Camshaft, Removing And Installing: Installing

• Tightening Specification. Refer to Figure.

-- Using a rotating plastic brush, remove any remaining sealant from the cylinder head and guide frame.

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

-- Oil running surfaces of both camshafts.

-- Place the camshafts in the cylinder head, being careful of their position so the guide frame can be laid on top without tension.

LEFT CYLINDER HEAD 

Fig 1: Identifying Intake Camshaft & Exhaust Camshaft (Left Cylinder Head)

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1. Intake camshaft
2. Exhaust camshaft

• Groove on end of shaft must lie as shown in illustration.

RIGHT CYLINDER HEAD 

Fig 2: Identifying Intake Camshaft & Exhaust Camshaft (Right Cylinder Head)

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1. Exhaust camshaft
2. Intake camshaft

• Groove on end of shaft must lie as shown in illustration.

CONTINUED FOR BOTH SIDES 

Fig 3: Identifying Compression Ring End Position

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-- Check the location of the compressor ring ends.

• The compression ring ends -1 and 2- must face upward or downward, and must never face sideways.

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

Fig 4: Cut Tube Nozzle At Front Marking

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-- Lay the seal -2- in the groove on the guide frame.

Fig 5: Identifying Seal Beads

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-- Apply sealant beads -1, 3 and 4- to the clean guide frame sealing surfaces as shown in the illustration.

• Thickness of sealant beads: 2.5 mm.

-- Place the guide frame on the cylinder head.

-- Install the :T40116  into the guide frame and cylinder head.

Fig 6: Identifying Guide Frame Securing Pins T40116

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-- Tighten the guide frame bolts. Refer to Figure.

Fig 7: Bearing Frame Tightening Sequence

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-- Drive in the sealing plugs -arrows- until they are flush.

Fig 8: Driving Sealing Plugs In Flush

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-- Remove the :T40116  with the :T10133/3  .

Fig 9: Identifying Guide Frame Securing Pins T40116 With Impact Puller T10133/3

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-- Rotate intake camshaft to "TDC" and tighten camshaft adjuster bolt -2- on camshaft with a socket SW 24 -1- inserted between.

Fig 10: Identifying Intake Camshaft TDC

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-- Position a lever or ratchet with the :T10035  on the bolt and turn the camshaft until the threaded hole for the :T40070  faces up.

-- Then install the :T40070  loosely on the intake camshaft.

• The :T40070  is correctly positioned when the holes for the cylinder head bolts remain free.

-- Change the camshaft adjuster bolt -2- and the 24 mm socket -1- to the exhaust camshaft.

-- Turn the exhaust camshaft until the threaded hole for the :T40070  faces up.

-- At the same time, position a 24 mm open end wrench on the :T40070  and turn the :T40070  against the exhaust camshaft in direction of -arrow-.

Fig 11: Adapting Camshaft Adjuster Screw And Socket 24 To Exhaust Camshaft

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-- Install the :T40070  on the exhaust camshaft by hand to prevent damage to the threads (a second technician is needed).

-- Tighten the :T40070  to 25 Nm -arrows-.

Fig 12: Mounting Camshaft Locating Tool T40070 To Both Cylinder Heads

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-- Turn the crankshaft to "TDC" in direction of engine rotation -arrow-.

Fig 13: Identifying Notch -Arrow A- On T40257 Must Face Color Dash -Arrow B- On Vibration Damper

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-- Install the :3242  in the hole and tighten to 20 Nm. Rotate the crankshaft -1- back and forth slightly to center the pin completely, if necessary.

Fig 14: Identifying Crankshaft Holder 3242

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Install in reverse order of removal.Note The Following: 

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

-- Position the camshaft timing chain on the camshafts. Refer to Installing .