Checking camshaft and fuel pump adjustment
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Checking camshaft and fuel pump adjustment
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1.
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Remove the battery cover and the negative battery cable.
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2.
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Remove the upper engine cover.
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3.
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Remove the turbocharger intake hose and plug the turbocharger inlet. Unplug the crankcase ventilation hose and mass air flow sensor connector.
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4.
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Remove the air filter housing lid and the air filter. Detach the intake hose and remove the filter housing.
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5.
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Remove the charge air hose and charge air pipe from the turbocharger, and the charge air pipe from the fan cowling. Plug the connections.
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6.
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Undo the rear wiring harness mounting from the camshaft cover.
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7.
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Disconnect the glow plug connectors and bend aside the wiring harness.
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8.
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Remove the lower bolt from the cable duct and lifting eye. Remove the heat shields from the exhaust manifold and turbocharger.
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9.
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Raise the car and remove the right-hand front wheel and right-hand wing liner.
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10.
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Remove the spoiler shield. Disconnect the headlight washer hose and unplug and remove the connector.
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11.
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Remove the lower engine cover.
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12.
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Mark the belt's direction of rotation. Detension and remove the poly-V-belt.
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13.
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Remove the belt tensioner. Place the belt tensioner standing upright.
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14.
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Remove the coolant pipe from the gearbox and cylinder block.
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15.
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Remove the crankshaft position sensor.
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16.
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Remove the bracket from the intermediate shaft. Suspend the exhaust pipe with a
83 95 212 Strap
.
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18.
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Remove the bolts securing the cable bracket by the vacuum pump.
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19.
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Disconnect the hoses from the vacuum pump and remove the vacuum pump. Have a rag at hand to catch any oil spills.
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20.
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Remove the camshaft cover.
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21.
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Turn the crankshaft to just before the mark for TDC for cylinder 1. Check that both the cams for cylinder 1 are pointing obliquely upward.
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22.
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Raise the car and insert
83 95 352 Adjustment tool, crankshaft
into the hole for the crankshaft position sensor. Press the tool in while turning the crankshaft to zero. The tool should enter a recess in the crankshaft and lock it.
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24.
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Remove the bolts from the cover on the timing cover. Carefully insert a pallet knife behind the cover and prise it off.
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2.
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Fit the crankshaft position sensor with a new O-ring.
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3.
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Lower the car and cover the opening in the timing cover with a lint free cloth. Clean any old gasket remains from the sealing surfaces and clean the sealing surface on the cover.
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4.
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Apply a 2 mm bead of
83 95 691 Flange sealant
to the cover. Remove the cloth from the timing cover and fit the cover.
Tightening torque 6 Nm (5 lbf ft)
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5.
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Raise the car and clean any gasket remains from the sealing surfaces of the cylinder head. Fit a new gasket to the camshaft cover. Apply
83 95 691 Flange sealant
to the sealing surface as illustrated and fit the camshaft cover.
Tightening torque 8 Nm (6 lbf ft)
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6.
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Position the vacuum pump. Apply
83 95 691 Flange sealant
as illustrated and fit the vacuum pump, adapter and a new gasket. Connect the hoses to the vacuum pump.
Tightening torque 8 Nm (6 lbf ft)
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7.
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Fit the bolts securing the cable duct by the vacuum pump.
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8.
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Raise the car and fit the coolant pipe mounting to the gearbox and cylinder block.
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9.
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Fit the belt tensioner.
Tightening torque, lower screw 24 Nm (18 lbf ft)
Tightening torque, upper screw 42 Nm (31 lbf ft)
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10.
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Release the tension of the poly-V-belt and fit it in the direction of rotation marked.
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11.
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Fit the lower engine cover.
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12.
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Fit the spoiler shield. Connect the headlight washer hose and fit and plug in the connector.
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13.
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Lower the car and fit the right-hand wing liner and front right wheel. See
Wheels
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14.
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Fit the heat shields over the exhaust manifold and turbocharger.
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15.
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Fit the lower bolt securing the cable duct and lifting eye.
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16.
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Connect the glow plug connectors.
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17.
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Fit the rear wiring harness mounting to the camshaft cover.
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18.
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Fit the charge air hose and charge air pipe to the turbocharger and the charge air pipe to the fan cowling.
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19.
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Fit the air filter housing and connect the intake hose. Fit the air filter and air filter housing lid.
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20.
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Connect the crankcase ventilation hose and plug in the mass air flow sensor. Fit the turbocharger intake hose.
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21.
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Connect the negative battery cable and fit the battery cover.
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22.
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Fit the upper engine cover.
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