Camshaft, Removing And Installing: Notes

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Depending on the version of the Assembly Tool: T10352/2 or : T10352/4
Counterhold - Vibration Damper: T10355
Chain Tensioner Lever: T40243
Tensioner Locking Tool: T40267
Camshaft Locks: T40271
Adapter: T40266
Sealant: D 154 103 A1

Removing

NOTE:

The sealing surfaces of the lower cylinder head cover and on the upper cylinder head must not be reworked.

The camshaft bearings are integrated in the cylinder head or cylinder head cover. The tension must be released from the camshaft timing chain before removing the cylinder head cover.

When installing, secure all cable ties back to same positions.

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the coolant hose -arrow-.

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-- Disconnect the connectors -1 and 2-. Open the bracket -3-.

-- Remove the ignition coils. Refer to IGNITION COILS WITH POWER OUTPUT STAGES, REMOVING AND INSTALLING .

-- Remove the ground cable bolt -1- and disconnect the coolant hoses -2 and 3-. Seal the lines using the : VAS6122 .

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-- Disconnect the connectors -arrows-.

-- Release the catch in direction of -arrow- and remove the wiring duct -4- upward from the bracket.

Fig 1: Identifying Bolts

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-- Remove the bolts -1, 2 and 3-. Pivot the coolant pipe to the side.

CAUTION:

Risk of destroying the coolant pipes through deformation.

- Never change the coolant pipe bend shape.

-- Remove the upper coolant pipe. Refer to UPPER COOLANT PIPES, REMOVING AND INSTALLING .

-- Disconnect the connector -1- from the EVAP Canister Purge Regulator Valve 1 -N80-.

Fig 2: Connector And EVAP Canister Purge Regulator Valve 1 -N80

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-- Press the release button on the crankcase ventilation hose -2- and remove the hose.

-- Remove the bolts -arrows- and the crankcase ventilation.

-- Remove the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Remove the vacuum pump. Refer to VACUUM PUMP, REMOVING AND INSTALLING .

-- Support the engine in the installation position. Refer to ENGINE, SUPPORTING IN INSTALLATION POSITION .

-- Remove the engine mount. Refer to ENGINE MOUNT, REMOVING AND INSTALLING .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the right wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the engine support. Refer to ENGINE SUPPORT, REMOVING AND INSTALLING .

-- Remove the upper timing chain cover. Refer to TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Turn the vibration damper with the : T10355 to the "TDC point".

Fig 3: Identifying Vibration Damper With Counterhold - Vibration Damper T10355

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The markings -1- on the camshaft chain sprockets must be opposite the markings -2 and 3-.
The notch on the vibration damper and the marking on the lower timing chain cover -arrow- must be align.

-- Remove the lower timing chain cover. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

Fig 4: Removing Control Valve

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NOTE:

The control valve has left-hand threads.

Depending on the version, different control valves can be installed. Use a fitting assembly tool -1-.

-- Remove the left and right control valve using the : T10352/2 or : T10352/4 in the direction of the -arrow-.

-- Remove the bolts -arrows- and remove the bearing bracket.

Fig 5: Identifying Bolts

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-- Remove the bolts -arrows-.

Fig 6: Identifying Bolts

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-- Install the : T40243 -arrows-.

Fig 7: Identifying Lever T40243 -Arrows-, Installation

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-- Press the chain tensioner circlip -1- together and hold it.

-- Slowly press and hold the : T40243 in the direction of -arrow-.

-- Secure the chain tensioner with the : T40267 .

Fig 8: Securing Chain Tensioner With T40267

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-- Remove the : T40243 .

-- Bolt the : T40271/2 to the cylinder head and slide into the splines on the chain sprocket in the direction of the -arrow 2-. Rotate the intake camshaft with the : T40266 -1- if necessary.

Fig 9: Identifying Camshaft Clamp T40271/2 And Assembly Tool T40266

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-- Install the : T40271/1 on the cylinder head.

Fig 10: Checking T40271/1 Installation Position

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The help of a second technician is necessary for the following step.

-- Hold the exhaust camshaft with the : T40266 in the direction of the -arrow A-. Remove the bolt -1- and guide the tensioning rail -2- downward. Turn the camshaft farther in a clockwise direction -A- until the : T40271/1 can slide into the chain sprocket splines -B-.

-- Check the installation position -C- of the : T40271/1 .

-- Remove the guide rail -1- by unlocking the latch -arrow- with a screwdriver and pushing the guide rail forward.

Fig 11: Removing Guide Rail

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-- Press the oil pump chain tensioner bracket in direction of -arrow- and lock with : T40011 .

Fig 12: Identifying Locking Pin T40011

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-- Remove the bolt -1- and remove the chain tensioner.

-- Remove the bolts -1- and remove the guide rail -2-.

Fig 13: Removing Glide Rail

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-- Remove the camshaft timing chain from the camshaft sprockets and guide downward.

-- Install the : T10531/3 . In the "TDC point" the flat area -1- points upward. Install the : T10531/4 . Turn the crankshaft with a 32 mm open end wrench counter-clockwise out of "TDC".

Fig 14: Identifying Assembly Tool - Turning Over Tool T10531/3

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-- Use the : T40266 to turn the intake camshaft in the direction of the -arrow 1-, slide out the : T40271/2 from the chain sprocket splines in direction of -arrow 2- and bring the camshaft into the rest position.

Fig 15: Identifying Adapter T40266 And Intake Camshaft

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-- Use the : T40266 to turn the exhaust camshaft in the direction of -arrow 1-, slide out the : T40271/1 from the chain sprocket splines -2- and bring the camshaft into the rest position.

Fig 16: Identifying Camshaft Locating Tool T40271/1

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-- Remove the cylinder head cover bolts in -1 to 6- sequence.

Fig 17: Cylinder Head Cover Bolt Loosening Sequence

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-- Pry up the cylinder head cover -2- using a tool for example a screwdriver -1- starting at the chain side.

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-- Remove the cylinder head cover.

-- Remove the camshaft and cover the open engine components.