Removing Camshafts

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→ Clean or replace dirty components.

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) 

Overview (view of cylinder bank 4-6): 

Fig 1: Overview Of Camshafts/Cylinder Head

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1. Intake camshaft 4-6
2. Outlet camshaft 4-6
3. Camshaft mounting saddles
4. External Torx screw, M6 x 37
5. Bearing saddle (upper part)
6. Bearing saddle (lower part)
7. External Torx screw, M6 x 55
8. Dowel sleeves for cylinder head
9. Bucket tappets (exhaust)
10. Switching tappets (intake)
11. Friction plate (diamond washer)
12. Sprocket 4-6
13. Central screw, M12 x 1.5 x 60
14. Camshaft actuator
15. Hexagon
16. Central screw, M12 x 1.5 x 110
17. Position of matching number on cylinder head

Information 

• The camshafts can only be removed in the overlapping position at the top dead center of pistons 1 or 4. 
• Only at this position can you be sure that the valves are not touching against the pistons and cannot be damaged when the engine turns. 

1. Turn the engine at the assembly support so that the cylinder bank to be worked on is at the top.
2. Use special tool turning device 9773 -1- to turn the crankshaft clockwise  at the vibration damper as far as the TDC marking on cylinder 1/4  .
   1. 2.1. Fix the vibration damper in place above the staking bore using a Locating Pin 9595/1 -2-  .
   2. 2.2. Check the position of the data matrix code on both camshafts. These must be facing the observer at overlapping position.
   Fig 2: Fixing Vibration Damper In Place Using Locating Pin 9595/1

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3. Check cam position on cylinders 1 and 4.
   1. 3.1. Overlap of cylinder 1:  The cams must be facing downwards at an angle to the cylinder head wall -arrows-  .
      1. Outlet camshaft 1-3
      2. Intake camshaft 1-3
         Fig 3: Locating Cam Position On Cylinder 1 At Overlap

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   2. 3.2. Overlap of cylinder 4:  The cams are facing each other and are at a slight angle with respect to the spark-plug recess -arrows-  .
      Fig 4: Locating Cam Position On Cylinder 4 At Overlap

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4. Remove central screws on camshaft timing gears.
   Fig 5: Identifying Central Screws On Camshaft Timing Gears

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5. Loosen internal Torx central screw (T55, M12 x 1.5 x 60) on the outlet sprocket. To do this, counter with special tool Holding Wrench 9775 -1-  .
   Fig 6: Loosening Internal Torx Central Screw

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6. Loosen internal Torx central screw (T55, M12 x 1.5 x 110) on the camshaft controller. To do this, counter with a long open-ended wrench (a/f 32) -1-  .
   Fig 7: Loosening Internal Torx Central Screw

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7. Remove chain tensioner.
   1. 7.1. Cylinder bank 1-3:  Chain tensioner sitting on underside of the crankcase.
   2. 7.2. Cylinder bank 4-6:  Chain tensioner sitting on top of cylinder head.
   3. 7.3. Replace sealing ring.
8. Loosen four external Torx screws (E10, M6 x 55) on the bearing saddle -2-  .
   1. 8.1. Then loosen the external Torx screws (M6 x 37) for the mounting saddles from the outside to the inside -1-  .
      Fig 8: Identifying Camshaft Mounting Saddles

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9. Lift camshafts out of the cylinder head. Lay the timing chain into the chain housing in the cylinder head.
   1. 9.1. Unscrew central screw on the camshaft controller.
   2. 9.2. Lift up the camshaft controller -1-  with the intake camshaft and pull the shaft -2-  to the flywheel side using one hand. Pay particular attention to the friction plate when doing so. Lift up the timing chain and remove the camshaft controller.
      Fig 9: Identifying Intake Camshaft With Camshaft Controller

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   3. 9.3. Join the controller to the intake camshaft again for storage. Tighten screw only slightly.
   4. 9.4. Remove outlet camshafts complete with the sprocket.
      Fig 10: Identifying Outlet Camshaft With Sprocket

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10. Replace the friction plates in the sprocket and on the intake camshaft.

    Information 

    • The camshaft controller must not be cleaned in a parts washer. 
    • Only the outside can be cleaned using a clean, lint-free cloth. 
11. Clean components.
    1. 11.1. Do not clean the camshaft controller in a parts washer.