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Valve gear, to remove (in car)

Valve gear, to remove (in car)


1. Drape the wing protectors over the wings and remove the engine cover.


2. Disconnect the negative cable from the battery.

3. Open the cap on the expansion tank and release the pressure.

4. Raise the car.

5. Remove the lower spoiler sections.


6. Drain the coolant from the radiator.

7. Insert two 83 95 238 Wedges , between the oil sump and subframe and between the gearbox and subframe.


8. Lower the car.

9. Remove the mass air flow sensor with hose.


10. Detach the power steering hose from the holder.

11. Remove the right-hand engine attachment with bracket and engine mount.

12. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley


13. Release the multigroove belt from tension.

14. Remove the coolant pump pulley and power steering pump pulley.

15. Remove the belt tensioner and generator air intake.

16. Remove the timing cover.

17. Remove the crankshaft pulley.

18. Unhook the throttle cable.


19. Remove the vacuum hoses and unplug the pressure sensor's connector from the upper intake manifold.

20. Detach the vacuum hose and the two water hoses from the throttle. Remove the turbo pressure hose with charge air bypass pipe. Unplug the throttle's connector and detach the venting-valve hose from the underside of the throttle.

21. Unplug the connectors for the ignition discharge module and injectors.


22. Detach the fuel lines.

23. Undo the upper intake manifold and move it aside.

24. Remove the middle intake manifold.


25. Remove the lower intake manifold. Plug the holes with paper or the like.

26. 1. Zero the engine. The markings on the camshaft drive belt and the timing cover should match. Use 83 95 006 Assembly kit KM-800-20, and the markings on the crankshaft. Fit the locking tools KM-800-1 and KM-800-2 for the camshaft drive belt and the locking tool KM-800-10 for the crankshaft.


27. Undo the tensioning pulley and adjusting rollers. Use tool 83 94 983 as a counterstay on the adjusting rollers.


28. Mark the direction of rotation on the belt. The belt can also be marked with the respective camshaft markings and crankshaft marking to facilitate refitting. Remove tool KM-800-10 from the crankshaft. Let locking tools KM-800-1 and KM-800-2 remain. Remove the lower adjusting roller. Ensure the washer behind the roller is also removed. Remove the timing belt.

29. Remove the bracket with tensioning roller and the upper adjuster roller.

30. Rotate the crankshaft to 60° BTDC. Note the marking.


31. Remove the camshaft sprockets.

32. Remove the coolant pump.

33. Remove the inner timing cover.

34. Remove the ignition discharge module.


35. Remove the camshaft cover. Make sure that the O-rings are in place and that they do not fall into the engine.

36. Undo and remove the camshafts. Undo the bolts in stages, 1/2 to 1 turn at a time. Note the marking on the bearing caps.


It is important to conclude removal at the bearing cap where the tappets are under load. Remove the stuffing boxes.

37. Lift out the tappets using tool 83 91 401.

38. Fit 83 95 022 Protective collar around the valve springs to protect the surface sealing of the tappets.

39. Rotate the crankshaft so the piston in the cylinder is in the upper stop position. Lock the engine with 83 94 868 Flywheel locking attachment and unscrew the spark plug for that cylinder. Use 83 95 485 Spark plug socket assembly with locating sleeves and install the 83 94 173 Compressed air adapter for spark plug hole . Connect compressed air and place the piston and valves under pressure.

40. Press down the valve disc with 83 95 246 Valve spring compressor and remove the collets.


41. Lift the spring cap and the valve spring and remove the valve stem seal with 83 94 157 Pliers for removing valve stem seal .