Camshafts, Installing

• 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.

-- 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 And Cylinder Head

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Fig 2: Placing Exhaust Camshaft In Cylinder Head Cover

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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.

-- 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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• 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.

• Pay attention that the cylinder head cover is not tilted.

With Markings on the Cylinder Head Cover, Excluding Engine Code DTJA:

Fig 5: Identifying Intake Camshaft With Adapter T40266

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-- 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 in direction of - arrow B-.

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

Fig 6: Turning Exhaust Camshaft W/ T40266

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With Markings on the Cylinder Head Cover, Engine Code DTJA:

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-- Turn the intake camshaft with the Assembly Tool:T40427  in the direction of -arrow B- until the marks -1 and 2- align. Push the Camshaft Lock:T40271/2  into the chain sprocket splines in direction of -arrow A-.

-- Turn the exhaust camshaft with the Assembly Tool:T40427  in the direction of -arrow B- until the marks -1 and 2- align. Push the Camshaft Lock:T40271/1  into the chain sprocket splines in direction of -arrow A-.

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Continuation for All:

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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".