Installing Camshafts, Setting Timing - Cylinder Bank 1-3

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Information 

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

• Torx screws: (E..) for external Torx, (T..) for internal Torx. 
• Hexagon-head bolts (internal and external hexagon): Wrench size (a/f) 

1. Continue to turn the crankshaft clockwise (running direction of engine)  to 60° before TDC at the vibration damper.
   1. 1.1. This position is marked U 3/6  on the surface.
   2. 1.2. Fix in place using a long locating pin 9595/1 -1-  .
      Fig 1: Identifying Mark U 3/6 On Surface

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2. Turn the engine on the assembly support until cylinder bank 1-3 is at the top.
3. Fit lower part of bearing saddle -1-  .
   1. 3.1. Check position of oil bores and position and fit the component on the dowel sleeves.
      Fig 2: Identifying Lower Part Of Bearing Saddle

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4. Oil the bearing surfaces of the camshafts with new engine oil.
   1. 4.1. When rebuilding the engine, apply a light coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
   2. 4.2. Check that all hydraulic tappets are installed correctly.
5. Lightly coat the sealing surface of the central screws for the sprocket and camshaft controller with new engine oil.
6. Fit the outlet camshaft and sprocket.
   Fig 3: Identifying Outlet Camshaft And Sprocket

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   1. 6.1. Check that the (new) friction plate is fitted in the sprocket.
      Fig 4: Identifying Friction Plate In Sprocket

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   2. 6.2. Screw in the central screw but make sure that the sprocket can still turn slightly.
   3. 6.3. Lift the timing chain and position the camshaft and sprocket at the overlapping position of cylinder 1. The cams must be facing outwards -arrows-  at an angle with respect to the cylinder head wall and the camshaft must lie loosely in the bearings.
      Fig 5: Locating Cam Position On Cylinder

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   4. 6.4. Another feature is the data matrix code marking on the reconditioned surface next to the dihedron -inset-  . These markings must be facing the observer at overlapping position.
      Fig 6: Identifying Mark On Camshafts

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      Information 

      The outlet sprocket must be positioned correctly in order to build up the pressure of the high-pressure pump correctly when starting the engine.

7. 3.4-litre DFI engine only:  After fitting the outlet camshaft, the sprocket must be aligned as follows with the driver for the high-pressure pump.
   1. 7.1. Cylinder head is vertical:  The sprocket -1-  must be positioned towards the top left using the deeper recess on the driver (15 mm) -2-  at approx. 15 degrees with respect to the sealing face of the cylinder head.
      Fig 7: Identifying Driver For High-Pressure Pump Position

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8. Fit the intake camshaft.
   1. 8.1. Check that the (new) friction plate is fitted on the shaft.
      Fig 8: Locating Friction Plate On Intake Camshaft

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   2. 8.2. Lift the timing chain and engage and secure the camshaft controller. Guide the intake camshaft into the controller and set it to the overlapping position of cylinder 4. The cams must be facing downwards at an angle with respect to the spark-plug recess and the camshaft must lie loosely in the bearings.
      Fig 9: Identifying Intake Camshaft With Camshaft Controller

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   3. 8.3. The square marking (data matrix code) on the camshaft must be facing the observer at the overlap.
   4. 8.4. Screw in the internal Torx central screw (T55, M12 x 1.5 x 110) by hand until the controller can still turn.
9. Check cam position of cylinder 1 before fitting the bearing saddle and bearing covers. The cams must be facing the outer cylinder head wall and must point downwards at an angle.
   1. 9.1. Check the position of the outlet sprocket again (position of driver for high-pressure pump).
      CAUTION: Timing chains positioned incorrectly

      • Too much wear on sprockets and timing chains
      • Engine damage

      → Perform a visual inspection to check the position of the timing chains on the tensioning and guide rails.

10. Use a torch to check that the timing chains are on the tensioning and guide rails between the guide pins -arrow-  .
    Fig 10: Locating Guide Rails

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11. Oil the bearing surfaces of the camshafts with new engine oil.
    1. 11.1. When rebuilding the engine, apply a light coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
12. Fit bearing saddle and bearing covers (observe matching numbers).
    1. 12.1. Position bearing saddle and bearing covers.
    2. 12.2. Fit four external Torx screws (E10, M6 x 55) on the bearing saddle.
    3. 12.3. Fit two external Torx screws (E10, M6 x 37) on each of the bearing covers.
    4. 12.4. Fit and tighten screws according to the specified tightening sequence -1 to 16-  .

       => Initial tightening torque for bearing covers and bearing saddle: 5 Nm (3.5 ftlb.) 

       => Final tightening torque angle for bearing covers and bearing saddle: 50 ° 

       Fig 11: Tightening Sequence For Mounting Camshafts

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13. Check axial bearing clearance by pulling and pressing on the camshaft controller and sprocket.
    1. 13.1. There must be perceptible clearance because otherwise the shafts will have to be fitted again.
14. Screw in and tighten chain tensioner with a new seal.

    => Tightening torque for chain tensioner: 80 Nm (59 ftlb.) 

    Set the timing, cylinder bank 1-3:  Essentially, the timing for cylinder bank 1-3 is set in the same way as for cylinder bank 4-6.

15. Check cam position for cylinder 1 -arrows-  and data matrix code position -inset  again.
    Fig 12: Locating Cam Position For Cylinder

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    Fig 13: Identifying Mark On Camshafts

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16. The adjusting device is positioned on the reconditioned dihedron of the camshafts -arrows-  .
    Fig 14: Positioning Dihedron Of Camshafts

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    1. 16.1. Check the position of the intake and outlet side.
       1. A  - A = Outlet
       2. E  - E = Intake
       1. Staking tool
       2. Staking guide
       Fig 15: Locating Outlet/Intake Staking Guide

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17. Fit special tool staking tool 9772 -1-  on the cylinder head and camshafts.
    1. 17.1. Tighten four screws (M6 x 25) -2-  on the cylinder head hand-tight.
       Fig 16: Identifying Screws For Cylinder Bank

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18. Tighten adjusting screw -arrow-  on the staking tool by turning it clockwise using a torque wrench -1-  .

    => Tightening torque for adjusting screw: 10 Nm (7.5 ftlb.) 

    Fig 17: Adjusting Screw On Staking

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19. Turn the crankshaft clockwise (running direction of engine)  to the TDC marking  at the vibration damper.
    1. 19.1. This position is marked TCD 1/4-inset-  on the vibration damper.
    2. 19.2. Fix in place using a long locating pin 9595/1 -2-  .
       Fig 18: Identifying Bolts On Vibration Damper

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20. 3.4-litre DFI engine only:  Check position of the outlet sprocket -1-  .
    1. 20.1. The driver must be positioned towards the top left with the deeper recess on the driver (15 mm) -2-  at approx. 45 degrees with respect to the sealing face of the cylinder head.
    2. 20.2. If this is not the case, the outlet camshaft must be re-aligned once again with the sprocket.
       Fig 19: Positioning Driver For High-Pressure Pump

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21. Tighten central screws on sprocket and camshaft controller to the prescribed initial tightening torque.
    1. 21.1. Tighten central screw on sprocket -1-  initially, countering with a holding wrench 9775  .

       => Initial tightening torque for central screw on outlet sprocket: 30 Nm (22 ftlb.) 

    2. 21.2. Tighten central screw on camshaft controller -2-  initially, countering with a long open-ended wrench (a/f 32) at the driver -3-  .

       => Initial tightening torque for central screw on camshaft controller: 35 Nm (26 ftlb.) 

       Fig 20: Identifying Central Screws On Camshaft Timing Gears

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       Information 

       Before final tightening (torque angle) of the central screws, the special tool staking tool 9772  must be removed.

22. Remove special tool staking tool 9772  .
    1. 22.1. Loosen the adjusting screw. A creaking noise is normal due to the tension in the tool.
    2. 22.2. Unscrew fastening screws on the cylinder head and remove the tool.
23. Tighten central screws on the sprocket and camshaft controller to the prescribed final torque using a torque angle wrench.
    1. 23.1. Tighten central screw on sprocket, countering with a holding wrench 9775 -1-  .

       => Final torque angle for central screw on outlet sprocket: 60 ° 

       Fig 21: Identifying Outlet Sprocket Threaded Joint

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    2. 23.2. Tighten central screw on camshaft controller, countering with a long open-ended wrench (a/f 32) -1-  .

       => Final torque angle for central screw on camshaft controller: 120 ° 

       Fig 22: Identifying Camshaft Controller Threaded Joint

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24. Then check the position of the camshafts on both sides again (pay attention to overlapping position).
    1. 24.1. It must be possible to screw in the adjusting screw by hand at the staking tool 9772  .
    2. 24.2. Remove the tool and complete the engine.