"VCC-119188 EN 2009-03-02"

Valve clearance, setting / adjusting

Special tools: 999 5006 , 999 5383 , 999 5460 , 999 5452 , 999 5199 , 999 5452 , 999 5454 , 999 5670 , 999
5765 , 999 5752 , 999 5451 , 951 2767 , 999 5454 , 999 5719 , 999 5718 , 999 5450
Note! As 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.
Preparation
Remove:
- the cable from the battery negative terminal. First read
Note when disconnecting and connecting the
battery lead .
Removing the starter motor
Remove:
- the screws for the starter motor
- the support bracket for the intake manifold
- the connector for the oil pressure switch
- unhook the starter motor and allow it to hang.
Removing components

Remove:
- the cover over the injector
- the cover over the throttle body (TB)
- the upper timing cover
- the cover over the ignition coils
- front timing cover
- the inlet hose between the mass air flow (MAF) sensor
and throttle body (TB)
- the auxiliaries belt.

Exposing the cable harness

Remove:
- the screw from the ignition coil ground
- the camshaft position (CMP) sensor.
Remove:
- the variable valve timing valve connector
- the ignition coil connectors.
Place the cable harness to one side.
Unscrew the cable duct from the rear edge of the cylinder
head and the throttle body (TB) bracket.
Remove:
- the connector for the engine coolant temperature
sensor
- the injector connectors.

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 "VCC-119188 EN 2009-03-02"

Place the cable duct and cable harness to one side.

Mark up and remove the ignition coils and ignition cables.
Remove:
- the rear cover for the camshaft
- the camshaft position (CMP) sensor housing
- the trigger wheel
- the hose for the crankcase ventilation from the
camshaft cover.
Installing the lifting beam and the lifting hook
Install the lifting beam and the lifting hook. See Replacing
the timing belt .
Right-hand engine mounting, removing
Remove the right-hand engine mounting. See Replace
the engine mountings .
Marking the engine
See Replacing the timing belt .
Removing the timing belt
Remove the timing belt. See Replacing the timing belt .
Removing the timing gear pulley
Remove the timing gear pulley. See Replacing the
camshaft seals .
Removing the camshaft cover and tappets
Note! Do not remove the cylinder head.
Remove the camshaft cover and tappets. See Cylinder
head / gasket, replace .
Cleaning

Use a razor blade or a gasket scraper and gasket solvent

P/N 1161 440 on the camshaft cover.
Warning! Use a fume bonnet or extractor when using
gasket solvent.
Use only a gasket scraper or razor blade on the cylinder
head.
Note! Take great care around the oil ducts for the
variable valve timing solenoid. This applies to both
the camshaft cover and the cylinder head. The
solenoid is extremely sensitive to contaminants.
Dry and blow all surfaces clean.
Preparations
Carefully tap the end of the valve stem to ensure that the
valve is correctly located in the seat. Use a plastic,
aluminium or brass drift to protect the valve and the
surface of the tappet.
The sound made by tapping reveals if the valve is
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 "VCC-119188 EN 2009-03-02"
correctly seated.

Installing the camshaft and tappet

Install both the tappets for the inlet valves at cylinder 1.

Check the notes made earlier. Select new tappets if
necessary.
Note! Only install two tappets. The tappets must be
placed at the same cylinder.
The valve clearance on a cold engine (approximately 20°
C/68°F) must be:
Reference values
Valve: Valve clearance:
Intake valve: 0.20 ±0.03 mm
Exhaust valve: 0.40 ±0.03 mm
Note! The tolerances are less at setting! When
checking the valve clearance through the plug hole
the tolerances are larger.
Install the intake camshaft. Ensure that the lobes at
cylinder 1 point upwards.
Apply a little oil to the cam lobe and the upper side of the
tappet to facilitate measurement later.
Installing the camshaft press

Install the lower section of camshaft press 999 5765 at the

intake valves for cylinder 1.
Tighten the tool against the cylinder head. Tighten to
17 Nm.
Turn the camshaft until it stops against the camshaft press.

Install the upper section of the camshaft press.

Tighten the screw which tensions the camshaft. Tighten to
12 Nm.

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 "VCC-119188 EN 2009-03-02"

Checking the valve clearance

Note! Measurement must be carried out on a cold
engine. A suitable temperature is approximately 20°
C/68°F.
Use feeler gauge 999 5752 .
Press with a finger so that the feeler gauge lies parallel to
the upper side of the tappet (see illustration).
Move the feeler gauge sideways when taking the reading
in order to obtain as accurate a measurement as possible.
The valve clearance on a cold engine (approximately 20°
C/68°F) must be:
Reference values
Valve: Valve clearance:
Intake valve: 0.20 ±0.03 mm
Exhaust valve: 0.40 ±0.03 mm
Note! The tolerances are less at setting! When
checking the valve clearance through the plug hole
the tolerances are larger.
Differences in valve clearance for different engines /
ambient temperatures:
- − 0.01 mm at 15°C
- + 0.01 mm at 25° C
- + 0.02 mm at 30° C
- + 0.03 mm at 35° C
- + 0.04 mm at 45° C.
Correcting measured clearance
Lift out the upper section of the press tool.
Lift out the camshaft.
Adjust the play by replacing the tappets.
Other tappets are available as replacement part /
replacement part kits.
Reinstall the camshaft and the upper section of the press
tool. Tighten to 12 Nm.
Take a new measurement. See Valve clearance,

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 "VCC-119188 EN 2009-03-02"
checking .
Measuring the correct valve clearance

Remove:
- press tool 999 5765
- the camshaft
- the tappets.
Carefully mark the tappets so that exact reinstallation can
be carried out, for example:
- Intake side: I1, I2, I3, I8
- Exhaust side: A1, A2, A3, ...... A8.
Repeat the procedure for measuring the valve clearance
for all cylinders on both the intake and exhaust sides. See
Valve clearance, checking .
Note! For tightening torques not in the text, see
Tightening torques for 4-cylinder petrol engines .
Installing the tappets and camshafts
Lubricate the valve guide wells.
Install all the tappets.
Note! Make sure that the lifters are in the same
position as before.
Lubricate the camshaft bearing seats.
Install the intake camshaft. Ensure that the groove at the
rear edge of the camshaft is above an imaginary centre
line.
Position the exhaust camshaft. Ensure that the groove at
the rear edge of the camshaft is below an imaginary
centre line.

Applying liquid gasket

Wipe the oil film off the mating surfaces on the camshaft
cover and cylinder head.
Install new O-rings around the spark plug wells on the
cylinder head.
Apply liquid gasket 116 1059 to the camshaft cover.
Use roller 951 2767 .
The surface must be completely covered without any
excess.
Note! Ensure that no liquid gasket gets into the
coolant or oil ducts. Only a thin layer of liquid gasket
is required.
Installing the camshaft covers
To install the camshaft adjustment tool, see Cylinder

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 "VCC-119188 EN 2009-03-02"
head / gasket, replace
Tighten the camshaft cover. Tighten to 14 Nm.
Install camshaft adjustment tool 999 5452 at the rear of
the camshafts.
Check that the screws securing the adjustment tool to the
camshafts and the screws holding the tool together are
well tightened.

Installing the front camshaft seal

To install the front camshaft seal, see Cylinder head /
gasket, replace .
Aligning the crankshaft
To align the crankshaft see Cylinder head / gasket,
replace .
Installing the timing gear pulley for the camshafts
Install the camshaft timing gear pulley. See Replacing the
camshaft seals .
Installing the timing belt
Install the timing belt. See Replacing the camshaft
seals .
Tightening the timing gear pulley
See Replacing the camshaft seals .
Check

- Press the belt to check that the indicator on the

tensioner moves easily
- Position the upper timing cover.

- Turn the crankshaft two turns. Check that the markings

on the crankshaft and camshaft pulley correspond.
Note! Check that the indicator on the belt tensioner
is within the marked area.

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 "VCC-119188 EN 2009-03-02"
- Remove the upper timing cover.

Installing the right-hand engine mounting

Screw the engine mounting onto the engine. Tighten to

67 Nm.
Install the engine mounting screw and nut in the
bodywork bracket. Tighten by hand.

Finishing
Remove the lifting beam and lifting hook.
Tighten the engine mounting nut. Tighten to 98 Nm.
Install:
- the power steering reservoir
- the metal bracket for the power steering hose on the
rotation protection for the auxiliaries belt
- the auxiliaries belt
- the rear camshaft cover. See Replacing cylinder head
gasket
- the trigger wheel. Tighten to 17 Nm
- the camshaft position (CMP) sensor housing. Tighten to
5 Nm
- the hose for the crankcase ventilation on the camshaft
cover.
Installing components

Install:
- the ignition coils and ignition cables according to the
earlier markings
- the connectors on the variable valve timing valve and
ignition coils
- the ground lead for the ignition coils
- the camshaft position (CMP) sensor.

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 "VCC-119188 EN 2009-03-02"

Place the cable duct and cable harness in position.

Install:
- the screws for the cable duct on the rear edge of the
cylinder head and throttle body (TB) bracket
- the connectors for the injectors
- the connector for the engine coolant temperature
sensor
- the inlet hose between the mass air flow (MAF) sensor
and throttle body (TB)
- front timing cover
- the cover over the ignition coils
- the upper timing cover
- the cover over the throttle body (TB)
- the cover over the injectors.
Installing the starter motor
Install the starter motor. See Cylinder head / gasket,
replace .
Finishing
Check:
- the engine oil level
- the coolant level.
Warm up the engine until the thermostat opens.
Check the engine for leaks.
Top up the coolant if necessary.

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