variant be used.
Inlet unit part is marked "EIN / IN" (fig.20a) and the Exhaust
unit part marked "AUS / EX" (fig.20b).
Installation
3.8.1
Assemble the unit of the Inlet camshaft, including the sensor
gear (front plate), and feed on to the inlet camshaft fitting the
chain onto the sprocket. Screw in a new bolt and tighten only so
there is no play or tilting (finger-tight).
fig.20b
VS4870
Issue No: 1 - 07/04/09
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