Installing camshafts: Requirements

Oil pump with coolant guide housing, intermediate shaft flange, belt pulley and guide rails fitted on the crankcase.

1. Move camshaft to basic position. Turn crankshaft clockwise until the bore 1 OT (top dead center) in the belt pulley is aligned with the fixing bore on the crankcase. Position or fix with fixing pin (short) of special tool 9595.
   Fig 1: Aligning Belt Pulley Bore 1 OT With Fixing Bore On Crankcase

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2. Fit auxiliary chain tensioner of special tool 9599 on the crankcase half of cylinder bank 4 - 6. Fit auxiliary chain tensioner without sealing ring and fasten on the crankcase only hand-tight. Adjust pre-tension with the hexagon-head bolt. The necessary pre-tension force has been achieve when the measuring pin is flush with the face surface of the pressure screw.
   Fig 2: Fitting Auxiliary Chain Tensioner Of Special Tool 9599 On Crankcase Half Of Cylinder Bank 4 - 6

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3. Turn engine by 90° on assembly support until cylinder bank 1-3 faces upwards.
4. Fit cylinder head gasket. The gasket is identified by Zyl. 1-3 and OBEN/TOP, plus the corresponding part number. Ensure correct seating of dowel sleeves in crankcase.
   Fig 3: Identifying Cylinder Head Gasket - Cylinder 1-3

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5. Fit cylinder head. The cylinder heads differ in the area of the chain tensioners and are therefore marked on the front with 1-3 or 4-6 to prevent mix-ups.

   Cylinder bank 1 - 3 

   Fig 4: Identifying Cylinder Bank 1-3

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   5.1 Tightening torques and tightening sequence: refer to INSTALLING CYLINDER HEAD .

   5.2 Fit shield. Tightening torque of the hexagon-head bolt M6 x 16: 10 Nm (7.5 ftlb.)

   NOTE: The shield is fitted only on cylinder head 1 - 3.
   Fig 5: Identifying Shield Hexagon-Head Bolt - Cylinder Bank 1 - 3

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6. Fit guide for valve tappets. Tighten pan-head screws (M6 x 35) from the inside to the outside. Tightening torque: 10 Nm (7.5 ftlb.)
   Fig 6: Tightening Pan-Head Screws

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7. Lightly oil the valve tappet and fit it in the guide.
8. Lay the completely preassembled unit, camshafts with chain and tensioning element into the cylinder head. The groove on the inlet camshaft or the lug on the camshaft position sensor cover faces upward.
   Fig 7: Identifying Groove On Inlet Camshaft

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9. Align camshafts accordingly and fasten with holding-down device, special tool 9611, and holding-down device, special tool 9624.
   Fig 8: Fastening Camshafts With Special Tools 9611 & 9624

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   9.1 Fasten holding-down device 9611 with auxiliary screws M6 x 45.

   Fig 9: Fastening Holding-Down Device 9611 To Camshafts

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   9.2 Fit holding-down device 9624 on the cylinder head using a M8 x 30 hexagon-head bolt.

   Fig 10: Fitting Holding-Down Device 9624

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10. Check dowel sleeves (4 ea.) of the bearing saddles to ensure that they are properly seated in the cylinder head. Grease bearing surface, fit bearing saddles in correct position and tighten evenly. Tightening torque: 10 Nm (7.5 ftlb.) It is essential to compare the pairing numbers of cylinder head, cylinder head cover and bearing saddles.
    Fig 11: Checking Camshaft Bearing Saddles

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    E Bearing saddle for inlet camshaft

    A Bearing saddle for exhaust camshaft

11. Fit tensioning element (VarioCam). Tighten 3 M6 x 95 pan-head screws. Tightening torque: 10 Nm (7.5 ftlb.)
12. Unscrew tensioning screw, special tool 9632, from the tensioning element.
13. Fit sprocket wheel with chain on the flange of the exhaust camshaft. Fasten guide rail. Tightening torque: 10 Nm (7.5 ftlb.)
    Fig 12: Fitting Sprocket Wheel With Chain On Flange Of Exhaust Camshaft

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14. Position drive plate on the sprocket wheel. Fit hexagon-head bolts M6 x 15 (10.9). Tighten hexagon-head screws by hand so that the sprocket wheel can still be rotated.
    Fig 13: Fitting Hexagon-Head Bolts M6 X 15 (10.9) On The Sprocket Wheel

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15. Fit auxiliary chain tensioner of special tool 9599 on cylinder head 1 - 3. Fit auxiliary chain tensioner without sealing ring and fasten on the cylinder head only hand-tight. Adjust pre-tension force with the hexagon-head bolt. The necessary pre-tension force has been achieved when the measuring pin is flush with the face surface of the pressure screw.

    15,1 Slightly tighten hexagon-head bolt on the sprocket wheel to 10 Nm (7.5 ftlb.).

    Fig 14: Tightening Hexagon-Head Bolt On Auxiliary Chain Tensioner - Cylinder Head 1 - 3

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16. Remove holding-down device, special tool 9611.
17. Holding-down device 9624 remains on the cylinder head until the cylinder head cover is fastened.
    Fig 15: Identifying Holding-Down Device 9624

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18. Prepare cylinder head cover for installation: Clean sealing surface of the cylinder head and cylinder head cover very carefully. Apply a silicone bead to the cylinder head cover. Refer to: SEALING COVER FOR CAMSHAFT HOUSING (CYLINDER HEAD COVER) .
    Fig 16: Preparing Cylinder Head Cover For Installation

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    Carefully place the cylinder head cover in the correct position so that the sealing bead is not damaged. Screw two studs or centering pins into the corners of the cylinder head as centering aids.

    Immediately remove silicone material emerging in the area of the camshaft closure cap.

19. Remove holding-down device 9624 from the cylinder head.
    Fig 17: Removing Holding-Down Device 9624 From Cylinder Head

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