Installing Camshafts And Setting Timing

Information 

• The part number and data matrix code must be facing the observer when inserting the camshafts. 

Information 

Camshaft actuator must not be disassembled! 

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Friction plate in camshaft actuator

• The camshaft actuator must never be disassembled. 
• To replace the friction plate -1- , lever it out carefully using a small slotted screwdriver -2- . 

1. Turn the engine on the assembly support so that cylinder bank 2 is at the top.
2. Insert lower part of bearing saddles -3-  , intake camshaft -1-  and outlet camshaft -2-  .
   1. 2.1  Check position of oil bores, position lower part of bearing saddles -3-  over the dowel sleeves.
   2. 2.2  Oil the bearing locations of the camshafts -2 and 3-  with new engine oil.

      When rebuilding the engine, apply a light coating of Optimal grease to the bearing locations.

   3. 2.3  Check that the rocker arms are seated correctly.
   4. 2.4  Insert intake camshaft -1-  and outlet camshaft -2-  .

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   Camshafts on cylinder bank 2

3. Position camshafts -2 and 3-  at TDC position of cylinder 4.

   The cams -1-  of the intake camshaft -2-  and outlet camshaft -3-  must be facing downwards at an angle to the spark-plug recess.

   The data matrix code -4-  on the camshafts is facing upwards.

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   Cam position at TDC position of cylinder 4

4. Install guide frame -18-  and bearing saddle -19-  .
   1. 4.1  Insert new  seal for guide frame.
   2. 4.2  Position camshaft guide frame -18-  and bearing saddle -19-  over the dowel sleeves.
   3. 4.3  Fit new  screws -1 to 12-  and tighten in the sequence -1 to 16-  .

      The inner screws on the guide frame -1, 3, 5, 7, 9 and 11-  are fitted with an O-ring.

      > Initial tightening 5 N.m (3.5 ft lb.) 

      > Final tightening 50° 

   4. 4.4  Fit new  screws -13 to 16-  and tighten in the sequence -13 to 16-  .

      > Initial tightening 5 N.m (3.5 ft lb.) 

      > Final tightening 90° 

      Fig 1: Guide Frame And Bearing Saddle Screws Tightening Sequence

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      Guide frame and bearing saddle

5. The central valves can be re-used if the sealing rings -2-  are in perfect condition.

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   Central valves

   1. 5.1  Coat sealing rings -2-  with oil.
   2. 5.2  Replace hexagon sleeves -3-  .
6. Insert new  friction plates -1-  in the camshaft actuator.

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   Friction plate

7. Install camshaft actuator -1-  for cylinder bank 2.
   1. 7.1  Check that the friction plates are fitted correctly.
   2. 7.2  Position camshaft actuator -1-  on camshafts and fit timing chain -3-  .
   3. 7.3  Screw in central valves -2-  , but do not tighten yet.

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   Camshaft actuator

8. Turn the engine on the assembly support so that cylinder bank 1 is at the top.
9. Turn the crankshaft another 360° at the vibration damper -1-  to TDC marking OT1  using > 9773 - turning device to turn it clockwise. 
   1. 9.1  Fix the vibration damper -1-  in place above the staking bore using > 9595/1 - locating pin  .

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   TDC marking on cylinder 1/4 at vibration damper

10. Install intake camshaft -1-  and outlet camshaft -2-  .
    1. 10.1  Oil the bearing locations of the camshafts -1 and 2-  with new engine oil.

       When rebuilding the engine, apply a light coating of Optimal grease to the bearing locations.

    2. 10.2  Check that all rocker arms are installed correctly.
    3. 10.3  Insert intake camshaft -1-  and outlet camshaft -2-  .

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    Camshafts

11. Position camshafts -2 and 3-  at TDC position of cylinder 1.

    The cams -1-  of the intake camshaft -2-  and outlet camshaft -3-  must be facing downwards at an angle to the outer cylinder head wall.

    The data matrix code -4-  on the camshafts is facing upwards.

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    Cam position at TDC position of cylinder 1

12. Install camshaft guide frame -18-  and bearing saddle -19-  .
    1. 12.1  Fit new  seal.
    2. 12.2  Position camshaft guide frame -18-  and bearing saddle -19-  over the dowel sleeves.
    3. 12.3  Fit new  screws -1 to 13-  and tighten in the sequence -1 to 13-  .

       The inner screws on the guide frame -1, 3, 5, 7, 9 and 11-  are fitted with an O-ring.

       > Initial tightening 5 N.m (3.5 ft lb.) 

       > Final tightening 50° 

    4. 12.4  Fit new  screws -13 to 16-  and tighten in the sequence -13 to 16-  .

       > Initial tightening 5 N.m (3.5 ft lb.) 

       > Final tightening 50° 

    5. 12.5  Fit and tighten screws -17-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

       Fig 2: Guide Frame And Bearing Saddle Screws Tightening Sequence

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       Guide frame and bearing saddle

13. Install camshaft actuator -1-  for cylinder bank 1.
    1. 13.1  Check that the friction plates are seated correctly.
    2. 13.2  Fit camshaft actuator -1-  on camshafts and fit timing chain -3-  .
    3. 13.3  Screw in central valves -2-  , but do not tighten yet.

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    Camshaft actuator

14. Secure the camshafts using > 9879/2 - locking tool-3-  .
    1. 14.1  Make sure that the adjusting screw -5-  on the > 9879/2 - locking tool-3-  is unscrewed.
    2. 14.2  Fit 9879-2 adapter A1  and 9879-2 adapter B1 -1 and 2-  facing outwards at the > 9879/2 - locking tool-3-  .
    3. 14.3  Position > 9879/2 - locking tool-3-  on the dihedron of the camshaft.

       Check the position of the intake and outlet side.

       1. 14.3.1  Position 9879-2 adapter A1 -1-  at the intake side.
       2. 14.3.2  Position 9879-2 adapter B1 -2-  at the outlet side.
       3. 14.3.3  Fit and tighten screws -4-  .

          > Tightening torque 5 N.m (3.5 ft lb.) 

    4. 14.4  Screw in and tighten adjusting screw -5-  on the > 9879/2 - locking tool-3-  .

       > Tightening torque 8 N.m (6 ft lb.) 

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    Locking tool

15. Screw in > 9683/1 - auxiliary chain tensioner-1-  with > 9683/3 - adapter  , connect 0.5 bar of compressed air and slowly increase to between 6 and 8 bar.

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    9683/1 Auxiliary chain tensioner - cylinder bank 1

16. Tighten central valves -1-  using > 9863 - socket wrench for camshaft  . Use > 9863/1 - ring insert wrench  to counter at the hexagon sleeves -2-  at the same time.

    > Initial tightening 30 N.m (22 ft lb.) 

    > Final tightening 40° 

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    Central valves

17. Remove > 9879/2 - locking tool  .
18. Turn the engine on the assembly support so that cylinder bank 2 is at the top.
19. Secure the camshafts using > 9879/2 - locking tool-3-  .
    1. 19.1  Make sure that the adjusting screw -5-  on the > 9879/2 - locking tool-3-  is unscrewed.
    2. 19.2  Fit 9879-2 adapter A2  and 9879-2 adapter B2 -1 and 2-  facing outwards at the > 9879/2 - locking tool-3-  .
    3. 19.3  Position > 9879/2 - locking tool-3-  on the dihedron of the camshaft.

       Check the position of the intake and outlet side.

       1. 19.3.1  Position 9879-2 adapter A2 -1-  at the intake side.
       2. 19.3.2  Position 9879-2 adapter B2 -2-  at the outlet side.
       3. 19.3.3  Fit and tighten screws -4-  .

          > Tightening torque 5 N.m (3.5 ft lb.) 

    4. 19.4  Screw in and tighten adjusting screw -5-  on the > 9879/2 - locking tool-3-  .

       > Tightening torque 8 N.m (6 ft lb.) 

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       Locking tool

20. Remove > 9595/1 - locating pin  .
21. Turn the crankshaft 360° in direction of rotation of the engine and disconnect flywheel with > 9595/1 - locating pin  on OT1.
22. Remove > 9683/1 - auxiliary chain tensioner-1-  with > 9683/3 - adapter  from cylinder bank 1.

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    9683/1 Auxiliary chain tensioner - cylinder bank 1

23. Install chain tensioner on cylinder bank 1.

    > 153619 REMOVING AND INSTALLING CHAIN TENSIONER 

24. Screw in > 9683/1 - auxiliary chain tensioner-1-  with > 9683/3 - adapter  into cylinder bank 2, connect 0.5 bar of compressed air and slowly increase to between 6 and 8 bar.

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    9683/1 Auxiliary chain tensioner - cylinder bank 2

25. Tighten central valves -1-  using > 9863 - socket wrench for camshaft  . Use > 9863/1 - ring insert wrench  to counter at the hexagon sleeves -2-  at the same time.

    > Initial tightening 30 N.m (22 ft lb.) 

    > Final tightening 40° 

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    Central valves

26. Remove > 9879/2 - locking tool  .
27. Remove > 9683/1 - auxiliary chain tensioner-1-  with > 9683/3 - adapter  from cylinder bank 2.

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    9683/1 Auxiliary chain tensioner - cylinder bank 2

28. Remove > 9595/1 - locating pin  .
29. Install chain tensioner on cylinder bank 2.

    > 153619 REMOVING AND INSTALLING CHAIN TENSIONER 

30. Install fuel line holder -1-  .
    1. 30.1  Clip fuel line holder -1-  into rubber sleeve -3-  .
    2. 30.2  Fit and tighten screw -2-  .

       > Tightening torque 13 N.m (9.5 ft lb.) 

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       Fuel line holder