With AVS: Camshafts

Special tools and workshop equipment required

Ignition Coil Puller T40039
Assembly Tool T10352 and Assembly Tool T10352/1
Counter Hold Tool T10355
Locking Pin T40011
Thrust Piece T10174
Drift T40196
Spacers T40191

Removing

NOTE:

The sealing surfaces of the lower cylinder head cover and on the upper cylinder head must not be reworked.

The camshaft bearings are integrated in the cylinder head or cylinder head cover. The tension must be released from the camshaft timing chain before removing the cylinder head cover.

If the cylinder head cover was removed, then the cover VALVETRAIN OVERVIEW must be replaced.

During installation, cable ties must be installed at the same location.

-- Remove the engine cover -arrows-.

Fig 1: Removing Engine Cover

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-- Remove the bolts -arrows- and air guide.

Fig 2: Removing Bolts -Arrows- And Air Guide

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-- Remove both the lower air guide and the air guide hose.

-- Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Fig 3: Air Flow Housing, Electrical Connector And Guide Hose

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-- Remove the air guide hose -2-.

-- Remove the bolt -4- and the air filter housing.

NOTE:

Ignore -3-.

-- Remove the bolts on the ignition coil connector strip.

-- Disconnect the connectors -arrows- from the camshaft adjuster actuators.

Fig 4: Removing Bolts

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-- Release the connector -arrows- and disconnect all the connectors at the same time from the ignition coils.

Fig 5: Connecting Connectors To Ignition Coils

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-- Remove the ignition coils using the T40039.

Fig 6: Identifying Ignition Coil Puller T40039 To Remove Ignition Coils

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-- Remove the camshaft adjuster actuators -arrows-.

Fig 7: Removing Camshaft Adjuster Actuators

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-- Disconnect the crankcase ventilation hoses -1 and 2-.

Fig 8: Crankcase Ventilation, Tightening Sequence

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-- Remove the bolts -arrows- and remove the crankcase ventilation.

-- Disconnect the lines -1 and 3-.

Fig 9: Camshaft Position Sensor Electrical Harness Connector

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-- Disconnect the connector -2- from the Camshaft Position (CMP) sensor -G40-.

-- Remove the noise insulation. Refer to Removal and Installation .

-- Remove the right noise insulation -arrows-.

Fig 10: Identifying Right Drive Axle Heat Shield

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-- Remove the frame for the noise insulation. Refer to Removal and Installation .

-- Remove the bolts -arrows-.

Fig 11: Air Guide Pipe And Bolts

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-- Lift the clamps -1 and 2- and remove the air guide pipe.

-- Disconnect the connector from the camshaft adjustment valve 1 -N205- -1-.

Fig 12: Camshaft Adjustment Valve And Bolts

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-- Remove the bolts -arrows- and then the camshaft adjustment valve 1.

-- Remove the bolts -1 through 5- and the timing chain guard upper section.

Fig 13: Identifying Upper Timing Chain Cover - Tightening Sequence

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CAUTION:

The control valve has a left thread.

-- Remove the control valve using the T10352 or T10352/1 in direction of -arrow- depending on the version.

Fig 14: Identifying Assembly Tool T10352 To Remove Control Valve

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-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 15: Bearing Bracket Bolts

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-- Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

Fig 16: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

Fig 17: T40196 May Be Installed Only In Shown Position

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CAUTION:

The engine could be destroyed.

The T40196 may be installed only in the shown positions.

-- Install the T40196 as illustrated.

-- Turn the crankshaft 2 complete turns in the direction of engine rotation.

NOTE:

The engine must be back at "TDC".

-- Remove the T40196.

-- Mark the camshaft timing chain and the cylinder head -arrows- to match the marking on the chain sprockets -1- with a waterproof marker.

Fig 18: Marking Camshaft Timing Chain And Cylinder Head

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-- Remove the plug -arrow-.

Fig 19: Locating Plug

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-- Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner direction of -arrow 1-.

Fig 20: Identifying Chain Tensioner Locking Wedge, Screwdriver, Crankshaft And Securing Pin T40011

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-- Turn the crankshaft opposite the engine direction of rotation -arrow direction 2- and secure it with a T40011.

NOTE:

The intake camshaft switches in the engine direction of rotation.

Fig 21: Guide Tensioning Rail, Upper Guide Rai And Bolt

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NOTE:

The intake camshaft switches in the engine direction of rotation.

-- Remove the bolt -1- and guide the tensioning rail -2- downward.

-- Remove the upper guide track -3- by unlocking the latch with a screwdriver and pushing the guide track forward.

-- Remove camshaft timing chain from chain sprockets.

CAUTION:

Risk of damaging valves and piston crowns.

If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.

-- Remove the high pressure pump. Refer to Removal and Installation .

-- Remove vacuum pump. Refer to Removal and Installation .

-- Remove the cylinder head cover bolts in sequence -1 to 6-.

Fig 22: Cylinder Head Cover Loosening Sequence

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-- Remove the cylinder head cover.

-- Remove the camshafts.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of the engine.

-- Make sure that no dirt or sealant residue can get into the cylinder head.

Installing

For the correct tightening specifications, refer to VALVETRAIN OVERVIEW .

NOTE:

Sealing surfaces must be completely free of oil and grease.

The pistons must not be positioned at TDC.

Make sure that all roller cam followers make contact correctly on the valve stem ends.

Silicone sealant.

Note the expiration date of the silicone sealant.

The cover must be installed within 5 minutes after application of the silicone sealant.

-- Remove any sealant residue on the cylinder head using the flat blade scraper.

WARNING:

Danger of eye injury.

Wear protective goggles.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.

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

Fig 23: Identifying Rotating Plastic Brush To Remove Sealant Residue From Sealing Flange, Cylinder Block And Upper Part Of Oil Pan

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

-- Lubricate the running surfaces of both camshafts.

WARNING:

Danger of eye injury.

Wear protective goggles.

-- Install the camshaft with the T40191 as illustrated, move the spacers into the correct position if necessary.

Fig 24: Transfer Self-Made Markings From Old Camshafts To New Camshafts

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NOTE:

If necessary, use a second set of T40191 or T40191/1.

-- Install the camshafts into the cylinder head; the markings -arrows- must be located as shown in the illustration.

Fig 25: Installing Camshafts Into Cylinder Head

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-- Check the alignment -arrows- of the camshafts.

Fig 26: Checking Alignment

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

Fig 27: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

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

Fig 28: Apply Silicone Sealant On Clean Sealing Surface

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Thickness of sealant bead: 2 to 3 mm.

NOTE:

The cylinder head cover must be installed within 5 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 tube.

Note the expiration date of the sealing compound.

Sealant.

-- Mount the cylinder head cover on the cylinder head.

-- Replace the cylinder head cover bolts.

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

NOTE:

Make sure the cylinder head cover is not tilted.

Drive the cap -1- in without sealing using the T10174.

Fig 29: Driving Cap In Using Thrust Piece T10174

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-a-: 1 to 2 mm

WARNING:

When rotating the crankshaft, make sure the timing chain cannot damage any other components.

-- Rotate the vibration damper using the T10355 into the "TDC" position -arrow-.

Fig 30: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

NOTE:

The marked links of the camshaft timing chain must be positioned on the markings on the chain sprockets.

Fig 31: Marked Links Of Camshaft Timing Chain Must Be Positioned On Markings On Chain Sprockets

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-- Turn the intake camshaft in direction of -arrow- with the wrench and install the camshaft timing chain. The markings on the camshaft timing chain and on the cylinder head -arrows- must line up with the markings on the chain sprockets -1-.

-- Mount the bearing bracket and the bolts -arrows- hand-tight.

Fig 32: Bearing Bracket Bolts

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-- Remove the T40011.

-- Tighten the bolts -arrows-. Refer to CAMSHAFT TIMING CHAIN OVERVIEW .

-- Install the control valve CAMSHAFT TIMING CHAIN OVERVIEW .

-- Install the vacuum pump. Refer to Removal and Installation .

-- Install the high pressure pump. Refer to Removal and Installation .

Assemble in reverse order of disassembly.