Removal & Installation

(if necessary inlet or exhaust side)

The inlet or exhaust camshaft can be replaced in the vehicle.

IMPORTANT: Incorrect assembly/removal without special tools exposes the camshaft to the risk of preliminary damage or breakage. The valves may also be bent by contact with the piston crown. Comply without fail with the job instructions, recommended special tools and work sequence.

Removal

Removal of camshafts is described separately from installation.

The assembly sequence for removal and installation is different.

Remove VANOS adjustment unit.

IMPORTANT: Cylinder for chain tensioning piston is under spring pressure.

Unfasten cylinder for chain tensioning piston.

Fig 1: Unfastening Cylinder For Chain Tensioning Piston

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Press down secondary chain tensioner at top and lock with special tool 11 3 292.

Fig 2: Pressing Down Secondary Chain Tensioner At Top And Lock With Special Tool

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Release nuts, remove sensor gear (1).

Fig 3: Removing Sensor Gear

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Remove plate spring (2).

Fig 4: Removing Plate Spring

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Release nuts on inlet side and remove corrugated washer (7).

Fig 5: Removing Corrugated Washer

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Unfasten screws.

Fig 6: Unfastening Screws

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Lift off exhaust and inlet chain wheels together with chain, friction washer (3) and toothed shaft (4).

NOTE: Toothed shaft (4) is and identical part for exhaust and inlet sides. Store used toothed shafts in order and reinstall on the same side only.

Fig 7: Lifting Off Exhaust And Inlet Chain Wheels

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Remove toothed shaft (5) with toothed sleeve (6).

Fig 8: Removing Toothed Shaft With Toothed Sleeve

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Unfasten screws. Remove secondary chain tensioner.

Fig 9: Removing Secondary Chain Tensioner

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Release screw-in pin.

Fig 10: Releasing Screw-In Pin

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Feed chain wheel (1) towards front out of timing chain (2).

Fig 11: Feeding Chain Wheel Towards Front Out Of Timing Chain

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NOTE: Timing chain remains positioned over exhaust camshaft.

Fig 12: Locating Timing Chain

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If necessary, release screw-in pin on inlet side.

Remove thrust washer.

Fig 13: Removing Thrust Washer

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Remove sensor gear.

Fig 14: Removing Sensor Gear

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IMPORTANT: Do "not" release these screws.

Fig 15: Locating Screws

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Unscrew studs.

Fig 16: Unscrewing Studs

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Pull special tool 11 2 300 back until flywheel is no longer secured in position.

Fig 17: Securing Flywheel

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IMPORTANT: To prevent damaging valves when fitting the camshafts, no pistons should be in TDC position.

Lift timing chain and hold under tension.

Rotate engine against direction of engine rotation approx. 30° using the central bolt.

Fig 18: Lifting Timing Chain And Holding Under Tension

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IMPORTANT: Bearing cap 1 of inlet camshaft is centered with adapter sleeves.

To prevent inlet camshaft from tilting in bearing strip, release nuts and remove bearing cap 1.

Fig 19: Locating Bearing Cap 1 Of Inlet Camshaft

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Fit special tool 11 3 260 to cylinder head and screw into spark plug threads in cylinders 1 and 4.

Fig 20: Fitting Special Tool To Cylinder Head

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Turn the eccentric shaft to tension the bearing caps.

Unfasten nuts on bearing cover.

Fig 21: Turning Eccentric Shaft To Tension Bearing Caps

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Relieve tension on eccentric shaft and remove special tool 11 3 260.

Remove bearing covers and place to one side in orderly fashion. Remove camshaft.

Fig 22: Removing Bearing Covers

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NOTE: If the cylinder head is then to be removed, remove complete bearing strip with bucket tappets.
Locate bucket tappets in bearing strip with special tool 11 3 250.
Lift out complete bearing strip with bucket tappet.

NOTE: Only re-use used bucket tappets in the same tappet bore.

Fig 23: Locating Bucket Tappets In Bearing Strip With Special Tool

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Check bearing points on bucket tappets for signs of wear (scoring).

Fig 24: Checking Bearing Points On Bucket Tappets For Signs Of Wear

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Bearing strips are marked "A" for exhaust side and "E" for inlet side.

Fig 25: Identifying Bearing Strips

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Note centering dowels on retaining pins at bearing points 2 and 7.

Install bearing strips.

Fig 26: Installing Bearing Strips

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Installation

Installation of camshafts is described separately from removal.

The assembly sequence for removal and installation is different.

NOTE: Camshafts, bearings and bearing caps, friction washers, all splines on toothed shafts and spline hubs must be oiled before installation.

IMPORTANT: The bucket tappets expand when not subjected to load by the camshaft and therefore require some time before they can be pushed back down. During a rapid assembly sequence, the "closed" valves may still be open and be in contact with the piston.

Comply with following waiting periods after installing camshaft and before cranking engine back to TDC position.

Room temperature (20 °C) 4 mins
10 °C... 20 °C 11 mins
0 °C... 10 °C 30 mins

Pull up timing chain and feed in exhaust camshaft.

Position timing chain on exhaust camshaft.

Fig 27: Positioning Timing Chain On Exhaust Camshaft

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Install camshafts so that cam tips on inlet and exhaust valves on 1st cylinder face one another.

Fig 28: Installing Camshafts

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Fit bearing cover.

NOTE: Bearing caps are marked from exhaust side:

A1... A7 for exhaust side

E1... E7 for inlet side

Fig 29: Fitting Bearing Cover

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Fit special tool 11 3 260 to cylinder head and screw into spark plug threads in cylinders 1 and 4.

Fig 30: Fitting Special Tool To Cylinder Head

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Turn the eccentric shaft to tension the bearing caps.

Tighten down bearing cover.

Tightening torque, see 11 31 1AZ in ENGINE - TIGHTENING TORQUES .

Remove special tool 11 3 260.

Fig 31: Turning Eccentric Shaft To Tension Bearing Caps

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IMPORTANT: Do not damage the cylinder head.

If necessary, machine open-end wrench accordingly.

Align camshafts with open-end wrench.

Fig 32: Aligning Camshafts With Open-End Wrench

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Fit special tool 11 3 240 to camshafts on cylinder 6. Align camshafts so that special tool 11 3 240 rests without gaps on cylinder head.

Fig 33: Fitting Special Tool To Camshafts On Cylinder 6

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Attach special tool 11 3 244 to special tool 11 3 240 and locate by way of spark plug thread.

Fig 34: Attaching Special Tool

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Lift timing chain and hold under tension.

Turn engine from 30° before TDC position in direction of rotation as far as TDC position.

Fig 35: Lifting Timing Chain And Holding Under Tension

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Secure crankshaft in firing TDC position with special tool 11 2 300.

IMPORTANT: Remove special tool 11 2 300 before starting engine.

Fig 36: Securing Crankshaft In Firing TDC Position With Special Tool

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Automatic transmissions only:

Illustration does not show automatic transmission.

IMPORTANT: On engines with automatic transmissions, there is shortly before the special tool bore (1) a large bore (2) which can be confused with the special tool bore.

If special tool 11 2 300 is secured in the correct bore (1), the engine can no longer be cranked at the central bolt.

Fig 37: Securing Crankshaft (Automatic Transmissions)

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Position sensor gear on inlet camshaft.

Fig 38: Positioning Sensor Gear On Inlet Camshaft

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Fit thrust washer and tighten down with dowels.

Tightening torque, see 11 31 11AZ in ENGINE - TIGHTENING TORQUES .

Fig 39: Fitting Thrust Washer And Tightening Down With Dowels

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Feed chain wheel onto timing chain so that arrow on chain wheel faces separating face of upper side of cylinder head.

Fig 40: Feeding Chain Wheel Onto Timing Chain

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Insert special tool 11 4 220 in cylinder head and bring adjustment screw into contact with tensioning rail, but do not pretension timing chain yet.

Check arrow on chain wheel to separating face of upper side of cylinder head, reposition chain wheel if necessary.

Fig 41: Inserting Special Tool In Cylinder Head

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Insert and tighten down screw-in pin.

Tightening torque, see 11 31 11AZ in ENGINE - TIGHTENING TORQUES .

Fig 42: Inserting And Tightening Down Screw-In Pin

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Install secondary chain tensioner.

Fig 43: Installing Secondary Chain Tensioner

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Fit toothed sleeve (6) and align to toothed shaft in camshaft so that tooth gaps are opposed.

Fig 44: Fitting Toothed Sleeve And Aligning To Toothed Shaft In Camshaft

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Secure toothed shaft (5).

Insert pin of toothed shaft (5) into tooth gaps of splines on camshaft and toothed sleeve (6).

Fig 45: Securing Toothed Shaft

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Push in toothed shaft (5) until the longitudinal holes in the toothed sleeve (6) are positioned centrally with respect to the thread.

Fig 46: Pushing In Toothed Shaft

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Place chain wheels in special tool 11 6 180, position tooth gap on inlet chain wheel as shown in illustration and feed on chain.

Fig 47: Placing Chain Wheels In Special Tool

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IMPORTANT: Do not alter position of chain wheels with respect to chain when removing from special tool 11 6 180.

Remove chain with sprocket wheels positioned from special tool 11 6 180 and so that tooth spaces oppose each other on inlet side.

Fig 48: Removing Chain With Sprocket Wheels

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Align chain with sprocket wheels so that tooth spaces are positioned exactly over each other on inlet side.

Fig 49: Aligning Chain With Sprocket Wheels

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Secure toothed shaft (4).

Insert pin of toothed shaft (4) into tooth gaps of splines on camshaft and chain wheel.

Fig 50: Securing Toothed Shaft

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Push in toothed shaft (4) until approx. 1 mm of splines can still be seen.

Fig 51: Pushing In Toothed Shaft

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Note installation direction of corrugated washer (7), "FRONT" lettering must be visible.

Install corrugated washer, tighten nuts by hand but do not tighten down fully yet.

Fig 52: Installing Corrugated Washer

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Insert screws on exhaust side, initially tighten to approx. 5 Nm and then slacken off again half a turn.

Fig 53: Inserting Screws On Exhaust Side

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Fit thrust washer (3).

Fig 54: Fitting Thrust Washer

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Note installation direction of cup spring (2), "F" lettering must be visible.

NOTE: If "F" lettering is no longer visible on an engine that has been run:

Install cup spring (2) so that small locating diameter of spring (2) points to sensor gear.

Fit cup spring (2) in position.

Fig 55: Installing Cup Spring

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Position sensor gear (1) so that arrow on sensor gear faces separating face of upper side of cylinder head.

Install nuts and tighten by hand but do not tighten down fully yet.

Fig 56: Positioning Sensor Gear

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Withdraw toothed shaft (5) up to stop.

Fig 57: Withdrawing Toothed Shaft

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Press down secondary chain tensioner at top and remove special tool 11 3 292.

Fig 58: Pressing Down Secondary Chain Tensioner

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Preload tensioning rail with special tool 11 4 220 by rotating adjusting screw with special tool 00 9 250 or standard torque wrench to 0.7 Nm.

Fig 59: Preloading Tensioning Rail With Special Tool

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Preload cup spring slightly by pressing on sensor gear (1) and tighten nuts by hand.

IMPORTANT: Do not tighten down nuts fully.

Fig 60: Preloading Cup Spring Slightly By Pressing On Sensor Gear

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Remove gasket.

Check dowel sleeves (1) for damage and correct installation position.

Keep sealing face clean and free of oil.

Fig 61: Checking Dowel Sleeves For Damage

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IMPORTANT: Fit special tool 11 6 150 "without gasket" only.

If gasket remains underneath special tool 11 6 150, camshaft timing will be "incorrectly" set.

Attach special tool 11 6 150 "without gasket", tighten nuts by hand and then tighten down uniformly until special tool 11 6 150 is in full contact with cylinder head.

Fig 62: Fitting Special Tool "Without Gasket" Only

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Insert screws (1) on exhaust side and initially tighten to approx. 5 Nm.

Fig 63: Inserting Screws On Exhaust Side

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Initially tighten nuts (2) on exhaust side and nuts (3) on inlet side to approx. 5 Nm.

Fig 64: Tightening Nuts On Exhaust Side

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Tighten down screws (1) on exhaust side.

Tightening torque, see 11 31 3AZ in ENGINE - TIGHTENING TORQUES .

Fig 65: Tightening Down Screws On Exhaust Side

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Tighten down nuts (2) on exhaust side and nuts (3) on inlet side.

Tightening torque, see 11 31 11AZ in ENGINE - TIGHTENING TORQUES .

Fig 66: Tightening Down Nuts On Exhaust Side And Nuts On Inlet Side

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Pull special tool 11 2 300 back until flywheel is no longer secured in position.

Fig 67: Securing Flywheel

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Remove special tool 11 3 244 and special tool 11 3 240.

Fig 68: Removing Special Tools

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Crank engine twice in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face one another.

Fig 69: Aligning Cam Tips On Inlet And Exhaust Camshafts

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Secure crankshaft in firing TDC position with special tool 11 2 300.

IMPORTANT: Do not turn the engine back.

Remove special tool 11 2 300 before switching on the engine.

Fig 70: Securing Crankshaft In Firing TDC Position With Special Tool

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Fit special tool 11 3 240 to camshafts.

Fig 71: Fitting Special Tool To Camshafts (1 Of 2)

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NOTE: The timing is correctly set if the special tool 11 3 240 rests without a gap on the cylinder head or protrudes up to 1 mm to the inlet side.

The timing must be reset if the special tool 11 3 240 protrudes to the exhaust side.

Fig 72: Fitting Special Tool To Camshafts (2 Of 2)

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Remove special tool 11 6 150.

Install VANOS adjustment unit.

Assemble engine.

Fig 73: Installing VANOS Adjustment Unit

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