Camshaft, Removing And Installing, 1.8L Engine: Installing

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The sealing surfaces must be free of oil and grease.
Pay attention that all roller rocker levers rest on the valve stem ends.
The crankshaft must not be at "TDC".

-- If the crankshaft was turned in the meantime: bring the piston for cylinder 1 to TDC and then turn the crankshaft back again slightly.

-- Remove any sealant residue from the groove on the cylinder head cover as well as on the sealing surfaces.

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CAUTION:

- Wear protective eyewear.

-- Remove any seal out of the groove in the cylinder head cover -1- as well as from any sealing surface using, for example, a rotating plastic brush.

-- Clean any oil or grease off the sealing surfaces.

TIP:

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Be sure to check the expiration date of the sealant.

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

For New Camshafts:

-- Transfer the self-made markings from the old camshafts to the new camshafts.

Versions without Notches:

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-- Lubricate the running surfaces of both camshafts.

-- Place the camshafts into the cylinder head; the factory markings -arrows- must be located as shown.

NOTE:

Ignore the self-made markings.

Versions with Notches:

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-- Lubricate the running surfaces of both camshafts.

-- Place the camshaft in the cylinder head; the notches -arrows- must be perpendicular to each other.

NOTE:

Ignore the self-made markings.

Continued for All Engines:

Different Sealant Bead Contour:

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Version 1:

Version 2:

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-- Apply the silicone sealant on the clean sealing surface of the cylinder head cover as shown -arrows-.

Sealant bead thickness: approximately 2 mm.

NOTE:

Pay attention that the cylinder head cover is not tilted.

The cylinder head cover must be installed within five minutes after application of silicone sealant.

The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake pipe screen.

-- Tighten the bolts in several steps, tightening sequence. Refer to Figure.

-- Drive the cap -1- in without sealant using the :T10174 .

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Installation depth -a- = 1 to 2 mm.

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-- Turn the vibration damper to the "TDC" -arrow- position.

When turning the crankshaft, make sure that no components are not damaged by the timing chain.
The notch on the vibration damper must align with the arrow marking on the lower timing chain cover.

-- Turn the intake camshaft in direction of -arrow 1- until the marking -3- aligns with the :T40271/2 .

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-- Slide the :T40271/2 into the chain sprocket splines in the direction of -arrow 2-.

With Wrench Clearance:

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-- Turn the exhaust camshaft in the direction of -arrow 1- until the marking -3- aligns with the :T40271/1 .

-- Slide the :T40271/1 into the chain sprocket splines in the direction of -arrow 2-.

Without Wrench Clearance:

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-- Bolt the :T40271/1 to the cylinder head.

The help of a second technician is necessary for the following steps.

-- Turn the exhaust camshaft in the direction of -arrow A- until the marking -1- aligns with the :T40271/1 .

-- Slide the :T40271/1 into the chain sprocket splines in the direction of -arrow B-.

-- Mount the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN, REMOVING FROM CAMSHAFTS .

-- Install the air filter housing. Refer to AIR FILTER [CAEB, CAED, CPMA, CPMB] .

There are additional procedures depending on the model. Refer to CAMSHAFT, REMOVING AND INSTALLING .