Camshaft, Removing And Installing: 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 -1- as well as from any sealing surface 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.

-- 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 2: Identifying Special Tool T40191

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WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Install the camshaft with the Camshaft Spacers T40191 as illustrated. Move the spacers into the correct position if necessary.

NOTE:

If available, use a second set of Camshaft Spacers T40191 or reposition the Camshaft Spacer T40191/1.

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

Fig 3: Identifying Camshaft Markings

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NOTE:

Ignore the self-made markings.

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

Fig 4: Check Alignment

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

Fig 5: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 1 Mm)

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

Fig 6: Apply Silicone Sealant On Clean Sealing Surface

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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.

-- 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 sealant using the Seal Installer - Selector Shaft Oil Seal T10174.

Fig 7: 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 8: 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 9: 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 10: 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 11: 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 12: 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 13: 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 14: 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 15: 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 16: 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 17: Identifying Bolt

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

-- Install the Camshaft Pins T40196 as illustrated.

Fig 18: Identifying T40196 Installation Locations

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-- Turn the crankshaft 4 turns in the direction of engine rotation.

-- Remove the Camshaft Pins T40196.

-- 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 OVERVIEW - HIGH PRESSURE PUMP .

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

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

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

Assemble in reverse order of disassembly.