Installing Camshafts, Setting Timing - Cylinder Bank 1-3

→ Protect components from dirt and contamination.

→ Clean or replace dirty components.

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

Information 

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

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: Fixing Crankshaft In Place Using Locating Pin 9595/1

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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 1-3

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4. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
   1. 4.1. Check that all bucket tappets are installed correctly.
5. Fit the outlet camshaft and sprocket.
   Fig 3: Identifying Outlet Camshaft And Sprocket (View Of Cylinder Bank 1-3)

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   1. 5.1. Check that the friction plate is fitted in the sprocket.
      Fig 4: Identifying Friction Plate In Sprocket

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   2. 5.2. Screw in the central screw but make sure that the sprocket can still turn slightly.
   3. 5.3. Lift the timing chain and position the camshaft and sprocket at the overlapping position of cylinder 1. The cams must be facing downwards at an angle with respect to the cylinder head wall and the camshaft must lie loosely in the bearing positions.
   4. 5.4. 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 5: Identifying Marking On Camshafts 1-3 At Overlap

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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.

6. After fitting the outlet camshaft, the sprocket must be aligned as follows with the driver for the high-pressure pump.
   1. 6.1. Cylinder head positioned vertically:  The sprocket -1-  must be pre-positioned towards the top left with the deeper recess on the driver (approx. 13.5 mm) -2-  at approx. 15 degrees with respect to the sealing face of the cylinder head.
      Fig 6: Identifying Sprocket Angle

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7. Fit the intake camshaft.
   1. 7.1. Check that the friction plate is fitted on the shaft.
      Fig 7: Identifying Position Of Friction Plate On Intake Camshaft

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   2. 7.2. Lift the timing chain and engage and secure the camshaft controller. Guide the intake camshaft -2-  into the controller -1-  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 bearing positions.
      Fig 8: Identifying Intake Camshaft With Camshaft Controller

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   3. 7.3. The square marking (data matrix code) on the camshaft must be facing the observer.
   4. 7.4. Screw in the internal Torx central screw (T55, M12 x 1.5 x 110) by hand until the controller can still turn.
8. Check cam position of cylinder 1 before fitting the bearing saddle and bearing covers. The cams must be facing the cylinder head wall and must point downwards at an angle.
   1. 8.1. Check the position of the outlet sprocket again (position of driver for high-pressure pump).
9. Use a torch to check that the timing chains are on the tensioning and guide rails between the guide pins -arrow-  .
   Fig 9: Locating Guide Pins On Tensioning And Guide Rails

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10. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
11. Fit bearing saddle and bearing covers.
    1. 11.1. Fit bearing saddle and bearing covers and observe markings.
    2. 11.2. Fit four external Torx screws (E10, M6 x 55) on the bearing saddle.
    3. 11.3. Fit two external Torx screws (E10, M6 x 37) on each of the bearing covers.
    4. 11.4. Fit and tighten screws according to the specified tightening sequence.

       → Initial tightening torque for bearing covers and bearing saddle: 5 Nm (3.5 ft. lb.) 

       → Re-tightening bearing covers and bearing saddle: 5 Nm (3.5 ft. lb.) 

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

       Fig 10: Tightening Sequence For Mounting Camshafts 1-3

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12. Check axial bearing clearance by pulling and pressing on the camshaft controller and sprocket.
    1. 12.1. There must be perceptible clearance because otherwise the shafts will have to be fitted again.
13. Screw in and tighten chain tensioner with a new seal.

    → Tightening torque for chain tensioner: 80 Nm (59 ft. lb.) 

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

14. Check cam position for cylinder 1 and markings again.
    Fig 11: Locating Cam Position For Cylinder 1 At Overlap

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    Fig 12: Locating Marking On Camshafts 1-3 At Overlap

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15. The adjusting device is positioned on the reconditioned dihedron of the camshafts -arrows-  .
    Fig 13: Locating Position Of Dihedron Of Camshafts 1-3

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    1. 15.1. Check the position of the intake and outlet side.
       1. A  - A = Outlet
       2. E  - E = Intake
       1. Staking tool
       2. Staking guide
          Fig 14: Fitting Position Of Staking Tool For Cylinder Bank 1-3

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16. Fit special tool staking tool 9772  on the cylinder head and camshafts.
    1. 16.1. Secure on the cylinder head with four M6 x 25 screws and tighten screws hand-tight.
       Fig 15: Identifying Staking Tool Screws For Cylinder Bank 1-3

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17. Tighten adjusting screw on the staking tool by turning it clockwise.

    → Tightening torque for adjusting screw: 10 Nm (7.5 ft. lb.) 

    Fig 16: Tightening Adjusting Screw On Staking Tool

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18. Turn the crankshaft clockwise (running direction of engine)  to the TDC marking  at the vibration damper.
    1. 18.1. This position is marked TDC 1/4  on the vibration damper.
    2. 18.2. Fix in place using a long Locating Pin 9595/1  .
       Fig 17: Fixing Crankshaft In Place Using Locating Pin 9595/1

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19. Check position of the outlet sprocket -1-  .
    1. 19.1. The driver must now be positioned towards the top left with the deeper recess on the driver (13.5 mm) -2-  at approx. 45 degrees with respect to the sealing face of the cylinder head.
       Fig 18: Identifying Outlet Sprocket Position

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    2. 19.2. If this is not the case, the outlet camshaft must be re-aligned once again with the sprocket.
20. Tighten central screws on sprocket and camshaft controller to the prescribed initial tightening torque.
    Fig 19: Identifying Central Screws On Camshaft Timing Gears

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    1. 20.1. Tighten central screw on sprocket -1-  initially and counter with a holding wrench 9775  while doing this.

       → Initial tightening torque for central screw on outlet sprocket: 30 Nm (22 ft. lb.) 

    2. 20.2. Tighten central screw on camshaft controller -2-  initially and counter with a long open-ended wrench (a/f 32) at the driver -3-  while doing this.

       → Initial tightening torque for central screw on camshaft controller: 35 Nm (26 ft. lb.) 

21. Remove special tool staking tool 9772  .
    1. 21.1. Loosen the adjusting screw. A creaking noise is completely normal due to the tension in the tool.
    2. 21.2. Unscrew fastening screws on the cylinder head and remove the tool.
22. Tighten central screws on the sprocket and camshaft controller to the prescribed final torque using a torque angle wrench.
    1. 22.1. Tighten central screw on sprocket and counter with a Holding Wrench 9775 -1-  while doing this.

       → Final tightening torque angle for central screw on outlet sprocket: 65 ° 

       Fig 20: Tightening Central Screw On Camshaft Controller And Counter With Holding Wrench 9775

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    2. 22.2. Tighten central screw on camshaft controller and counter with a long open-ended wrench (a/f 32) -1-  while doing this.

       → Final tightening torque angle for central screw on camshaft controller: 125 ° 

       Fig 21: Tightening Central Screw On Camshaft Controller And Counter With Long Open-Ended Wrench

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23. Then check the position of the camshafts on both sides again (pay attention to overlapping position).
    1. 23.1. It must be possible to screw in the adjusting screw by hand at the staking tool 9772  .
    2. 23.2. Remove the tool and complete the engine.