Camshaft, Removing And Installing, 1.8L Engine: Installing

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 valve stem ends.

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

WARNING:

Danger of eye injury.

Wear protective eyewear.

CAUTION:

Risk of contaminating lubricating system and bearing.

Cover open parts of engine.

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

Fig 1: Cleaning Sealing Surfaces

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

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

Fig 2: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

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-- Lubricate the running surfaces of both camshafts.

For new camshafts

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

All

Fig 3: Camshaft Recesses

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-- Place the camshaft into the cylinder head; the recesses -arrows- must be perpendicular to each other.

-- Replace the cylinder head cover bolts.

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

Fig 4: Clean Cylinder Head Cover Sealing Surface Silicone Sealant Locations

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Sealant bead thickness: 2 to 3 mm.

NOTE:

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 tube.

Note the expiration date of the sealing compound.

Sealant.

-- Tighten bolts in several stages in tightening sequence Figure.

NOTE:

Make sure the cylinder head cover is not tilted.

Drive the cap -1- in without sealant using the Seal Installer - Selector Shaft Oil Seal T10174.

Fig 5: Driving Cap In Using Thrust Piece T10174

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- a -: 1 to 2 mm

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

Fig 6: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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The notch on the vibration damper must line up 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 Camshaft Lock - Component 2 T40271/2.

Fig 7: Attach T40271/2 To Cylinder Head

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-- Slide the Camshaft Lock - Component 2 T40271/2 into the chain sprocket splines in the -direction of arrow 2-.

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

Fig 8: Attach T40271/1 To Cylinder Head

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

-- Position the markings on the chain links -arrows- at the chain sprockets -1- to mount the camshaft timing chain.

Fig 9: Identifying Markings On Chain Links

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-- Install the upper guide rail -2-.

-- Turn the exhaust camshaft in -direction of arrow 1-, slide the Camshaft Locks T40271/1 out of the chain sprocket splines in -direction of arrow 2- and release the camshaft.

Fig 10: Turn Exhaust Camshaft

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-- Remove the Camshaft Locks - Component 1 T40271/1.

-- Guide the tensioning rail -2- upward and install the bolt -1-.

Fig 11: Identifying Tensioning Rail Bolt

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-- Turn the intake camshaft in -direction of arrow 1-, slide the Camshaft Locks - Component 2 T40271/2 out of the chain sprocket splines in -direction of arrow 2- and release the camshaft.

Fig 12: Turn Intake Camshaft

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-- Remove the Camshaft Lock - Component 2 T40271/2.

-- Check the valve timing. The camshaft timing chain and cylinder head -arrows- must align with the markings on the chain sprockets -1-.

Fig 13: Check Valve Timing

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-- The markings for the camshaft timing chain and the camshaft timing chain guide rail -2- must align.

-- The notch on the vibration damper must be opposite the marking on the lower timing chain cover -3-.

NOTE:

If the self-made markings are no longer visible, check the valve timing. Refer to VALVE TIMING, CHECKING .

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

Fig 14: Bearing Bracket Bolts

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-- Depending on the version, remove either the Locking Pin (3 pc.) T40011 or the Tensioner Locking Tool T40267.

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

-- Install the bolt -arrow-.

Fig 15: Identifying Bolt

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-- Install the control valve. Refer to -item 6- Control Valve (See Figure).

-- Install the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Install the vacuum pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING or OVERVIEW - HIGH PRESSURE PUMP .

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

Assemble in reverse order of disassembly.

-- Reset the service position. Refer to SERVICE POSITION, PERFORMING AND RESETTING .