Removing Camshafts

Information 

• The camshafts can only be removed in the overlapping position at the top dead center of pistons 1 or 4. 
• Only at this position can you be sure that the valves are not touching against the pistons and cannot be damaged when the engine turns. 

1. Turn the crankshaft at the vibration damper -1-  to TDC marking OT1  using > 9773 - turning device to turn it clockwise. 
   1. 1.1  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

2. Check 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 at cylinder 1.

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

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   Cam position at TDC position of cylinder 1

3. Check TDC position of cylinder 4 by checking the cam position on 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. Turn the engine on the assembly support so that cylinder bank 1 is at the top.
5. Remove fuel line holder -1-  .
   1. 5.1  Unscrew screw -2-  .
   2. 5.2  Unclip fuel line holder -1-  from rubber sleeve -3-  .

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   Fuel line holder

6. Secure the camshafts using > 9879/2 - locking tool-3-  .
   1. 6.1  Make sure that the adjusting screw -5-  on the > 9879/2 - locking tool-3-  is unscrewed.
   2. 6.2  Fit the relevant 9879-2 adapters  to the > 9879/2 - locking tool-3-  with the marking facing outwards.
      1. 6.2.1  Observe marking on 9879-2 adapters -1 and 2-  :

         A1 and B1 for cylinder bank 1

         A2 and B2 for cylinder bank 2

   3. 6.3  Position > 9879/2 - locking tool-3-  on the dihedron of the camshaft.

      Check the position of the intake and outlet side.

      1. 6.3.1  Position 9879-2 adapter A1  or 9879-2 adapter A2 -1-  at the intake side.
      2. 6.3.2  Position 9879-2 adapter B1  or 9879-2 adapter B2 -2-  at the outlet side.
      3. 6.3.3  Fit and tighten screws -4-  .

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

   4. 6.4  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

      Information 

      The hexagon sleeves will be deformed during the loosening process and must be replaced!

7. Loosen 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.

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   Central valves

8. Remove chain tensioner.

   > 153619 REMOVING AND INSTALLING CHAIN TENSIONER 

9. Remove camshaft actuator -1-  .
   1. 9.1  Unscrew central valves -2-  .
   2. 9.2  Pull camshaft actuator -1-  off the camshafts and remove it from the timing chains -3-  .

      Secure the timing chain to prevent it from falling down. 

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      Camshaft actuator

10. Remove camshaft guide frame -18-  and bearing saddle -19-  .
    1. 10.1 Only for guide frame of cylinder bank 1: 

       Unscrew screw -17-  .

    2. 10.2  Unscrew screws in the opposite sequence -1 to 16-  .
    3. 10.3  Remove camshaft guide frame -18-  and bearing saddle -19-  .
    Fig 1: Guide Frame And Bearing Saddle Screws Loosening Sequence

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    Guide frame and bearing saddle

11. Remove intake camshaft -1-  and outlet camshaft -2-  .

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    Camshafts

12. Turn the engine on the assembly support so that the cylinder bank 2 is at the top.
13. Turn the crankshaft another 360° at the vibration damper -1-  to TDC marking OT1  using > 9773 - turning device to turn it clockwise. 
    1. 13.1  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

14. Repeat steps  6 to  11 for cylinder bank 2.
15. Remove intake camshaft -1-  , outlet camshaft -2-  and lower part of bearing saddle -3-  .

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Camshafts on cylinder bank 2