Camshaft, Removing And Installing, Engine With Guide Rail Version 1: Installing

WARNING: This page is about a different variant/trim than selected.

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.

The crankshaft must not be at "TDC".

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

CAUTION:

Risk of Injuring the Eyes from Sealant Residue.

- Wear protective eyewear.

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

-- Remove any sealant residue on the cylinder head using the flat-blade scraper.

-- 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.

-- Install the cam adjustment actuator. Refer to CAM ADJUSTMENT ACTUATOR, REMOVING AND INSTALLING .

-- 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 1: Identifying Intake Camshaft And Cylinder Head

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Fig 2: Placing Exhaust Camshaft In Cylinder Head Cover

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CAUTION:

Risk of Injuring the Eyes Due to the Sliding Bar Ball Springing Out.

- Wear protective eyewear.

-- Place the exhaust camshaft in the cylinder head cover as shown. The cam pair -A and B- must be pushed together.

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

Fig 3: Locating Alignment Marks

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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

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

Fig 4: Turning Camshafts

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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 in direction of -arrow B-.

Fig 5: Identifying Intake Camshaft With Adapter T40266

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-- 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 6: Turning Exhaust Camshaft W/ T40266

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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 7: 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 8: Camshaft Timing Chain And Intake Camshaft

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

Fig 9: Removing Glide Rail

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-- Install the upper guide rail -1-.

Fig 10: 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 in direction of -arrow B-.

II - Release the camshaft in 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 11: 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 12: Identifying Bolts

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

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NOTE:

The adapter sleeve -1- is not present on every bearing bracket.

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

Fig 13: Identifying Bolts
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-- Mount the bearing bracket and the bolts -arrows- hand-tight.

-- Remove the : T40267 .

Fig 14: Securing Chain Tensioner With T40267

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

-- 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 15: 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 16: Identifying Painted Chain Links Must Line Up With Markings On Chain Sprockets

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-- Install the control valves -item ) Control Valves.

-- 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 17: 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 the appropriate Service Information .

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