Camshaft, Removing And Installing, Engine With One Camshaft Adjuster

Special tools and workshop equipment required

Assembly Tool: T10352C , Assembly Tool: T10352/3 and Assembly Tool: T10352/4

Fig 1: Assembly Tool
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Locking Pin (3 pc.): T40011

Fig 2: Identifying Locking Pin T40011
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Chain Tensioner Lever: T40243

Fig 3: Chain Tensioner Lever
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Wrench - 21mm: T40263

Fig 4: Identifying Wrench - 21mm
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Adapter: T40266

Fig 5: Adaptor
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Tensioner Locking Tool: T40267

Fig 6: Tensioner Locking Tool
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Camshaft Locks: T40271

Fig 7: Camshaft Locks
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Adapter: T40314

Fig 8: Adapter T40314
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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 ONE CAMSHAFT ADJUSTER .

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

-- Remove the vacuum pump. Refer to OVERVIEW - VACUUM PUMP .

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

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

Fig 9: 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 Wrench - 21mm: T40263 , Adapter: T40314 and 24 mm socket are better suited than the Counterhold - Vibration Damper: 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 10: Identifying Assembly Tool T10352 To Remove Control Valve
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-- Remove the left and right control valve in the direction of -arrow-.

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

Central Valve Assembly Tool: T10352
Assembly Tool: T10352/1A
Assembly Tool : T10352/2
Assembly Tool: T10352/3
Assembly Tool: T10352/4

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

-- To do so, use the Wrench - 21mm: T40263 , Adapter: T40314 and 24 mm socket to counterhold the crankshaft at the vibration damper.

Fig 11: Using T40263 & T40314

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-- Remove the bolts -arrows-.

Fig 12: 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 13: Identifying Bolts

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-- Remove the bolt -arrow-.

Fig 14: Identifying Bolt

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-- Install the Chain Tensioner Lever: T40243 -arrows-.

Fig 15: Identifying Lever T40243 -Arrows-, Installation

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

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

-- Secure the chain tensioner with the Tensioner Locking Tool: T40267 .

Fig 16: Securing Chain Tensioner With T40267

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-- Remove the Chain Tensioner Lever: T40243 .

-- Install the Camshaft Lock: T40271/2 on the cylinder head and slide it into the chain sprocket splines in the direction of -arrow 2-. If necessary, turn the intake camshaft in the direction of the arrow -1- using the Adapter: T40266 .

Fig 17: Identifying Camshaft Clamp T40271/2 And Assembly Tool T40266

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

Fig 18: Identifying Camshaft Lock - Component 1T40271/1

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

-- Use the Counterhold - Multiple Use: T10172A to turn the exhaust camshaft in the direction of the -arrow A- and hold it firmly in this position. Remove the bolt -1- and guide the tensioning rail -2- downward. Turn the camshaft clockwise -arrow A- until the Camshaft Lock: T40271/1 can be slid into the chain sprocket splines -C- in the direction of the -arrow B-.

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

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

Fig 19: Identifying Guide Rail

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-- Press the oil pump chain tensioner bracket in the direction of -arrow- and lock with Locking Pin (3 pc.): T40011 .

Fig 20: 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 21: Identifying Bolts And Glide Rail

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

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

Fig 22: Identifying Assembly Tool - Turning Over Tool T10531/3

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-- Use the Adapter: T40266 to turn the intake camshaft in the direction of the -arrow 1-, push the Camshaft Lock: T40271/2 out of the chain sprocket splines in the direction of the arrow -2-, and move the camshaft into its resting position.

Fig 23: Identifying Adapter T40266 And Intake Camshaft

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-- Use the Counterhold - Multiple Use: T10172A to turn the exhaust camshaft in the direction of the -arrow A-, slide the Camshaft Lock: T40271/1 out of the chain sprocket splines in the direction of the -arrow B- and move the camshaft into the resting position.

Fig 24: Identifying Counterhold - Multiple Use T10172A

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

Fig 25: 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 26: Identifying Intake Camshaft And Cylinder Head

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

Fig 27: 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 28: 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 29: 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 30: 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 Adapter: T40266 in the direction of the arrow -A- until the marks -1 and 2- align. Push the Camshaft Lock: T40271/2 into the chain sprocket splines -B-.

Fig 31: Identifying Intake Camshaft With Adapter T40266

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

Fig 32: 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 33: 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 34: Camshaft Timing Chain On Intake Camshaft

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

Fig 35: Identifying Bolts And Glide Rail

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-- Install the upper guide rail -1-.

Fig 36: Identifying Guide Rail

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

Fig 37: Identifying Counterhold - Kit - Multiple Use T10172

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I - Turn the exhaust camshaft slightly in the direction of the -arrow A- using the Counterhold - Multiple Use: T10172A . Push the Camshaft Lock: T40271/1 out of the chain sprocket splines in the direction of the -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 using the Adapter: T40266 in the direction of the -arrow 1- until the Camshaft Lock: T40271/2 can be pushed out of the chain sprocket splines in direction of -arrow 2-. Release the camshaft.

Fig 38: Identifying Assembly Tool T40266 And Camshaft Clamp T40271/2

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

-- Install the bolts -arrows- and tighten them. Tightening specification. Refer to -item : Bolt.

Fig 39: Identifying Bolts

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

Fig 40: Bearing Bracket Bolts
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-- Mount the bearing bracket and the bolts -arrows- hand-tight.

-- Remove the Tensioner Locking Tool: T40267 .

Fig 41: Securing Chain Tensioner With T40267

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

Fig 42: Bearing Bracket Bolts

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-- Install the chain tensioner -2- and tighten the bolt -1-. Remove the Locking Pin (3 pc.): T40011 . The oil pump chain tensioner bracket must make contact in the opening on the oil pan upper section -arrow-.

Fig 43: 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 44: 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 Assembly Tool - Knurled Nut: T10531/4 and remove the Assembly Tool - Turning Over Tool: T10531/3 .

Fig 45: 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 OVERVIEW - VACUUM PUMP .

-- 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 ONE CAMSHAFT ADJUSTER .

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