Camshaft, Removing And Installing: Installing

Tightening Specification. Refer to Figure.

NOTE:

Replace Seals And Sealing Rings.

Replace Any Bolts That Were Tightened With An Additional Turn.

CAUTION:

Risk Of Contaminating Lubricating System And Bearing.

Cover open parts of engine.

WARNING:

Danger Of Eye Injury.

Wear protective eyewear.

-- Using a rotating plastic brush, remove any remaining sealant from the cylinder head and guide frame.

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

-- Oil running surfaces of both camshafts.

-- Place the camshafts in the cylinder head, being careful of their position so the guide frame can be laid on top without tension.

LEFT CYLINDER HEAD

Fig 1: Identifying Intake Camshaft & Exhaust Camshaft (Left Cylinder Head)

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Intake camshaft
Exhaust camshaft

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

RIGHT CYLINDER HEAD

Fig 2: Identifying Intake Camshaft & Exhaust Camshaft (Right Cylinder Head)

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Exhaust camshaft
Intake camshaft

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

CONTINUED FOR BOTH SIDES

Fig 3: Identifying Compression Ring End Position

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-- Check the location of the compressor ring ends.

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

NOTE:

Note The Expiration Date Of The Sealing Compound.

-- Cut the tube nozzle at the front marking (nozzle diameter: about 2 mm).

Fig 4: Cut Tube Nozzle At Front Marking

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-- Lay the seal -2- in the groove on the guide frame.

Fig 5: Identifying Seal Beads

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CAUTION:

Risk Of Contaminating Camshaft Bearing With Excess Sealant.

Do not apply sealant beads thicker than indicated.

-- Apply sealant beads -1, 3 and 4- to the clean guide frame sealing surfaces as shown in the illustration.

Thickness of sealant beads: 2.5 mm.

NOTE:

The Guide Frame Must Be Installed Within 5 Minutes After Applying The Sealant.

-- Place the guide frame on the cylinder head.

NOTE:

Ensure Camshafts Can Be Inserted In Guide Frame Axial Bearing Without Force.

-- Install the :T40116 into the guide frame and cylinder head.

Fig 6: Identifying Guide Frame Securing Pins T40116

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-- Tighten the guide frame bolts. Refer to Figure.

Fig 7: Bearing Frame Tightening Sequence

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NOTE:

The Sealant Must Harden For Approximately 30 Minutes After Installing The Guide Frame.

-- Drive in the sealing plugs -arrows- until they are flush.

Fig 8: Driving Sealing Plugs In Flush

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-- Remove the :T40116 with the :T10133/3 .

Fig 9: Identifying Guide Frame Securing Pins T40116 With Impact Puller T10133/3

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

Fig 10: Identifying Intake Camshaft TDC

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NOTE:

When Tightening The Bolt, Use Pliers To Counterhold The Socket.

-- Position a lever or ratchet with the :T10035 on the bolt and turn the camshaft until the threaded hole for the :T40070 faces up.

-- Then install the :T40070 loosely on the intake camshaft.

The :T40070 is correctly positioned when the holes for the cylinder head bolts remain free.

-- Change the camshaft adjuster bolt -2- and the 24 mm socket -1- to the exhaust camshaft.

-- Turn the exhaust camshaft until the threaded hole for the :T40070 faces up.

-- At the same time, position a 24 mm open end wrench on the :T40070 and turn the :T40070 against the exhaust camshaft in direction of -arrow-.

Fig 11: Adapting Camshaft Adjuster Screw And Socket 24 To Exhaust Camshaft

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-- Install the :T40070 on the exhaust camshaft by hand to prevent damage to the threads (a second technician is needed).

-- Tighten the :T40070 to 25 Nm -arrows-.

Fig 12: Mounting Camshaft Locating Tool T40070 To Both Cylinder Heads

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-- Turn the crankshaft to "TDC" in direction of engine rotation -arrow-.

Fig 13: Identifying Notch -Arrow A- On T40257 Must Face Color Dash -Arrow B- On Vibration Damper

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-- Install the :3242 in the hole and tighten to 20 Nm. Rotate the crankshaft -1- back and forth slightly to center the pin completely, if necessary.

Fig 14: Identifying Crankshaft Holder 3242

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Install in reverse order of removal.Note The Following:

-- Install the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Position the camshaft timing chain on the camshafts. Refer to Installing .

CAUTION:

Risk Of Damaging Valves And Piston Heads After Working On Valve Train.

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