Left Cylinder Head Camshaft

Left Cylinder Head Camshaft

Special tools, testers and auxiliary items required

• Puller (T10320)

• Camshaft Fitting Tool (T40094)

• Camshaft Fitting Too (T40095)

• Component of T40096 (T40096)

• Pry Lever - Rmv Outside Mirror (80 - 200)

• Retainer (3036)

• Hand drill with plastic brush attachment

• Protective eyewear

• Sealant, refer to the Parts Catalog

Removing

- Remove the affected camshaft timing chain from the camshaft. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, Removing From Camshafts.

- Remove the upper section of the intake manifold.






- Remove the high pressure pump toothed belt.






- Loosen the toothed belt drive sprocket bolt - 1 - 2 turns using the (3036).






- Remove the toothed belt drive sprocket using the (T10320).






- Remove the left cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover.

- Remove the exhaust gas recirculation (EGR) cooler switch-over valve (N345) - 1 - from the bracket.






- Remove the bolt - 4 - and the engine cover bolts - 2 -.

- Free up the wiring harness - 3 - on the top of the coolant pipe on the left side.

• Ignore - arrows -.

• Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.






- Remove the high pressure line union nut - 1 -.

- Remove the bolts - arrows - and remove the fuel rail from the left cylinder head.

- Loosen the guide frame bolts and nuts in the sequence - 18 to 1 -.






• Be careful of the roller rocker lever and the adjusters when removing the camshafts.

- Carefully remove the bearing bracket and camshafts.

Installing

• Tightening specifications, refer to => [ Cylinder Head Overview ] Cylinder Head Overview, => [ Coolant Pipes Overview ] Coolant Pipes Overview.

• Replace the front cover in the cylinder head on the right side.

Danger of destroying the axial bearing in the bearing bracket.

• Install the camshaft as described with the (T40094).

Risk of contaminating lubricating system.

• Cover any open parts in the cylinder head.

Risk of eye injury.

• Wear protective eyewear.

- Remove the sealant residue on the cylinder head and guide frame and the upper section of the oil pan, for example using a rotating plastic brush.

- Clean the sealing surfaces; they must be free of oil and grease.

- Lubricate the running surfaces of both camshafts.

Set up the (T40094) as follows:






- Install the (T40094/2) in - A -.

- Install the (T40094/1) in - D -.

- Install the exhaust camshaft - 1 - into the (T40094/1) and (T40094/2).






- Turn the exhaust camshaft so that it can be locked with the straight-edge in the "TDC" position - arrow -.

- Mount the (T40096) onto the teeth of the exhaust camshaft so that one arm of the clamping device engages in one sprocket half.

- Tension the clamping devise with the thumb wheel until the tooth faces align.

- Place the intake camshaft - 2 - into the (T40094).






• The securing pin - 3 - must engage in the groove on the intake camshaft.

- Push the exhaust camshaft - 1 - toward the intake camshaft - arrows - until the splines engage.

- Make sure the camshaft is positioned correctly:






• The notches - arrows - on both camshafts must face upward.

- Place the bearing brackets - 1 - on both camshafts.






• All the camshaft bearings must lie on the camshafts.

- Mount the (T40095) onto the camshafts by aligning the pliers and tension with the knurled nuts - 2 -.

- Tension the camshafts by tightening the nuts - 3 -.

- Make sure the alignment pins - arrows - are in the cylinder head. Insert any missing alignment pins.






• Note the expiration date of the sealing compound.

- Cut the tube nozzle at the front marking (nozzle diameter approximately 1.5 mm).






• The guide frame is shown without the camshafts.

- Turn the guide frame around.

The lubrication system could be plugged with excess sealant.

• Do not apply sealant beads thicker than specified.

- Apply sealant beads - arrows - to the clean sealing surfaces on the guide frame as shown in the illustration.






• The grooves of sealing surface must be completely filled with sealant.

• The sealant beads must be 1.5 to 2.0 mm above the sealing surface.

• The guide frame must be installed within 5 minutes after applying the sealant.

The engine could be damaged.

• Make sure all the roller rocker levers are seated correctly on the valve stem ends and the adjusters.

- Mount the guide frame together with both camshaft and the (T40095) to the cylinder head.






- Tighten the guide frame bolts. Refer to => [ Left Cylinder Head Guide Frame, Tightening Specifications and Sequence ] Valvetrain Overview.

- Remove the (T40095) and (T40096).

• After installing the guide frame, let the sealant harden for approximately 30 minutes.

The rest of the installation is performed in reverse order of removal, noting the following:

- Install the fuel rail and the high pressure lines.

- Install the left cylinder head cover. Refer to => [ Left Cylinder Head Cover ] Left Cylinder Head Cover.

- Camshaft seal, removing and installing. Refer to => [ Camshaft Seal ] Service and Repair.

- Install the high pressure pump toothed belt and the upper section of the intake manifold.

- Install the camshaft timing chains => [ Installing ] Camshaft Timing Chains, Removing From Camshafts.

Risk of damaging valves and piston heads after working on valvetrain.

• The motor must not be started for about 30 minutes after installing camshafts because the hydraulic equalization elements must seat themselves.

• To ensure valves do not strike pistons when starting, carefully rotate engine at least 2 full revolutions.