Camshaft, Removing And Installing, Engine With One Camshaft Adjuster

Special tools and workshop equipment required

Assembly Tool : T10352B , Assembly Tool : T10352/3 , Assembly Tool : T10352/4
Locking Pin (3 pc.): T40011
Chain Tensioner Lever: T40243
Wrench - 21mm: T40263
Adapter: T40266
Tensioner Locking Tool: T40267
Camshaft Locks: T40271
Camshaft Lock - Component 1: T40271/1
Camshaft Lock: T40271/2
Adapter: T40314
Sealant. Refer to the Parts Information.

Removing

The cylinder head cover sealing surfaces on the cylinder head must not be worked on.
The camshaft bearings are integrated in the cylinder head or cylinder head cover. Before removing the cylinder head cover the tension from the camshaft timing chain must be released.
During installation, all cable ties must be installed at the same location.

Preliminary work may be required depending on the model. Refer to CAMSHAFT, REMOVING AND INSTALLING .

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

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

-- Remove the vacuum pump. Refer to VACUUM PUMP, REMOVING AND INSTALLING .

-- Remove the engine support. Refer to ENGINE SUPPORT, REMOVING AND INSTALLING .

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

Fig 1: Identifying Vibration Damper With Counterhold - Vibration Damper T10355

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

TIP:

The combination of the : T40263 , : T40314 and 24 mm socket are better suited than the : T10355 for positioning the vibration damper.

-- Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER, REPLACING .

Pay attention to the direction of rotation: the control valves have left-hand threads - risk of damaging the threads.

Fig 2: Identifying Assembly Tool T10352 To Remove Control Valve
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-- Remove the left and right control valve in direction of -arrow-.

Depending on the version of the control valve use one of the tools listed:

: T10352A
: T10352/1A
: T10352/2
: T10352/3
: T10352/4

-- Remove the control valve in direction of -arrow- using the : T10352/2 .

-- To do so, use the : T40263 , : T40314 and 24mm socket to counterhold the crankshaft at the vibration damper.

Fig 3: Using T40263 & T40314

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-- Remove the bolts -arrows-.

Fig 4: Bearing Bracket Bolts

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Carefully remove the bearing bracket without tilting - risk of damage.

-- Remove the bearing mount.

-- Remove the bolts -arrows-.

Fig 5: Identifying Bolts

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-- Remove the bolt -arrow-.

Fig 6: Identifying Bolt

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-- Install the : T40243 -arrows-.

Fig 7: Identifying Lever T40243 -Arrows-, Installation

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-- Press the chain tensioner circlip -1- together and hold it.

-- Slowly press and hold the : T40243 in direction of -arrow-.

-- Secure the chain tensioner with the : T40267 .

Fig 8: Securing Chain Tensioner With T40267

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-- Remove the : T40243 .

-- Bolt the : T40271/2 to the cylinder head and slide into the splines on the chain sprocket in direction of -arrow 2-. Rotate the intake camshaft with the : T40266 in direction of -arrows 1- if necessary.

Fig 9: Identifying Camshaft Clamp T40271/2 And Assembly Tool T40266

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-- Install the : T40271/1 on the cylinder head.

Fig 10: Identifying Camshaft Lock - Component 1T40271/1

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The help of a second technician is necessary for the following step.

-- Turn the exhaust camshaft with the : T10172A in direction of -arrow A- and hold. Remove the bolt -1- and guide the tensioning rail -2- downward. Turn the camshaft clockwise -A- until the : T40271/1 can be slid, in direction of -arrow B-, into the chain sprocket splines -C-

-- Check the installation position -C- of the : T40271/1 .

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

Fig 11: Identifying Guide Rail

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-- Press the oil pump chain tensioner bracket in direction of -arrow- and lock with : T40011 .

Fig 12: Identifying Locking Pin T40011

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-- Remove the bolt -1- and remove the chain tensioner.

-- Remove the bolts -1- and remove the guide rail -2-.

Fig 13: Identifying Bolts And Glide Rail

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-- Remove the camshaft timing chain from the camshaft sprockets and guide downward.

-- Install the : T10531/3 . The flat area -1- points upward toward the cylinder head when in the "TDC point". Install the : T10531/4 . Turn the crankshaft with a 32 mm open end wrench counter-clockwise out of "TDC".

Fig 14: Identifying Assembly Tool - Turning Over Tool T10531/3

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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 -2- and bring the camshaft into the rest position.

Fig 15: Identifying Adapter T40266 And Intake Camshaft

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-- Use the : T10172A to turn the exhaust camshaft in direction of -arrow A-, slide the : T40271/1 out of the chain sprocket splines in direction of -arrow B- and bring the camshaft into the rest position.

Fig 16: Identifying Counterhold - Multiple Use T10172A

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-- Remove the cylinder head cover bolts in -1 to 6- sequence.

Fig 17: Cylinder Head Cover Bolt Loosening Sequence

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-- Pry up the cylinder head cover -2- using a tool for example a screwdriver -1- starting at the chain side.

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-- Remove the cylinder head cover.

-- Remove the camshaft and cover the open engine components.

-- If necessary for continuing work: mark the roller rocker lever and hydraulic lifter for reinstallation, remove them and place on a clean surface.

Camshafts, Installing

NOTE:

Sealing surfaces must be completely free of oil and grease.

Pay attention that all roller rocker levers rest on the valve stem ends.

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

-- 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.

-- Lubricate the running surfaces of both camshafts.

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

Fig 18: Identifying Intake Camshaft And Cylinder Head

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-- Insert the exhaust camshaft -1- in the cylinder head cover. Turn the cam lobes of cylinder 4 -arrows- upward.

Fig 19: Identifying Exhaust Camshaft And Cylinder Head Cover

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-- Turn the intake camshaft -1- and the exhaust camshaft -2- until the markings -arrows- are in the position shown.

Fig 20: Identifying Intake Camshaft And Exhaust Camshaft

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-- The cams of the intake camshaft -1- and the exhaust camshaft -2- must point upward as shown -arrows-.

Fig 21: Identifying Intake Camshaft And Exhaust Camshaft

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

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CAUTION:

Risk of engine damage due to excess sealant in the lubrication system.

- Do not apply sealant bead thicker than indicated.

Sealant bead thickness: 1.5 to 2.5 mm

-- Mount the cylinder head cover 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.

Fig 22: Identifying Cylinder Head Cover

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-- Replace the cylinder head cover bolts.

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

NOTE:

Pay attention that the cylinder head cover is not tilted.

-- Turn the intake camshaft with the : T40266 in direction of -arrow A- until the marks -1 and 2- align. Push the : T40271/2 in the chain sprocket splines -B-.

Fig 23: Identifying Intake Camshaft With Adapter T40266

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-- Turn the exhaust camshaft using the : T10172A in direction of -arrow A- until the markings -1 and 2- align. Slide the : T40271/1 into the chain sprocket splines in direction of -arrow B-. The mark -2- is offset slightly to the right.

Fig 24: Identifying Camshaft Lock T40271/1

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-- Turn the crankshaft on the hex fitting -2- to the "TDC point". The flat area -1- faces upward toward the cylinder head when in the "TDC point".

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Installing the Camshaft Timing Chain

Fig 25: Camshaft Timing Chain And Camshaft Sprocket

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-- Engage the camshaft timing chain with the painted links -arrows- on the camshaft pins.

-- Place the camshaft timing chain on the intake camshaft, exhaust camshaft and the crankshaft. Position the painted chain links -arrows- on the marks on the chain sprockets.

Fig 26: Camshaft Timing Chain On Intake Camshaft

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-- Install the guide rail -2- and tighten the bolts -1-.

Fig 27: Identifying Bolts And Glide Rail

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-- Install the upper guide rail -1-.

Fig 28: Identifying Guide Rail

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The help of a second technician is necessary for the following step.

Fig 29: Identifying Counterhold - Kit - Multiple Use T10172

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I - Turn the exhaust camshaft using the : T10172A slightly in direction of -arrow A-. Slide the : T40271/1 out of the chain sprocket splines in direction of -arrow B-.

II - Release the camshaft in the direction of -arrow C-, until the timing chain touches the guide rail -1-. Hold the camshaft in this position, install the tensioning rail -2- and tighten the bolts -3-. Release the camshaft.

-- Turn the intake camshaft with the : T40266 in direction of -arrow 1- until the : T40271/2 can be pushed out of the chain sprocket splines -2-. Release the camshaft.

Fig 30: Identifying Assembly Tool T40266 And Camshaft Clamp T40271/2

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-- Remove the : T40271/1 and : T40271/2 .

-- Install the bolts -arrows- and tighten them. Tightening specification -item ) Bolt.

Fig 31: Identifying Bolts

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

Fig 32: Bearing Bracket Bolts
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-- Mount the bearing bracket and the bolts -arrows- hand-tight.

-- Remove the : T40267 .

Fig 33: Securing Chain Tensioner With T40267

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-- Tighten the bearing bracket bolts -arrows-. Tightening specification OVERVIEW - CAMSHAFT TIMING CHAINS .

Fig 34: Bearing Bracket Bolts

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-- Install the chain tensioner -2- and tighten the bolt -1-. Remove the : T40011 , the oil pump chain tensioner must come into contact with the cut-out in the oil pan upper section -arrow-.

Fig 35: Identifying Chain Tensioner

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-- Check the adjustment. The painted chain links -arrows- must line up with the markings on the chain sprockets.

Fig 36: Identifying Painted Chain Links Must Line Up With Markings On Chain Sprockets

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-- Install the control valve -item ) Control Valve.

-- Let the engine turn a second time in the direction of engine rotation.

NOTE:

Due to the ratio, the painted chain links no longer match up after the engine has been turned.

-- Remove the : T10531/4 and remove the : T10531/3 .

Fig 37: Identifying Assembly Tool - Turning Over Tool T10531/3

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-- Install the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER, REPLACING .

-- Install the engine support. Refer to ENGINE SUPPORT, 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 .

-- 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 CAMSHAFT, REMOVING AND INSTALLING .

After Removing or Replacing the Camshafts the Adaptation Values for the Chain Length must be Adapted Again.

-- Connect the Vehicle Diagnostic Tester.

-- Select Diagnostic operating mode and Start diagnostics .

-- Select the Select individual test tab and select the following tree structure consecutively:

Drivetrain
Select the engine code and engine
01 - OBD-capable systems .
01 - Engine Electronics
01 - Engine electronics, functions
01 - Chain length diagnostic adaptation

Tightening Specifications

Refer to OVERVIEW - VALVETRAIN