Valve Timing Adjustment

301294Valve Timing, Adjust (Z 22 SE) Page 1 of 15
Valve Timing, Adjust (Z 22 SE)
Remove
1. Open the bonnet.

2. Disconnect the battery.
3. Open the engine cover (1).
4. Detach the engine cover.
• 6 bolts (2) and (3)
5. Release the fuel pressure.

6. Warning:
• Fuel may escape – observe the safety
regulations and relevant national
legislation.
• Release the fuel pressure with the
pressure tester KM-J-34730-91 via test
connection (1).
file://C:\Program%20Files\cosids\DATA\TMP\00301294.rtf.html 12/20/2005
– Collect any escaping fuel in a

suitable container.
7. Disconnect the fuel

lines (3).
• 2 union nuts (1)
• Fuel line bracket
– 2 bolts (2)
• Reposition the fuel
lines with the fuel
line bracket to one
side.
8. Detach the ignition module (1).

• Release and detach the wiring harness
connector.
• 4 bolts (2)
9. Remove the cylinder

head cover.
• Detach the engine
breather hose (2).
• Detach the engine
lifting eyes (5) and
(6).
– 2 bolts, 1 nut
• Detach the ground
cable (7).
– 1 bolt
• 12 bolts (1), (3), (4)
and (8)
10. Raise the lifting ramp.
11. Remove the lower engine splash shield

(1).
• 13 bolts
12. Align the crankshaft.

• Rotate the crankshaft in the normal
direction of rotation to TDC on cylinder
no. 4 (marking 1).
13. Lower the lifting ramp.
14. Remove the guide rail (1).

• 2 bolts (2)
15. Note:
If there is no marking (1) on the camshaft
timing chain tensioner (2), then it should
be replaced with a new camshaft timing
chain tensioner (part number 24 448 509)
including a new camshaft timing chain
tensioner rail (part number 24 449 448).
16. Remove the camshaft timing chain

tensioner (1).
17. Remove the exhaust camshaft sprocket

(1).
• Hold the exhaust camshaft by the
hexagon.
Adjust
18. Attach KM-6148.

19. Note:
• In this position the
cams (1) and (2)
of cylinder no. 4
point upwards.
• Attach KM-6148
with the enclosed
bolts (4).
• Slide the
positioning bolt (5)
into the
designated bore
(3) on the
camshaft
sprocket.
20. Fit the camshaft timing chain.

21. Important:
The TDC reference points on the timing
chain are indicated by coloured links in the
chain. These must line up with the
markings on the timing sprockets. It must
be possible to insert blocking tool KM-
6148.
22. Feed the camshaft timing chain by hand
through the timing case.
• Chain link (copper colour) (1) to INT
marking (2) on the intake camshaft
sprocket
– Secure the camshaft timing chain
with cable ties to the intake
camshaft sprocket.
23. Detach KM-6148.

24. Install the exhaust camshaft sprocket.
Note: Check that the TDC reference
points line up.
• Chain link (1) to EXH marking (2) on
the exhaust camshaft sprocket
• Rotate the exhaust camshaft by the
hexagon until the exhaust camshaft
sprocket is seated in the guide.
• Use a new bolt.
• Hold the camshaft by the hexagon.
– Tightening torque 85 Nm + 30° +
15°
– Detach the cable ties from the

intake camshaft sprocket.
25. Recut the thread.

• 2 off
26. Install the guide rail.
• Coat the bolts with thread locking
compound (red) and insert them.
– Tightening torque 8 Nm
27. Attach KM-6148.

Note: In this position
the cams (1) and (2)
of cylinder no. 4 point
upwards.
• Attach KM-6148
with the enclosed
bolts (4).
• Slide the
positioning bolts
(5) into the
designated bores
(3) on the
camshaft
sprockets.
28. Install the camshaft timing chain

tensioner.
• Pull out the piston (4) from the housing
(1).
– Clamp the piston at the square
into a vice.
– Turn clockwise to lock the
internal piston (6) in the last latch
position (5).
– Insert the piston into the housing.
• Use new oil seals (2) and (3).
• Tightening torque 75 Nm
29. Detach KM-6148.
Important: Failure to
follow this instruction could
cause the camshaft timing
chain to jump.
30.
Release the camshaft
timing chain tensioner
by pressing on the
tensioner rail or the
camshaft timing chain
(using a blunt tool –
e.g. a smooth–edged
assembly lever).
Note: If the TDC
markings no longer
line up with the
coloured chain links,

refit the camshaft
timing chain. Once
the crankshaft has
been rotated another
turn they will no
longer line up.
31. Raise the lifting ramp.
32. Rotate the crankshaft720°.

• Rotate the crankshaft in the normal
direction of rotation to TDC on cylinder
no. 4 (marking 1).
33. Install the lower engine splash shield
34. Lower the lifting ramp.
35. Attach KM-6148.

Note: In this position
the cams (1) and (2)
of cylinder no. 4 point
upwards.
• Attach KM-6148
with the enclosed
bolts (4).
• Slide the
positioning bolts
(5) into the
designated bores
(3) on the
camshaft
sprockets.
36. Detach KM-6148.
Install
37. Attach the cylinder head cover

• Clean the sealing surfaces.
• Use new gaskets.
Note: The sealing lips of the seals (1)
must be inserted into the groove on
the cylinder head cover.
• Attach the ground cable
• Attach the engine lifting eyes.
– 2 bolts, 1 nut
• Attach the engine breather hose.
• Attach the fuel line bracket.
38. Attach the ignition module.

• Tightening torque 9 Nm
• Attach and secure the wiring harness
connector.
39. Connect the fuel lines.

• 2 union nuts
• Fuel line bracket
– 2 bolts
40. Install the engine cover.

• Check the alignment.
• 6 bolts, tightening torque 14 Nm
41. Close the engine cover.
42. Connect the battery.
43. Close the bonnet.
44. Reprogram the volatile memories.

Valve Timing Adjustment

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301294Valve Timing, Adjust (Z 22 SE) Page 1 of 15

Valve Timing, Adjust (Z 22 SE)

1. Open the bonnet.

5. Release the fuel pressure.

– Collect any escaping fuel in a

7. Disconnect the fuel

8. Detach the ignition module (1).

9. Remove the cylinder

11. Remove the lower engine splash shield

12. Align the crankshaft.

14. Remove the guide rail (1).

16. Remove the camshaft timing chain

17. Remove the exhaust camshaft sprocket

18. Attach KM-6148.

20. Fit the camshaft timing chain.

23. Detach KM-6148.

– Detach the cable ties from the

25. Recut the thread.

27. Attach KM-6148.

28. Install the camshaft timing chain

coloured chain links,

32. Rotate the crankshaft720°.

35. Attach KM-6148.

37. Attach the cylinder head cover

38. Attach the ignition module.

39. Connect the fuel lines.

40. Install the engine cover.

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