Camshaft, Removing And Installing, 1.8L Engine: 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, refer to 15- Cap, must be replaced (See Figure).

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

Always seal off any open channels in the intake and exhaust tract with suitable plugs. For example, from the Engine Bung Set VAS6122.

-- Perform a service position. Refer to SERVICE POSITION, PERFORMING AND RESETTING .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Disconnect the connector from Camshaft Adjustment Valve 1 -N205- -1-.

Fig 1: Disconnect Connector

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-- Remove the bolts -arrows- and then the Camshaft Adjustment Valve 1 -N205-.

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

Fig 2: Identifying Upper Timing Chain Cover - Tightening Sequence

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Fig 3: Identifying Assembly Tool T10352 To Remove Control Valve

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CAUTION:

The control valve has a left thread.

-- Remove the control valve in the -direction of the arrow- with the Central Valve Assembly Tool T10352 or Central Valve Assembly Tool T10352/1, depending on the version.

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

Fig 4: Bearing Bracket Bolts

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

Fig 5: Identifying Markings -1- On Camshafts Aligned To Point Upward

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The notch on the vibration damper and the marking on the lower cover for timing chain must be opposite one another -arrow-.
The markings -1- on the camshafts must point upward.

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

Fig 6: Mark camshaft timing chain and the cylinder head

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-- In addition, mark the camshaft timing chain to the camshaft timing chain guide rail -2- with a permanent marker.

-- Remove the plug -arrow-.

Fig 7: Identifying Plug

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-- Remove the bolts -arrows-.

Fig 8: Identifying Bolts

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-- Remove the bolt -arrow-.

Fig 9: Identifying Bolt

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Two different chain tensioners may be installed depending on the version:

Fig 10: Identifying Version 1

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Version 1

-- Install the Chain Tensioner Lever T40243 -arrows-.

-- Lift up the locking wedge for the chain tensioner by inserting a scriber or a suitable screwdriver into the chain tensioner opening in -direction of arrow 1-. Slowly press and hold the Chain Tensioner Lever T40243 in -direction of arrow 2-.

-- Secure the chain tensioner using the Locking Pin (3 pc.) T40011.

Fig 11: Securing Chain Tensioner

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Version 2

Fig 12: Identifying Version 2

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-- Install the Chain Tensioner Lever T40243 -arrows-.

-- Press the chain tensioner locking ring -1- together and slowly press and hold the Chain Tensioner Lever T40243 in -direction of arrow-.

-- Secure the chain tensioner with the Tensioner Locking Tool T40267.

Fig 13: Securing Chain Tensioner

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All Versions

Fig 14: Bolt Camshaft Locating Tool

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-- Remove the Chain Tensioner Lever T40243.

-- Bolt the Camshaft Locks - Component 2 T40271/2 to the cylinder head and push the chain sprocket splines in the -direction of arrow 2-. If necessary, turn the intake camshaft with a wrench in -direction of arrow 1-.

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

Fig 15: Identifying Tensioning Rail Bolt

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-- Install the Camshaft Lock - Component 1 T40271/1 on the cylinder head.

Fig 16: Attach T40271/1 To Cylinder Head

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-- Turn the exhaust camshaft with the wrench in the -direction of arrow 1- and slide the Camshaft Locks T40271/1 into the chain sprocket splines in -direction of arrow 2-.

NOTE:

Mark the camshafts to the Camshaft Lock - Component 1 T40271/1 and Camshaft Lock - Component 2 T40271/2.

Fig 17: Mark Camshaft Sprocket

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

Not making the marks will result in much more work when reinstalling.

-- Mark the camshaft sprocket to the Camshaft Lock - Component 1 T40271/1 and the Camshaft Lock - Component 2 T40271/2 -arrow-.

-- Remove the upper guide rail -1- by unlocking the latch with a screwdriver and pushing the guide rail 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.

-- Turn the intake camshaft with a wrench in the -direction of arrow 1-, slide the Camshaft Lock - Component 2 T40271/2 out of the chain sprocket splines in -direction of arrow 2- and bring the camshaft into the rest position.

Fig 18: Turn Intake Camshaft With A Wrench In Direction Of Arrow

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-- Turn the exhaust camshaft with a wrench in the -direction of arrow 1-, slide the Camshaft Lock - Component 1 T40271/1 out of the chain sprocket splines in -direction of arrow 2- and bring the camshaft into the rest position.

Fig 19: Turn Exhaust Camshaft With A Wrench In Direction Of Arrow