Camshaft, Removing And Installing: Removing

• The sealing surfaces of the lower cylinder head cover and on the upper cylinder head must not be reworked.
• 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 oil separator. Refer to OIL SEPARATOR, REMOVING AND INSTALLING .

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

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

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-- Turn the crankshaft using the : T40263  , : T40314  and a 24 mm socket in the direction of engine rotation -arrow- until the vibration damper is at "TDC point".

• The notch -1- on the vibration damper must align with the arrow marking -2- on the lower timing chain cover.

• The markings -arrows- on the camshafts must point upward.
  Fig 1: Identifying Mark Points On Intake And Exhaust Camshafts

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-- If the markings do not point upward, turn the crankshaft an additional turn.

Without Marks in the Cylinder Head Cover 

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-- Mark the position of the camshaft sprocket -1- with a waterproof marker, as shown on the cylinder head cover -arrows-.

Continued for All Engines: 

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

TIP:

The control valves have left-hand thread.

-- Remove the left and right control valves using the Assembly Tool -1- in the direction of -arrow-.

Fig 2: Removing Control Valve

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

• : T10352 
• : T10352/1 
• : T10352/2 
• : T10352/3 
• : T10352/4 

-- Remove the bolts -arrows- and bearing bracket.

Fig 3: Identifying Bolts

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• Carefully remove the bearing bracket without tilting it.

-- Remove the bearing mount.

-- Remove the bolts -arrows-.

Fig 4: Identifying Bolts

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-- Remove the bolt -arrow-.

Fig 5: Identifying Bolt

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-- Install the : T40243  -arrows-.

Fig 6: 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 7: Securing Chain Tensioner With T40267

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-- Remove the : T40243  .

-- Bolt : 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 : T40266  -1- in direction of -arrows- if necessary.

Fig 8: Identifying Camshaft Clamp T40271/2 And Assembly Tool T40266

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

Fig 9: Checking T40271/1 Installation Position

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

-- Hold the exhaust camshaft with the : T40266  in direction of -arrow A-. Remove the bolt -1- and guide the tensioning rail -2- downward. Turn the camshaft further clockwise in direction of -arrow A- until the : T40271/1  can slide into the chain sprocket splines direction of -arrow B-.

-- 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 10: Removing Guide Rail

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Without Marks in the Cylinder Head Cover 

Fig 11: Mark Camshaft Sprocket

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-- Mark the camshaft sprocket to the : T40271/1  and the : T40271/2  -arrow-.

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

Continued for All Engines: 

Fig 12: Identifying Locking Pin T40011

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

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

-- Remove the bolts -1- and remove the camshaft timing chain glide rail -2-.

Fig 13: Removing 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".

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

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-- Install the : T10531/4  . Turn the crankshaft with a 32 mm open end wrench 90° counter-clockwise out of "TDC".

-- 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 bring the camshaft into the rest position.

Fig 15: Identifying Adapter T40266 And Intake Camshaft

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-- 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 bring the camshaft into the rest position.

Fig 16: Identifying Camshaft Locating Tool T40271/1

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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.