Installing Camshafts, Setting Timing - Cylinder Bank 4-6

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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. 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.
      Fig 1: Fixing Crankshaft In Place Using Locating Pin 9595/1

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   2. 1.2. Fix in place using a long Locating Pin 9595/1 -1-  .
2. Turn the engine at the assembly support so that the cylinder bank to be fitted 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. When rebuilding the engine, apply a light coating of OptimolOptipit grease (Part No. 000.043.204.17) on the bearings.
   1. 4.1. Check that all hydraulic tappets are installed correctly.
5. Fit the outlet camshaft and sprocket.
   Fig 3: Fitting Outlet Camshaft And Sprocket (Cylinder Bank 1-3)

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

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   2. 5.2. Tighten the central screw only slightly so that the sprocket can still turn.
   3. 5.3. Lift the timing chain and position the camshaft and sprocket at 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.
6. Fit the intake camshaft.
   1. 6.1. Check that the friction plate -2-  is fitted on the shaft -1-  (-arrow-  ).
      Fig 5: Locating Position Of Friction Plate On Intake Camshaft

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   2. 6.2. Lift the timing chain and engage and secure the camshaft controller -1-  . Guide the intake camshaft -2-  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 bearing positions.
      Fig 6: Identifying Camshaft Controller And Intake Camshaft

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   3. 6.3. Screw in internal Torx central screw (T55, M12 x 1.5 x 110) loosely by hand so that the controller can still turn.
7. Check cam positions for cylinder 4. The cams must be facing downwards at an angle with respect to the spark-plug recess.
   1. Outlet camshaft
   2. Intake camshaft
      Fig 7: Checking Camshaft Positions For Cylinder 4

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   1. 7.1. Another feature is a data matrix code marking on the reconditioned surface next to the dihedron -inset-  . These markings must be facing the observer at overlapping position.
      Fig 8: Identifying Marking On Camshafts 4-6 At Overlap

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   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.

8. 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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9. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light coating of OptimolOptipit grease (Part No. 000.043.204.17) on the bearings.
10. Fit bearing saddle and bearing covers.
    1. 10.1. Fit bearing saddle and bearing covers and observe markings.
    2. 10.2. Fit four external Torx screws (E10, M6 x 55) on the bearing saddle.
    3. 10.3. Fit two external Torx screws (E10, M6 x 37) on each of the bearing covers.
    4. 10.4. Fit and tighten screws according to the specified tightening sequence -1 to 16-  .

       → Initial tightening: 5 Nm (3.5 ft. lb.) 

       → Subsequent tightening: 5 Nm (3.5 ft. lb.) 

       → Torque angle: 50° 

       Fig 10: Tightening Sequence For Mounting Camshafts

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11. Check axial bearing clearance by pulling and pressing on the camshaft controller and sprocket.
    1. 11.1. There must be perceptible clearance because otherwise the shafts will have to be fitted again.
12. Screw in and tighten chain tensioner with a new seal.

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

    Set the timing, cylinder bank 4-6: 

13. Check cam position for cylinder 4 -arrows-  .
    Fig 11: Identifying Cam Position For Cylinder 4 At Overlap

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    Data matrix code is facing the observer.

    Fig 12: Identifying Marking On Camshafts 4-6 At Overlap

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14. The adjusting device is positioned on the reconditioned dihedron of the camshafts -arrows-  .
    Fig 13: Locating Position Of Dihedron Of Camshafts 4-6

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    1. 14.1. Check the position of the intake and outlet side -arrows-  .
       1. A  - A = Outlet
       2. E  - E = Intake
       1. Staking tool
       2. Staking guide
          Fig 14: Fitting Position Of Staking Tool For Cylinder Bank 4-6

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15. Fit special tool Staking Tool 9772 -1-  on the cylinder head and camshafts.
    1. 15.1. Secure on the cylinder head with four screws (M6 x 25) -2-  . Tighten screws only slightly.
       Fig 15: Staking Tool Screws For Cylinder Bank 4-6

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16. Tighten adjusting screw -arrow-  on the staking tool to the specified torque by turning it clockwise.

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

    Fig 16: Tightening Adjusting Screw On Staking Tool

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17. Turn the crankshaft clockwise (running direction of engine)  to the TDC marking  at the vibration damper.
    1. 17.1. This position is marked TCD 1/4  on the surface.
    2. 17.2. Fix in place using a long Locating Pin 9595/1 -1-  .
       Fig 17: Fixing Crankshaft In Place Using Locating Pin 9595/1

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18. Tighten central screws for sprocket and camshaft controller to the prescribed initial tightening torque.
    Fig 18: Identifying Central Screws On Camshaft Timing Gears

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    1. 18.1. Tighten central screw on sprocket -1-  initially and counter with a holding wrench 9775  while doing this.

       → Initial tightening: 30 Nm (22 ft. lb.) 

    2. 18.2. 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: 35 Nm (26 ft. lb.) 

19. Staking Tool 9772  must now be removed.
    1. 19.1. Loosen the adjusting screw. A creaking noise is completely normal due to the tension in the tool.
    2. 19.2. Unscrew fastening screws on the cylinder head and remove the tool.
20. Tighten central screws on the sprocket and camshaft controller to the prescribed final torque using a torque angle wrench.
    1. 20.1. Tighten central screw on sprocket and counter with a Holding Wrench 9775 -1-  while doing this.

       → Torque angle: 65°+/-5° 

       Fig 19: Tightening Central Screw On Camshaft Controller And Counter With Holding Wrench 9775

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    2. 20.2. Tighten central screw on camshaft controller and counter with a long open-ended wrench (a/f 32) -1-  while doing this.

       → Torque angle: 125°+/-5° 

       Fig 20: Tightening Central Screw On Camshaft Controller And Counter With Long Open-Ended Wrench

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