Removing Camshaft Actuator

NOTIFICATION 

Timing not set correctly 

• Risk of engine damage 
• Rough running engine 
• Loss of engine power 
  1. → Do not use force when fitting the staking tool.
  2. → Make sure that the gap is equal on both sides.
  3. → When inserting the staking tools, do not use force to turn the camshafts against any resistance.
  4. → The engine must be exactly at top dead centre.
  5. → The opposite cylinder must be at ignition TDC.

NOTIFICATION 

Dirt and contamination 

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

Information 

Never use the camshaft clamps -T40331- as a counterhold tool for loosening and tightening the camshaft controllers.

1. Turn the crankshaft until the marking on the vibration damper -1-  is positioned at TDC -2-  .

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   TDC marking on vibration damper

2. The markings on the camshaft actuators (cylinder bank 1) -1 and 2-  must be aligned with the reference points -Arrows-  on the camshaft housing. Turn the crankshaft further by one turn if necessary.

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   Markings on camshaft actuator (cylinder bank 1)

3. The markings on the camshaft actuators (cylinder bank 2) -1 and 2-  must be aligned with the reference points -Lines-  on the camshaft housing.

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   Markings on camshaft actuator (cylinder bank 2)

4. Remove stoppers on camshafts -1-  .

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   Stoppers on camshafts

   1. 4.1  Release and disconnect quick connector -3-  .
   2. 4.2  Move vacuum hoses -4-  aside so that the stoppers on the camshafts -1-  are accessible.
   3. 4.3  Remove screws -2-  .
   4. 4.4  Remove stoppers -1-  .
5. Screw adapter T40331/2 -1-  from T40331 - camshaft clamp  tool set into the camshaft housing on cylinder bank 1 and tighten to 9 Nm (6.5 ftlb.). 

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   Adapter on camshaft housing, cylinder bank 1

6. Screw adapter T40331/3 -1-  from T40331 - camshaft clamp  tool set into the camshaft housing on cylinder bank 2 and tighten to 9 Nm (6.5 ftlb.). 

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   Adapter on camshaft housing, cylinder bank 2

   Information 

   The camshaft clamp must be easy to insert and must not be fitted using a striking tool. 

   Information 

   It may be necessary for another person to carefully position the camshafts at the actuators using T90001 - counterhold tool  and VAS 261 001 - Ring wrench insert, a/f 41  .

7. Install T40331 - camshaft clamp  .
   1. 7.1  Fit T40331 - camshaft clamp  .

      cylinder bank 1

      1. 7.1.1 T40331/9 -1-  must be screwed in by hand. Tighten screws on the camshaft clamps -Arrows-  to 9 Nm (6.5 ftlb.). 

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         Camshaft clamps on cylinder bank 1

         1	T40331/1 - The letter "A" must be facing you.
         2	T40331/9
         3	T40331/2
         4	T40331/5 - Outlet camshaft
         5	T40331/4 - Intake camshaft

8. 7.2  Cylinder bank 2
   1. 7.2.1 T40331/9 -2-  must be screwed in by hand. Tighten screws on the camshaft clamps -Arrows-  to 9 Nm (6.5 ftlb.). 

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      Camshaft clamps on cylinder bank 2

      1	T40331/1 - The letter "B" must be facing you.
      2	T40331/9
      3	T40331/3
      4	T40331/5 - Outlet camshaft
      5	T40331/8 - Intake camshaft

   2. Secure the crankshaft
      1. 8.1  Unscrew screw plug -1-  .

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         Screw plug for crankshaft

      2. 8.2  Remove holder for vacuum reservoir -3-  .
      3. 8.3 T40069 - Locking pin  must be screwed into the bore -2-  by hand.

         Turn the crankshaft back and forth slightly to do this, if necessary.

      4. 8.4  Tighten T40069 - locking pin  to 20 Nm (15 ftlb.). 

         Information 

         Counterhold tool (T90001) can only be inserted at one position. To do this, the markings on the camshaft actuator and chain housing must be aligned.

   3. VAS 261 001 - Ring spanner insert, a/f 41  with T90001 - counterhold tool  must be fitted on the camshaft actuators.

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      Hook wrench T90001 on camshaft controller

   4. Loosen camshaft actuator -1-  .

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      Camshaft actuator

      1. 10.1  Counter the camshaft actuator -1-  using VAS 261 001 - ring spanner insert, a/f 41 -3-  and T90001 -counterhold tool-2-  and loosen using T90000 - socket E24  .

         Do not unscrew the camshaft actuator from the camshaft. 

      2. 10.2  Mark camshaft actuator and camshafts for re-installation using a coloured marker.
   5. Lock both chain tensioners.

      Information 

      The chain tensioner piston is oil-damped and can only be pressed back slowly and with constant pressure.

      1. 11.1  Press the chain tensioner piston -1-  back fully using a screwdriver.

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         Fixing device for chain tensioner

      2. 11.2  Lock the chain tensioner -1-  using T03006 - locking pin-3-  .
   6. Unscrew control valves and remove camshaft actuator from the camshaft and out of the timing chain. Make sure that the timing chain does not fall into the chain housing.
   7. Secure the timing chain to prevent it from falling down.