Camshaft, Removing And Installing: Installing

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The sealing surfaces must be free of oil and grease.
Pay attention that all roller rocker levers rest on the valve stem ends.

-- Remove any sealant residue from the groove on the cylinder head cover as well as on sealing surfaces. They must be free of oil and grease.

In the case that the crankshaft has been turned in the meantime:

-- Turn the crankshaft on the hex fitting -2- to "TDC" point.

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In "TDC" point the flattened position -1- is in an imaginary vertical line between the camshaft sprockets.

-- Then turn the crankshaft 90° counter-clockwise out of "TDC".

-- Bring the pin of the cam adjustment actuator into the installation position. Refer to Installing - The cam adjustment actuator pin must be brought into the installation position. .

-- Lubricate the running surfaces of both camshafts.

CAUTION:

Risk of injuring the eyes due to the sliding bar ball springing out.

- Wear protective eyewear.

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

Fig 1: Identifying Intake Camshaft And Cylinder Head

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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 in direction of -arrows-.

Fig 2: Placing Exhaust Camshaft In Cylinder Head Cover

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

Fig 3: Locating Alignment Marks

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NOTE:

The illustration shows the version with mark -B- applied at the factory.

On versions with a mark made earlier, the mark -A- and the mark applied earlier must align on the cylinder head.

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

Fig 4: Sealant Application Locations

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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 (0.059 to 0.098 inches)

-- 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 in direction of -arrows- until the cylinder head cover lays >>free of tension<< on the cylinder head.

Fig 5: Turning Camshafts

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-- Replace the cylinder head cover bolt after removing.

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

Pay attention that the cylinder head cover is not tilted.

With Marks in the Cylinder Head Cover

Fig 6: Identifying Intake Camshaft With Adapter T40266

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-- 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 in direction of -arrow B-.

-- Turn the exhaust camshaft with the : T40266 in direction of -arrow A- until the marks -1 and 2- align. Push the : T40271/1 in the chain sprocket splines in direction of -arrow B-. The mark -2- is offset slightly to the right.

Fig 7: Turning Exhaust Camshaft W/ T40266

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Without Marks in the Cylinder Head Cover

Fig 8: Identifying Markings And Camshaft Clamp T40271/2

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

-- 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 .

Fig 9: Identifying Markings And Camshaft Locating Tool T40271/1

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

Continued for All Engines:

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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".

In "TDC" point the flattened position -1- is in an imaginary vertical line between the camshaft sprockets.

Installing the Camshaft Timing Chain

Fig 10: 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 11: Camshaft Timing Chain And Intake Camshaft

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

Fig 12: Removing Glide Rail

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-- Install the upper glide rail -1-.

Fig 13: Removing Guide Rail

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

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I - Turn the exhaust camshaft slightly in direction of -arrow A- using the : T40266 and push the : T40271/1 out of the chain sprocket splines -B-.

II - Release the camshaft in the direction -arrow C-, until the timing chain touches the glide 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 in direction of -arrow 2-. Release the camshaft.

Fig 14: 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 ) OVERVIEW - CYLINDER HEAD - List Item: Bolt.

Fig 15: Identifying Bolts

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

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-- Check if the adapter sleeve -1- is installed. (Not present on every bearing bracket.)

Fig 16: Identifying Bolts

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Carefully mount the bearing bracket without tilting it.

-- Attach the bearing mount and install the bolts -arrows- all the way by hand.

-- Remove the : T40267 .

Fig 17: Securing Chain Tensioner With T40267

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

-- Install the chain tensioner -2-. The wire clip must come in to contact with the oil pan upper section opening -arrow-. Tighten the bolt -1- and remove the : T40011 .

Fig 18: Identifying Chain Tensioner

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-- Checking adjustment:

Fig 19: Identifying Painted Chain Links Must Line Up With Markings On Chain Sprockets

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The painted chain links must align with the markings on the chain sprockets. -arrows-.

-- Install the control valves -item ) OVERVIEW - CAMSHAFT TIMING CHAINS - List Item: Control Valves.

-- Turn the engine twice in the direction of engine rotation.

TIP:

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

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

Fig 20: 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 .

Checking Valve Timing - with Marks on the Cylinder Head Cover

Fig 21: Identifying Vibration Damper With Counterhold - Vibration Damper T10355

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TIP:

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

-- 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 cover.

Checking Valve Timing - without Marks on the Cylinder Head Cover

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TIP:

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

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

The marks applied to the cylinder head cover -arrows- must align with the marks on the chain sprockets -1-.
The notch on the vibration damper must align with the marking on the lower timing chain cover -2-.

NOTE:

If the self-made markings are no longer visible, check the valve timing. Refer to VALVE TIMING, CHECKING .

Continued for All Engines:

-- 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 oil separator. Refer to OIL SEPARATOR, REMOVING AND INSTALLING .

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

-- Install the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

CAUTION:

There is a risk of damaging the valves and piston crowns after working on valvetrain from adjusted valve timing.

- To ensure that the vales do not make contact when starting, carefully rotate the engine at least two full revolutions.

-- When working on the chain drive perform an adaptation using the Vehicle Diagnostic Tester.

There are additional procedures depending on the model. Refer to CAMSHAFT, REMOVING AND INSTALLING .

Tightening Specifications

Refer to OVERVIEW - VALVETRAIN
Refer to NOISE INSULATION, REMOVING AND INSTALLING .