Camshaft, Removing And Installing, Engine With Guide Rail Version 2: Installing

• The crankshaft must not be at "TDC".
• Replace the bolts that were tightened with an additional turn after removing them.

-- Make sure all the roller rocker levers lie correctly on the ends of the valve stems and are clipped onto the respective hydraulic lifters.

-- If the crankshaft was turned in the meantime: bring the piston for cylinder 1 to TDC and then turn the crankshaft back again slightly.

-- To prevent contamination of the lubricating system with sealant residue, place a clean cloth over the open engine components.

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

-- Remove any sealant residue from the groove on the cylinder head cover as well as on the sealing surfaces.

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

• The adjusting element pins must not be in the outward position.

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-- Press down the cam adjustment actuator pins in direction of -arrow- by hand.

-- Lubricate the running surfaces of both camshafts.

-- If the camshafts are replaced, the markings -arrow- need to be transferred onto the new camshafts.

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-- Place the intake camshaft -A- in the cylinder head. Turn the cam lobes of cylinder 4 -arrows- upward.

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-- Place the exhaust camshaft in the cylinder head cover as shown. The cam pair -A- and -B- must be pushed together.

-- Turn the exhaust camshaft until the markings -A- and -B- align.

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

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• Sealant bead thickness: 1.5 to 2.5 mm

-- Secure the camshaft and place the cylinder head cover with the camshaft on the cylinder head.

-- Lightly push on the cylinder head cover by hand and while doing so turn the camshaft slightly until the cylinder head cover lays >>free of tension<< on the cylinder head.

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-- Replace the cylinder head cover bolts.

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

-- Turn the intake camshaft in direction of -arrow 1- until the marking -3- aligns with the : T40271/2  .

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-- Slide the : T40271/2  into the chain sprocket splines in direction of -arrow 2-.

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

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

-- Turn the vibration damper in the "TDC" position.

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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-.

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

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-- Install the upper guide rail -2-.

-- Use the : T40266  to turn the exhaust camshaft in direction of -arrow 1-, slide out the : T40271/1  from the chain sprocket splines in direction of -arrow 2- and release the camshaft.

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

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-- Use the : T40266  to turn the intake camshaft in direction of -arrow 1-, slide out the : T40271/2  from the chain sprocket splines in direction of -arrow 2- and release the camshaft.

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Checking Valve Timing - with Marks on the Cylinder Head Cover 

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-- Turn the vibration damper in the "TDC" position.

• The notch on the vibration damper must align with the arrow marking on the lower timing chain cover -arrow-.
• The markings -1- on the camshaft chain sprockets must be opposite the markings -2 and 3- on the cylinder head.

Checking Valve Timing - without Marks on the Cylinder Head Cover 

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

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

-- The notch on the vibration damper must align with the marking on the lower timing chain cover -3-.

Continued for All Engines: 

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-- Install the bolts -arrows- and tighten them. Tightening specification, refer to -item  4- Bolt (OVERVIEW - CYLINDER HEAD).

-- Lubricate the holes -arrows- with engine oil.

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• Carefully connect the bearing bracket without tilting - risk of damage.

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

-- Remove the : T40267  .

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-- Tighten the bearing bracket bolts. Refer to Figure.

-- Install the control valves, refer to -item  7- (OVERVIEW - CAMSHAFT TIMING CHAIN, ENGINE WITH TWO CAMSHAFT ADJUSTERS).

-- Install the vacuum pump. Refer to VACUUM SYSTEM .

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

-- Install the upper timing chain cover. Refer to TIMING CHAIN COVER, REMOVING AND INSTALLING, ENGINE WITH TWO CAMSHAFT ADJUSTERS .

There are additional procedures depending on the model. Refer to OVERVIEW - VALVETRAIN, ENGINE WITH TWO CAMSHAFT ADJUSTERS  or OVERVIEW - VALVETRAIN, ENGINE WITH ONE CAMSHAFT ADJUSTER . .

-- After performing work on the chain drive the adaptation value in the engine control module must be adapted. To do so, turn on the ignition and select the following menu items on the Vehicle Diagnostic Tester:

• 01 - Engine Electronics 
• Guided Functions 
• 01 - Adaptation after repair work on the chain drive