Camshaft, Removing and Installing, 1.8L Engine: Installing

• 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.
  CAUTION: Risk of Injuring the Eyes from Sealant Residue

  • 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.

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• Clean any oil or grease off the sealing surfaces.

TIP: 

Be sure to check the expiration date of the sealant.

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

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For New Camshafts: 

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

Versions without Notches: 

• Lubricate the running surfaces of both camshafts.
• Place the camshafts into the cylinder head; the factory markings -arrows- must be located as shown.

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Versions with Notches: 

• Lubricate the running surfaces of both camshafts.
• Place the camshaft in the cylinder head; the notches -arrows- must be perpendicular to each other.

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Continued for All Engines: 

Different Sealant Bead Contour: 

Version 1: 

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Version 2: 

• Apply the silicone sealant on the clean sealing surface of the cylinder head cover as shown -arrows-.
  • Sealant bead thickness: approximately 2 mm.

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• Tighten the bolts in several steps, tightening sequence. Refer to Cylinder Head Cover - Tightening Specifications and Sequence .
• Drive the cap -1- in without sealant using the -T10174-.
  • 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-.
• Slide the -T40271/2- into the chain sprocket splines in the direction of -arrow 2-.

With Wrench Clearance: 

• 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-.

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Without Wrench Clearance: 

• 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 HOUSING, REMOVING AND INSTALLING .

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There are additional procedures depending on the model. Refer to Camshaft Timing Chain, Removing from Camshafts .