Cylinder Bank 1 (Right) Camshaft Housing, Removing And Installing: Installing

Replace bolts that were tightened with an additional turn after removing them.
Replace the seal after removal.
The hydraulic lifters and roller rocker lever are inserted.
Pay attention to the camshaft housing pairing number and cylinder head. Refer to Figure.

When only one camshaft housing is removed the "TDC" position of the camshaft must be checked when the camshaft housing is installed.

CAUTION:

Risk of destroying the engine by adjusting the valve timing.

- The camshafts must be in TDC point.

-- Remove the Camshaft Position Sensor 4 -G301-. Refer to CAMSHAFT POSITION SENSOR, REMOVING AND INSTALLING .

The exhaust camshaft -2- has a flattened side -1-. The flattened side needs to be visible through the installation opening of the corresponding camshaft position sensor in "TDC" position (example image).

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The crankshaft is locked using the Locking Pin:T10492 or Crankshaft Locking Pin:T40069 at "TDC" point.
The Camshaft Positioning Tool :T40331/1 is tightened on the right camshaft housing.

-- To prevent contamination of the lubricating system with sealant residue, place a clean cloth over the open engine components.

Fig 1: Cleaning Sealing Surfaces

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CAUTION:

Risk of injuring the eyes from sealant residue.

- Wear protective eyewear.

-- Remove any sealant residue on the camshaft housing -1- and cylinder head using a rotating plastic brush.

-- Clean any oil or grease off the sealing surfaces.

Be sure to check the expiration date of the sealant.

Fig 2: Cut Tube Nozzle At Front Marking
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-- Cut the tube nozzle at the front marking (nozzle diameter: about 2.5 mm).

-- Check if the alignment sleeves -arrows- for centering the camshaft housing are installed.

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-- Check if the check valve -2- is inserted.

-- Insert the seal -5-.

CAUTION:

There is a risk that the lubrication system could be blocked by excess sealant.

- Do not apply sealant bead thicker than indicated.

-- Apply sealant beads -1, 3 and 4- on the clean sealing surfaces of the camshaft housings.

Sealant bead thickness: 3.0 mm
Install the camshaft housing within five minutes of applying the sealant.

Procedure, if the engine is removed due to preliminary work.

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-- Position the camshaft housing -1- on the cylinder head but do not press on the sealant beads yet.

The sealant must not get into the threaded holes.

-- Insert the Locating Pins:T40116 into the camshaft housing and cylinder head.

Procedures, where the engine is NOT removed:

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-- Position the camshaft housing -1- on the cylinder head but do not press on the sealant beads yet.

The sealant must not get into the threaded holes.

-- Insert the Locating Pins:T40116 into the front camshaft housing and cylinder head.

-- Insert the Camshaft Adjustment Pins:T40060 into the rear camshaft housing and cylinder head.

Continuation:

-- Next install all bolts for the camshaft housing by hand and then tighten.

-- Remove the Locating Pins:T40116 with the Injector/Combustion Chamber Seal Tool Set - Sliding Hammer :T10133/3 .

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-- If necessary remove the Camshaft Adjustment Pins:T40060 using pliers.

Install in reverse order of removal.

-- Insert the lower section of the noise insulation.

-- Install the right high pressure pipe. Refer to HIGH PRESSURE PIPE, INSTALLING .

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

-- Install the fuel injectors. Refer to FUEL INJECTORS, REMOVING AND INSTALLING .

-- Position the camshaft timing chain (adjust the valve timing). Refer to CAMSHAFT TIMING CHAIN, REMOVING FROM CAMSHAFTS .

-- Install the Camshaft Position Sensor 4 -G301-. Refer to CAMSHAFT POSITION SENSOR, REMOVING AND INSTALLING .

Additional procedures depending on the model. Refer to CAMSHAFT HOUSING, REMOVING AND INSTALLING .