Installing Camshafts And Setting Timing

NOTIFICATION 

Dirt and contamination 

• Risk of damage to units or components 
  • → Protect components from dirt and contamination.
  • → Clean or replace dirty components.

Information 

• Before final tightening (torque angle) of the central screws, the  > 9772/1 - staking tool must be removed. 
• Replace the hexagon sleeves for the central screws. 

Information 

• The procedure for installing and adjusting the camshafts is described on one cylinder bank as an example. 
• To adjust the opposite side, turn the engine further by one turn in clockwise direction. 

1. Turn the crankshaft clockwise (direction of rotation of engine)  to position 260° after TDC.
   1. 1.1 Secure > 9888 - locking tool-1-  to the crankshaft with three screws -2-  .
   2. 1.2 Turn the crankshaft using > 9773 - turning device  until the bores are aligned.
   3. 1.3 Fix using a long > 9595/1 - locating pin-3-  .

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   Position 260° after TDC

2. Turn the engine at the assembly support so that the cylinder bank to be fitted is at the top.
3. Only for cylinder bank 3-4:  Insert lower part of bearing saddle -1-  .

   Check matching number! 

   1. 3.1 Check position of oil bores and position and fit the component over the dowel sleeves.

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   Lower part of bearing saddle - cylinder bank 3-4

4. Check that all hydraulic tappets are installed correctly.
   1. 4.1 During re-installation, the tappets must be coated fully with new engine oil and must be inserted again according to installation position before removal! 
   2. 4.2 Also coat new hydraulic tappets with Renolin or new engine oil! 
5. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply Optimol Optipit grease (Part No. 000.043.204.17) on the bearing locations.
6. Insert camshafts at the correct position.
   1. 6.1 Camshafts are lying loosely in the bearing locations.
   2. 6.2 The data matrix code markings on the dihedron -1 and 2-  are facing you.

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   Data matrix code on camshafts

7. Position > 9772/1 - locking tools  on the reconditioned dihedron of the camshafts -Arrows-  .
   1. 7.1 Position locking tools -3-  on the bearing cover supports for cylinder 2 or 4 and tighten cheese head bolts -4-  slightly.

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   Assembly position of locking tools (shown on cylinder bank 1-2)

   1. Outlet camshaft
   2. Intake camshaft
   3. Locking tools 9772/1
   4. Adjusting screws
   5. Cheese head bolts
8. Check that the new friction plates -2-  are inserted into the actuators -3-  .

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   Friction plate in camshaft actuator

9. Coat thread, sealing face and head contact surface of central screws (central valves) with new engine oil! 
10. Insert camshaft actuator -1 and 2-  with new friction plates.
    1. 10.1 Fit the timing chain.
    2. 10.2 Tighten central screws with new hexagon sleeves -3-  hand-tight.

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    Installation overview of central screws for camshaft controllers

    1. Actuator for intake camshaft
    2. Actuator for outlet camshaft
    3. Central screws (central valves)
11. Install bearing saddle and bearing covers.

    Install the bearing covers for cylinder 2 or 4 after setting the timing! 

    1. 11.1 Fit bearing saddle and bearing covers and check markings! 
    2. 11.2 Fit four screws (M6 x 38 or M6 x 70) -9 to 12-  on the bearing saddle.
    3. 11.3 Fit two screws (M6 x 38) -1, 2, 5, 6-  on each of the bearing covers.
12. Fit and tighten screws according to the specified tightening sequence (without item 3, 4, 7 and 8).

    Tool:  > 9768 - Electronic torque wrench, 2 - 100 Nm (1.5 - 74 ftlb.) 

    1. 12.1 Screws, M6 x 38: 

       > Initial tightening 5 Nm (3.5 ftlb.) 

       Final tightening: > Torque angle 50° 

    2. 12.2 Only for cylinder head 1-2: Screws, M6 x 38 (bearing saddle): 

       > Initial tightening 5 Nm (3.5 ftlb.) 

       Final tightening: > Torque angle 50° 

    3. 12.3 Only for cylinder head 3-4: Screws, M6 x 70 (bearing saddle): 

       > Initial tightening 5 Nm (3.5 ftlb.) 

       Final tightening: > Torque angle 90° 

    Fig 1: Camshaft Bearing Cover/Bearing Saddle Bolts Tightening Sequence

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    Tightening sequence for camshaft bearing cover/bearing saddle (view of cylinder head 1-2)

    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.
13. Use a torch to check that the timing chains -1-  are on the tensioning and guide rails between the guide pins -Arrows-  .

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    Position of timing chain in tensioning and guide rails

    Information 

    • For camshaft control adjustment, auxiliary chain tensioners from the 9A1 engine must be used (Part No. 9A1.105.157.03). 
    • These have a higher spring force than the standard chain tensioners and prevent too much chain play in the timing drive. 
14. Install auxiliary chain tensioners. 

    > Tightening torque 80 Nm (59 ftlb.) 

    1. 14.1 Cylinder bank 1-2:  Screw in and tighten auxiliary chain tensioner -1-  with sealing ring.

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       Chain tensioner 1-2

    2. 14.2 Cylinder bank 3-4: 
       1. 14.2.1 Lift up oil separator -1-  (-Arrow-  ).
       2. 14.2.2 Screw in and tighten auxiliary chain tensioner -3-  with new O-ring and sealing ring.

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    Chain tensioner 3-4

15. Tighten > 9772/1 - locking tools  hand-tight using the cheese head bolts.
16. Tighten adjusting screws -1-  of the locking tools slowly on both sides.

    Do not exceed the specified tightening specification (tool will become tilted)! 

    > Tightening torque 1.5 Nm (1 ftlb.) + 0.5 Nm (0.4 ftlb.) 

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    Adjusting screws on locking tools (similar to illustration)

17. Pre-tighten central screws.

    Use the same tools as for loosening! 

    1. 17.1 Pre-tighten central screws and counter at the hexagon sleeve with the > 9863/3 - open-ended wrench, a/f 39  . > Initial tightening 30 Nm (22 ftlb.) +/- 1 Nm (0.5 ftlb.) 
18. Remove > 9772/1 - locking tools  .
    1. 18.1 Loosen adjusting screws.
    2. 18.2 Unscrew cheese head bolts and remove tools.
19. Install bearing covers on the camshafts for cylinder 2 or 4.
    1. 19.1 Fit and tighten screws uniformly.

       > Initial tightening 5 Nm (3.5 ftlb.) 

       Final tightening:  > Torque angle 50° 

20. Tighten central screws to their final tightening torque.

    Tools: 

    • -item 1-  : > 9863/3 - Open-ended wrench, a/f 39  for countering
    • -item 2-  : > 9863 - Socket wrench for camshaft 
    • -item 3-  : > 9768 - Electronic torque wrench, 2 - 100 Nm (1.5 - 74 ftlb.) 
    1. 20.1 Tighten central screws and set threshold torque on the electronic torque wrench to 30 Nm (22 ftlb.).

       The help of another person is required! 

       Final tightening:  > Final tightening torque angle 40° +/- 5° 

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    Tightening camshaft actuator - (similar to illustration)

21. Remove auxiliary chain tensioners and install the original chain tensioners with new O-rings and seals! 

    > Tightening torque 80 Nm (59 ftlb.) 

22. Remove > 9888/1 - crankshaft turning tool  .