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Set basic position of camshafts - AR05.20-P-6020EL

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ENGINE 157, 276, 278 in MODEL 212, 218 

MODIFICATION NOTES

26.3.14 Adapted to new repair method    

Shown on engine 278 

Fig 1: Camshafts Basic Position - Shown On Engine 278
G09974341DANGERREMOVINGSPECIAL TOOLSPECIAL TOOLIMPORTANTIMPORTANTIMPORTANTIMPORTANTIMPORTANTINSPECTIMPORTANTIMPORTANTINSTALLINGIMPORTANTIMPORTANTIMPORTANTIMPORTANTSPECIAL TOOLDANGERCourtesy of MERCEDES-BENZ USA
DANGER Risk of injury  . Moving parts can pinch, crush or, in extreme cases even sever extremities. No parts of the body or limbs should be within the operating range of the mechanism when moving components. AS00.00-Z-0009-01A
REMOVING Remove     
1 Remove centrifuge ENGINE 276.8 AR01.20-P-2100ELS
    ENGINE 276.9 AR01.20-P-2100EL
    ENGINE 157, 278 AR01.20-P-2100ELB
2 Remove cylinder head covers Engine 276.8 - left cylinder head cover AR01.20-P-5013ELS
    Engine 276.8 - right cylinder head cover AR01.20-P-5012ELS
    Engine 276.9 - right cylinder head cover AR01.20-P-5012EEL
    Engine 276.9 - left cylinder head cover AR01.20-P-5013EEL
    Engine 157, 278 - right cylinder head cover AR01.20-P-5012ELB
    Engine 157, 278 - left cylinder head cover AR01.20-P-5013ELB
3 Check segmented discs (4) for marking (4m)    
4 Remove camshafts (1) If marking (4m) is not present on the segmented discs (4) AR05.20-P-6992EL
5 Attach marking (4m) to the segmented discs (4) If marking (4m) is not present on the segmented discs (4) AR05.20-P-6292-04MM 
    SPECIAL TOOL Template Figure
6 Install camshafts (1) If marking (4m) is not present on the segmented discs (4) AR05.20-P-6992EL
7 Mount hold-down tool (01) on camshafts (1) SPECIAL TOOL Tie-down set Fig 2
8 Detach charge air cooler and press to the front with attached coolant lines ENGINE 276.8 AR09.41-P-6819ELS
9 Rotate engine at crankshaft center bolt in direction of engine rotation to a 40° crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC) IMPORTANT After performing repair work on crank assembly ensure that this stands at 40° after ignition TDC. If the crank assembly should stand at 40° after overlap TDC for assembly, all camshafts (1) have a wrong position of about 1/2 a tooth for the basic setting. If the crankshaft is turned with the secondary chain removed, this may only take place in 720° steps in order to again come to the correct ignition TDC on the crank assembly. AR05.10-P-7620-04MM 
10 Remove both chain tensioners ENGINE 276 AR05.10-P-7800EL 
    ENGINE 157, 278
IMPORTANT For removed cylinder head covers both chain tensioner can be removed for a 40°  crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC). To remove RH chain tensioner the tensioning rail should be relieved by an assistant by turning the exhaust camshaft.		 AR05.10-P-7800ELB 
11 Remove camshaft positioner (3) for right exhaust camshaft ENGINE 276.8 AR05.20-P-7201ELS
    Engine 157, 276.9, 278
IMPORTANT To loosen and tighten control valve on the RH camshaft positioner (3), the camshaft (1) must be counterheld by a helper.		 AR05.20-P-7201EL
12 Remove timing chain (2) from camshaft positioners (3) IMPORTANT To relieve tensioning rail the camshafts (1) should be held by an assistant in the basic position.  
13 Turn camshafts (1) into basic position IMPORTANT The camshafts (1) must be held in the basic position using a suitable tool by a helper.  
INSPECT Check     
14 Check timing chain (2) on left cylinder head for correct seating IMPORTANT Check whether the timing chain (2) lies on both camshaft positioners (3) and sits correctly in the toothings.
If this is not the case:
↓
The respective camshaft (1) has to be turned until the timing chain (2) lies on correctly.		  
15 Check camshafts (1) for correct installation position IMPORTANT Markings (4m) on segment discs (4) must be aligned with edges on the cylinder heads  
INSTALLING Install     
16 Mount camshaft positioner (3) for right exhaust camshaft and also lay timing chain (2) on both camshaft positioner (3) for the right cylinder bank at the same time ENGINE 276.8 AR05.20-P-7201ELS
    Engine 157, 276.9, 278
IMPORTANT To tighten the control valve on the right camshaft positioner (3) and to relieve the tensioning rail, the camshafts (1) should be held by an assistant in the basic position.		 AR05.20-P-7201EL
17 Install both chain tensioners ENGINE 276 AR05.10-P-7800EL 
    ENGINE 157, 278
IMPORTANT For removed cylinder head covers both chain tensioner can be installed for a 40°  crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC). To install RH chain tensioner the tensioning rail should be relieved by an assistant by turning the exhaust camshaft.		 AR05.10-P-7800ELB 
18 Crank engine at crankshaft center bolt in direction of engine rotation through about 720°.    
19 Rotate engine at crankshaft center bolt in direction of engine rotation to a 40° crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC) IMPORTANT After performing repair work on crank assembly ensure that this stands at 40° after ignition TDC. If the crank assembly should stand at 40° after overlap TDC during assembly, all camshafts (1) have a wrong position of about a tooth for the basic setting. If the crankshaft is turned with the secondary chain removed, this may only take place in 720° steps in order to again come to the correct ignition TDC on the crank assembly. AR05.10-P-7620-04MM 
20 Check engine valve timing IMPORTANT The engine must stand at a 40° crank angle (CKA) after top dead center (TDC) on cylinder 1 (ignition TDC) (marking on belt pulley/vibration damper) and markings (4m) on the segmented disks (4) must be flush with the edges on the cylinder heads.
If the timing of the engine is incorrect:
↓
Perform work procedure as of operation step 9 again		  
21 Mount charge air cooler ENGINE 276.8 AR09.41-P-6819ELS
22 Remove hold-down tool (01) on camshafts (1) SPECIAL TOOL Tie-down set Fig 2
23 Install cylinder head covers Engine 276.8 - left cylinder head cover AR01.20-P-5013ELS
    Engine 276.8 - right cylinder head cover AR01.20-P-5012ELS
    Engine 276.9 - right cylinder head cover AR01.20-P-5012EEL
    Engine 276.9 - left cylinder head cover AR01.20-P-5013EEL
    Engine 157, 278 - right cylinder head cover AR01.20-P-5012ELB
    Engine 157, 278 - left cylinder head cover AR01.20-P-5013ELB
24 Install centrifuge ENGINE 276.8 AR01.20-P-2100ELS
    ENGINE 276.9 AR01.20-P-2100EL
    ENGINE 157, 278 AR01.20-P-2100ELB
DANGER Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
25 Carry out an engine test run, checking the engine for proper operation and leaktightness    
Fig 2: Identifying Tie-Down Set (276 589 01 40 00)
G09974342Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Template (278 589 00 23 00)
G09974343Courtesy of MERCEDES-BENZ USA
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