Camshafts, removing and installing

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Special tools, testers and auxiliary items required 

• Multi-point socket T10035
• Tool set T10133
• Socket T40058
• Securing pins 1 set = qty. 2 T40116

• Hand drill with plastic brush attachment
• Protective glasses
• Sealant

Removing 

• Remove cylinder head cover: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .
• Remove left and right timing chain covers → Installing .
• Remove camshaft timing chains from camshafts → Camshaft timing chains, removing from camshafts .

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• Disconnect electrical connector at intake camshaft position sensor - arrow  -.
• Remove high-pressure pump → 24 - MULTIPORT FUEL INJECTION (MFI) .

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• Remove Crankshaft Holder 3242 from upper part of oil pan.

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• Insert guide pin of socket T40058 so that large diameter - arrow 1  - points to adapter. Small diameter - arrow 2  - points to engine.

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• Rotate crankshaft with Socket T40058 opposite engine rotation direction 40° out of "TDC" position - arrow  -.

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• Remove Camshaft Clamp T40070 at cylinder head.

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• Loosen guide frame bolts in sequence - 24 to 1  -.

• Carefully remove guide frame.
• Mark camshafts for reinstallation and remove them.

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Installing 

• Tightening torque → Bearing frame tightening sequence 

• Remove sealant residue on cylinder head and guide frame, e.g. with rotating plastic brush.
• Clean sealing surfaces so they are completely free of any oil or grease.
• Oil journal surfaces of camshafts.
• Place camshafts in cylinder head, noting position of camshafts so that guide frame can be installed without tension.

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Left cylinder head:

1. Intake camshaft
2. Exhaust camshaft

• Groove on end of shaft must lie as shown in illustration.

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Right cylinder head:

1. Exhaust camshaft
2. Intake camshaft

• Groove on end of shaft must lie as shown in illustration.

Continued for both sides:

• Check location of compression ring ends.

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• The compression ring ends - 1 and 2  - must face upward or downward, and must never face sideways.

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• Cut off nozzle on tube of sealant at front mark (dia. of nozzle approx. 2 mm).

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• Lay seal - 2  - in guide frame groove.
• Apply sealant beads - 1, 3, 4  - on clean guide frame sealing surfaces as shown in illustration.

• Thickness of sealant beads: 2.5 mm.

• Place guide frame on cylinder head.

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• Insert locating pins T40116 in guide frame and cylinder head.

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• Tighten guide frame bolts → Bearing frame tightening sequence 

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• Drive sealing plugs - arrows  - in flush.

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• Remove locating pins T40116 with impact puller T10133/3.

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• Rotate intake camshaft to "TDC" and tighten camshaft adjuster screw - 2  - on camshaft with a socket SW 24 - 1  - inserted between.

• Position a lever or ratchet with Socket T10035 on screw and rotate camshaft until threaded holes for Camshaft Clamp T40070 face up.
• Next, loosely fasten Camshaft Clamp T40070 to intake camshaft.

• The Camshaft Locating Tool T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

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• Adapt camshaft adjuster screw - 2  - and socket 24 - 1  - to exhaust camshaft.
• Rotate exhaust camshaft until threaded hole for Camshaft Clamp T40070 faces up.
• At the same time, position a counter-hole SW 24 on Camshaft Clamp T40070 and swing Camshaft Clamp T40070 against exhaust camshaft to install - arrow  -.
• Tighten Camshaft Clamp T40070 by hand onto exhaust camshaft to avoid damaging threads (2nd technician needed).

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• Tighten Camshaft Clamp T40070 bolts to 25 Nm.

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• Using Socket T40058, rotate crankshaft in direction of engine rotation - arrow  - to "TDC".

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• Install crankshaft holder 3242 into hole to 20 Nm, if necessary rotate crankshaft very slightly back and forth to completely center holder.

The rest of installation is in reverse order of removal, note the following:

• Install high pressure pump → 24 - MULTIPORT FUEL INJECTION (MFI) .
• Position camshaft timing chains on camshafts → Installing .
• Install left and right timing chain covers → Installing .
• Install cylinder head covers: Left → Left cylinder head cover, removing and installing , right → Right cylinder head cover, removing and installing .