Setting The Timing For Camshafts

→ Never turn the crankshaft against the rolling direction or when the chain tensioner is removed.

→ Proceed carefully with your work.

→ Only turn the engine at the crankshaft.

→ Reset the timing after working on the camshaft.

→ Observe general warning notes and working regulations.

→ Do not use force when fitting the staking tool.

→ Make suressss that the gap is equal on both sides.

→ When inserting the staking tools, do not use force to turn the camshafts against any resistance.

→ The engine must be exactly at top dead centre.

→ The opposite cylinder must be at ignition TDC.

1. Turn the crankshaft at the vibration balancer so that the staking bore of the vibration balancer -2-  is located approx. 45° degrees in front of the lower staking point on the timing-case cover -1-  .
   Fig 1: Staking Bore 45 Degrees Before TDC Of Cylinder 1

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2. Loosen camshaft controller and sprockets on the four camshafts just until they can turn freely (no wobbling). Always counter at the hexagon on the components when doing this.
   Fig 2: Loosening Camshaft Sprockets

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   Fig 3: Loosening Camshaft Controller

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3. Unscrew engine chain tensioner. → Removing chain tensioner 
4. Screw in assembly chain tensioner auxiliary chain tensioner 9683/1  by hand. Connect 1 bar of compressed air and slowly increase to 5.0 up to 5.5 bar (prevents the assembly chain tensioner from 'crashing' against the timing chain). -arrow- 
   Fig 4: Locating Assembly Chain Tensioner

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5. Turn the four camshafts at the hexagon using an open-ended wrench until both staking tools 9678/1  can be fitted uniformly at the same time on the side edges (dihedron) of the two intake and outlet camshafts in question between cylinders 3/4 and 7/8. For information on possible errors, see "INFORMATION ".
   Fig 5: Turning Four Camshafts At Hexagon Using Open-Ended Wrench

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   1. 5.1. Position the staking tool according to the section above entitled "Correct setting and possible errors".
   2. 5.2. Position the staking tool over the side edges of the two camshafts in such a way that the narrow end of the side edges of the camshafts points upwards to the staking tool. When positioning the staking tool, take into consideration the structural difference in height of the camshafts in the cylinder head. Turn the staking tool if necessary.
   3. 5.3. Carefully turn the camshafts at the hexagon using an open-ended wrench until the staking tool can be fitted over the side edges. Then, carefully turn the camshafts alternately back and forth at the hexagon. Turning camshafts while mounting tool and slowly and carefully tighten the valve cover screws at the staking tool. When doing this, check that the staking tool protrudes at the same distance from the cylinder head on both sides (visual inspection with pocket lamp). Depending on the production tolerance, the staking tool may lie directly on the cylinder head or there may be a small gap. Everything is fixed correctly when the staking tool is fitted uniformly and there is no longer any play on the camshaft when the hexagon is turned.
      Fig 6: Turning Camshafts

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      Fig 7: Installing Staking Tool On Camshafts

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      Fig 8: Staking Tool Screwed Uniformly On Cylinder Head

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   4. 5.4. Set other cylinder bank in the same way (fix camshafts).
   5. 5.5. Now all four camshafts are fitted uniformly and without play with both staking tools. When you inspect the camshafts with the torch, you can see no apparent gap between the side adjustment edges of the camshafts and the staking tool.
6. Insert staking pin locating pins 9595/1  into the staking bore in the vibration balancer -2-  .
   Fig 9: Inserting Staking Pin Locating Pins Into Vibration Balancer Staking Bore

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7. Turn the crankshaft at the vibration balancer -3-  so that the staking pin in the vibration balancer slips into the lower staking point on the timing-case cover -1-  . At the same time, exert gentle pressure on the staking pin while turning.
   Fig 10: Turning Crankshaft At Vibration Balancer

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8. If you accidently turn the vibration balancer too far, do not try to turn it back again!  The staking tools must be removed and the camshafts must be turned in such a way that there is only the slightest pressure on the valve springs. Turn the crankshaft once and start the setting procedure again.
9. Camshafts and crankshaft are fixed correctly.
   1. Screwed-in assembly chain tensioner with approx. 5.0 to 5.5 bar pressure.
   2. Two fixed staking tools on the camshafts.
   3. Staking pin fixes crankshaft in TDC of cylinder 1.
      Fig 11: Fixing Staking Tools On Camshafts

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10. Screw down camshaft controller and sprockets on the four camshafts as instructed. Always counter at the hexagon on the components when doing this. Camshaft controller Observe the following sequence.

    Sprocket on cylinders 1 to 4 for outlet camshaft	Camshaft controller on cylinders 1 to 4 for intake camshaft
    Camshaft controller on cylinders 5 to 8 for intake camshaft	Sprocket on cylinders 5 to 8 for outlet camshaft

    Fig 12: Loosening Camshaft Sprocket

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    Fig 13: Loosening Camshaft Sprockets

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    Fig 14: Exploded View Of Camshaft Control

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    1. Screw, M12 Tighten fully after setting the timing.  1st turn → Tightening torque: 10 Nm (7.5 ft lbs.);  2nd turn → Tightening torque: 50 Nm (37 ft lbs.);  final tightening (torque angle) → Torque angle: 135° 
    2. Hexagon sleeve
    3. Camshaft controller
    4. Washer (reusable); replace if disassembled completely
    5. Hydraulic valve for camshaft control
    6. Screw, M5 x 12
    1. Direction of travel
       Fig 15: Identifying Timing Chain And Sprockets

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    1. Double-chain camshaft drive
    2. Camshaft sprocket
    3. Screw, M12 Tighten fully after setting the timing.  1st turn → Tightening torque: 10 Nm (7.5 ft lbs.)  ; 2nd turn → Tightening torque: 50 Nm (37 ft lbs.);  final tightening (torque angle) → Torque angle: 90° 
    4. Deflection rail
    5. Screw, M8 x 35
    6. Camshaft-to-camshaft guide pad
    1. Direction of travel
11. Remove tools.
12. Mount chain tensioner. → Installing chain tensioner