Left Cylinder Head Camshaft, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Puller - Toothed Belt Pulley T10320
Camshaft Fitting Tool T40094A
Camshaft Fitting Tool T40095
Camshaft Fitting Tool T40096
Pry Lever 80-200
Wrench - Pin Type 3036
Hand drill with plastic brush attachment
Protective eyewear
Sealant.

Removal

Fig 1: Identifying Bolts -Arrows-

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-- Remove the affected camshaft timing chain from the camshaft, refer to CAMSHAFT TIMING CHAINS, REMOVAL FROM CAMSHAFTS .

-- Remove the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

-- Remove the high pressure pump toothed belt. Refer to HIGH PRESSURE PUMP TOOTHED BELT, REMOVING AND INSTALLING .

Fig 2: Identifying Toothed Belt Tensioning Roller And Bolt -Arrow-

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-- Loosen the toothed belt drive sprocket bolt -1- two turns using the Wrench - Pin Type 3036.

Fig 3: Identifying Toothed Belt Drive Sprocket Bolt -1- And 3036

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-- Remove the toothed belt drive sprocket using the Puller - Toothed Belt Pulley T10320.

Fig 4: Identifying Toothed Belt Drive Sprocket Using T10320

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-- Remove the left cylinder head cover. Refer to LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Remove the EGR Cooler Switch-Over Valve -N345- -1- from the bracket.

Fig 5: Identifying EGR Cooler Switch-Over Valve -N345- -1-, Engine Cover Ball Studs -2-, Wiring Harness -3- And Bolt -4-

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-- Remove the bolt -4- and the engine cover bolts -2-.

-- Free up the wiring harness -3- on the top of the coolant pipe on the left side.

NOTE:

Ignore -arrows-.

NOTE:

Follow all the rules of cleanliness. Refer to FUEL SUPPLY, INJECTION SYSTEM AND CHARGING SYSTEM CLEAN WORKING CONDITIONS .

Fig 6: Identifying High Pressure Line Union Nut -1- And Bolts -Arrows-

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-- Remove the high pressure line union nut -1-.

-- Remove the screws -arrows- and remove the fuel rail from the left cylinder head.

-- Loosen the guide frame bolts and nuts in the sequence -18 to 1-.

Fig 7: Identifying Left Cylinder Head Guide Frame, Tightening Specifications and Sequence

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NOTE:

Be careful of the roller rocker lever and the adjusters when Removal the camshafts.

-- Carefully remove the bearing bracket and camshafts.

Installation

Tightening specifications, refer to CYLINDER HEAD OVERVIEW and COOLANT PIPES OVERVIEW .

NOTE:

Replace the front cover in the cylinder head on the right side.

CAUTION:

Danger of destroying the axial bearing in the bearing bracket.

Install the camshaft as described with the Camshaft Fitting Tool T40094A.

Risk of contaminating lubricating system.

Cover any open parts in the cylinder head.

WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove the sealant residue on the cylinder head and guide frame and the upper section of the oil pan, for example using a rotating plastic brush.

-- Clean the sealing surfaces; they must be free of oil and grease.

-- Lubricate the running surfaces of both camshafts.

Set up the Camshaft Fitting Tool T40094A as follows:

Fig 8: Identifying Bracket T40094/1 And Bracket T40094/2

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-- Install the Bracket T40094/2 in -A-.

-- Install the Bracket T40094/1 in -D-.

-- Install the exhaust camshaft -1- into the Bracket T40094/1 and Bracket T40094/2.

Fig 9: Identifying Camshaft Insertion Tools T40094 And T40096

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-- Turn the exhaust camshaft so that it can be locked with the straight-edge in the "TDC" position -arrow-.

-- Mount the Camshaft Fitting Tool T40096 onto the teeth of the exhaust camshaft so that one arm of the clamping device engages in one sprocket half.

-- Tension the clamping devise with the thumbwheel until the tooth faces align.

-- Place the intake camshaft -2- into the Camshaft Fitting Tool T40094A.

Fig 10: Identifying Intake Camshaft -2- In Camshaft Insertion Tool T40094

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The securing pin -3- must engage in the groove on the intake camshaft.

-- Push the exhaust camshaft -1- toward the intake camshaft -arrows- until the splines engage.

-- Make sure the camshaft is positioned correctly:

Fig 11: Locating Camshaft Notches

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The notches -arrows- on both camshafts must face upward.

-- Place the bearing brackets -1- on both camshafts.

Fig 12: Placing Bearing Brackets -1- On Both Camshafts

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All the camshaft bearings must lie on the camshafts.

-- Mount the Camshaft Fitting Tool T40095 onto the camshafts by aligning the pliers and tension with the knurled nuts -2-.

-- Tension the camshafts by tightening the nuts -3-.

-- Make sure the alignment pins -arrows- are in the cylinder head. Insert any missing alignment pins.

Fig 13: Locating Cylinder Head Alignment Pins

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NOTE:

Note the expiration date of the sealing compound.

Fig 14: Cut Tube Nozzle At Front Marking

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-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1.5 mm).

NOTE:

The guide frame is shown without the camshafts.

Fig 15: Identifying Sealant Beads -Arrows- On Clean Sealing Surfaces Of Guide Frame

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-- Turn the guide frame around.

CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant beads thicker than specified.

-- Apply sealant beads -arrows- to the clean sealing surfaces on the guide frame as shown in the illustration.

The grooves of sealing surface must be completely filled with sealant.
The sealant beads must be 1.5 to 2.0 mm above the sealing surface.

NOTE:

The guide frame must be installed within 5 minutes after applying the sealant.

CAUTION:

The engine could be damaged.

Make sure all the roller rocker levers are seated correctly on the valve stem ends and the adjusters.

-- Mount the guide frame together with both camshaft and the Camshaft Fitting Tool T40095 to the cylinder head.

Fig 16: Identifying Left Cylinder Head Guide Frame, Tightening Specifications and Sequence

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-- Tighten the guide frame bolts, refer to Figure.

-- Remove the Camshaft Fitting Tool T40095 and Camshaft Fitting Tool T40096.

NOTE:

After Installation the guide frame, let the sealant harden for approximately 30 minutes.

Install in reverse order of removal. Note the following:

-- Install the fuel rail and the high pressure lines. Refer to HIGH PRESSURE LINES, INSTALLING .

-- Install the left cylinder head cover. Refer to LEFT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Camshaft Seal, Removing and Installing, refer to CAMSHAFT SEAL, REMOVING AND INSTALLING .

-- Install the high pressure pump toothed belt and the intake manifold upper section. Refer to HIGH PRESSURE PUMP TOOTHED BELT, REMOVING AND INSTALLING and INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

-- Install the camshaft timing chains. Refer to CAMSHAFT TIMING CHAINS, REMOVAL FROM CAMSHAFTS .

CAUTION:

Risk of damaging valves and piston heads after working on valve train.

The motor must not be started for about 30 minutes after Installation camshafts because the hydraulic equalization elements must seat themselves.
To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.