Camshaft, Removing And Installing: Installing

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

-- Remove any remaining sealant residue out of the groove in the cylinder head cover as well as from the 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.

-- 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 Camshaft Spacers Special Tool T40191

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

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

Fig 3: Identifying Camshaft Markings

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

Fig 4: Checking Camshafts 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.

Sealant, refer to parts.

-- 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.

-- 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 "Top Dead Center (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 T40271/2.

Fig 9: Attaching T40271/2 To Cylinder Head

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-- Slide the Camshaft Lock 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 T40271/1.

Fig 10: Attaching T40271/1 To Cylinder Head

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-- Slide the Camshaft Lock 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 track -2-.

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

Fig 12: Turning Exhaust Camshaft

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-- Remove the Camshaft Lock 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 Lock 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 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: Checking 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-.

-- 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 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- (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 VACUUM PUMP, REMOVING AND INSTALLING .

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

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

-- Install the ignition coils with power output stages, refer to IGNITION COILS WITH POWER OUTPUT STAGES, REMOVING AND INSTALLING .

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

-- Install the engine cover, refer to ENGINE COVER, REMOVING AND INSTALLING .

Further installation is done in the reverse order of removal.

Hybrid Vehicles 

-- Install the torque support and crossmember, refer to TORQUE SUPPORT AND CROSSMEMBER, REMOVING AND INSTALLING .

-- Install the front noise insulation, refer to OVERVIEW - NOISE INSULATION .

Tightening specifications 

• Refer to OVERVIEW - VALVETRAIN