Camshafts, Installing

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NOTE:

Sealing surfaces must be completely free of oil and grease.

Pay attention that all roller rocker levers rest on the valve stem ends.

-- If the crankshaft was turned in the meantime, bring the piston for cylinder 1 to TDC and then turn the crankshaft back again slightly.

-- Remove any sealant residue from the groove on the cylinder head cover as well as on the sealing surfaces.

-- Sealing surfaces must be free of oil and grease.

-- Lubricate the running surfaces of both camshafts.

-- Place the intake camshaft -A- in the cylinder head. Turn the cam lobes of cylinder 4 -arrows- upward.

Fig 1: Identifying Intake Camshaft And Cylinder Head

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-- Check if the valve lifters for the cam adjustment actuators are retracted.

Fig 2: Bring the Cam Adjustment Actuators into the Installed Position

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-- Place the exhaust camshaft in the cylinder head cover as shown. The cam pair -A and B- must be pushed together.

Fig 3: Placing Exhaust Camshaft In Cylinder Head Cover

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-- Turn the exhaust camshaft until the markings -A and B- align.

Fig 4: Locating Alignment Marks

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-- Apply the sealant on the clean sealing surface of the cylinder head cover as shown -arrows-.

Fig 5: Sealant Application Locations

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Sealant bead thickness: 2 to 3 mm.

-- Secure the camshaft and place the cylinder head cover with the camshaft on the cylinder head.

-- Lightly push on the cylinder head cover by hand and while doing so turn the camshaft slightly until the cylinder head cover lays >>free of tension<< on the cylinder head.

Fig 6: Turning Camshafts

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-- Replace the cylinder head cover bolts.

-- Tighten the bolts in several steps. Refer to Figure for the tightening sequence.

NOTE:

Pay attention that the cylinder head cover is not tilted.

-- Turn the intake camshaft with the : T40266 in the direction of the -arrow A- until the marks -1 and 2- align. Push the : T40271/2 in the chain sprocket splines in direction of -arrow B-.

Fig 7: Identifying Intake Camshaft With Adapter T40266

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-- Turn the exhaust camshaft with the : T40266 in the direction of the -arrow A- until the marks -1 and 2- align. Push the : T40271/1 in the chain sprocket splines in direction of -arrow B-. The mark -2- is offset slightly to the right.

Fig 8: Turning Exhaust Camshaft W/ T40266

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-- Turn the crankshaft on the hex fitting to the "TDC point". In the "TDC point" the flat area -1- is upward.

Fig 9: Identifying Assembly Tool - Turning Over Tool T10531/3

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Installing the Camshaft Timing Chain

Fig 10: Camshaft Timing Chain And Camshaft Sprocket

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-- Engage the camshaft timing chain with the painted links -arrows- on the camshaft pins.

-- Place the camshaft timing chain on the intake camshaft, exhaust camshaft and the crankshaft. Position the painted chain links -arrows- on the markings on the chain sprockets.

Fig 11: Camshaft Timing Chain And Intake Camshaft

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-- Install the guide rail -2- and tighten the bolts -1-.

Fig 12: Removing Glide Rail

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-- Install the upper glide rail -1-.

Fig 13: Removing Guide Rail

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

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I - Turn the exhaust camshaft slightly in the direction of the -arrow A- using the : T40266 and push the : T40271/1 out of the chain sprocket splines in direction of -arrow B-.

II - Release the camshaft in the direction of -arrow C-, until the timing chain touches the glide rail -1-. Hold the camshaft in this position, install the tensioning rail -2- and tighten the bolts -3-. Release the camshaft.

-- Turn the intake camshaft with the : T40266 in the direction of the -arrow 1- until the : T40271/2 can be pushed out of the chain sprocket splines in the direction of the -arrow 2-. Release the camshaft.

Fig 14: Identifying Assembly Tool T40266 And Camshaft Clamp T40271/2

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-- Remove the : T40271/1 and : T40271/2 .

-- Install the bolts -arrows- and tighten them. Tightening specification. Refer to -Item ) Bolt.

Fig 15: Identifying Bolts

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-- Lubricate the holes -arrows- with engine oil.

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NOTE:

If the adapter sleeve -1- is installed, it must be driven back when reusing the bearing bracket. The adapter sleeve must be flush with the cylinder head side of the bearing bracket.

-- Attach the bearing mount. Do not tilt it when doing this. Tighten the bolts -1 to 6- hand-tight.

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-- Remove the : T40267 .

Fig 16: Securing Chain Tensioner With T40267

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-- Tighten the bearing bracket bolts -arrows-. Tightening specification. Refer to OVERVIEW - CAMSHAFT TIMING CHAINS .

Fig 17: Identifying Bolts

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-- Install the chain tensioner -2-. The wire clip must come in to contact with the oil pan upper section opening -arrow-. Tighten the bolt -1- and remove the : T40011 .

Fig 18: Identifying Chain Tensioner

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-- Check the adjustment. The painted chain links -arrows- must line up with the markings on the chain sprockets.

Fig 19: Identifying Painted Chain Links Must Line Up With Markings On Chain Sprockets

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-- Install the control valves. Refer to -Item ) Control Valves.

-- Let the engine turn a second time in the direction of engine rotation.

NOTE:

Due to the ratio, the painted chain links no longer match up after the engine has been turned.

-- Remove the : T10531/4 and remove the : T10531/3 .

Fig 20: Identifying Assembly Tool - Turning Over Tool T10531/3

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-- Install the lower timing chain cover. Refer to Installing .

NOTE:

Tighten the bolts -1 and 4- with an additional turn after installing the vibration damper. The bolts must be removed again to install the vibration damper.

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-- Install the vibration damper. Refer to VIBRATION DAMPER, REMOVING AND INSTALLING .

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

-- Install the ribbed belt tensioner. Refer to RIBBED BELT TENSIONER, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

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

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

Further installation is performed in reverse order of removal, while noting the following:

-- After performing work on the chain drive the adaptation value in the engine control module must be adapted. To do so, turn on the ignition and select the following menu items on the Vehicle Diagnostic Tester:

01 - Engine Electronics
Guided Functions
01 - Adaptation after repair work on the chain drive

Tightening Specifications

Refer to OVERVIEW - CAMSHAFT TIMING CHAINS
Refer to OVERVIEW - BALANCE SHAFT DRIVE CHAIN
Refer to OVERVIEW - VALVETRAIN
Refer to OVERVIEW - AIR FILTER HOUSING
Refer to OVERVIEW - HIGH PRESSURE PUMP
Refer to OVERVIEW - NOISE INSULATION .