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

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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• Assembly Tool: T40427  for engine code DTJA

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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 TWO CAMSHAFT ADJUSTERS .

-- 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 "TDC".

• 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 9: Identifying Assembly Tool T10352/2

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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 

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

-- Remove the bolts -arrows-.

• Carefully remove the bearing mount, without tilting.

-- Remove the bearing mount.

-- Remove the bolts -arrows-.

-- Remove the bolt -arrow-.

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

-- 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  .

-- Remove the Chain Tensioner Lever:T40243  .

Excluding Engine Code DTJA:

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

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

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

-- Hold the exhaust camshaft with the Adapter:T40266  in the direction of -arrow A-. Remove the bolt -1- and guide the tensioning rail -2- downward. Continue to turn the camshaft clockwise in the direction of -arrow A- until the Camshaft Lock:T40271/1  can be pushed into the chain sprocket splines in the direction of -arrow B-.

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

Engine Code DTJA:

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-- Install the Camshaft Lock:T40271/2  on the cylinder head.

-- Push the fixation in the splines of the chain sprocket in direction of -arrow B-.

-- If required, turn the intake camshaft with the Assembly Tool:T40427  slightly back and forth in direction of -A arrows-.

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

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

-- Hold the exhaust camshaft using the Assembly Tool:T40427  . Remove the guide pin -1- and remove the tensioning rail -2- downward.

-- Turn the exhaust camshaft clockwise -arrow A- again until the Camshaft Locks -T40271/1- can be pushed in the chain sprocket splines in direction of -arrow B-.

Continuation for All:

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

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

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

-- Remove the bolts -1- and remove the guide rail -2-.

-- 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".

Excluding Engine Code DTJA:

-- 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.

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

Engine Code DTJA:

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-- Reduce the intake camshaft pretension using the Assembly Tool:T40427  in the direction of -arrow B-, pull the Camshaft Lock:T40271/2  out of the chain sprocket splines in direction of -arrow A-, and bring the camshaft into its resting position.

-- Reduce the exhaust camshaft pretension using the Assembly Tool:T40427  in the direction of -arrow B-, pull the Camshaft Lock:T40271/1  out of the chain sprocket splines in direction of -arrow A-, and bring the camshaft into its resting position.

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Continuation for All:

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

-- 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.