Camshaft: Service and Repair
Camshafts
Special tools, testers and auxiliary items required
• Camshaft Gear Counter-Holder (T10051)
• Puller (T10052)
• Camshaft Insertion Tool (T40094)
• Camshaft Insertion Tool (T40095)
• Tensioning Tool (T40096/1)
• Hand drill with plastic brush attachment
• Protective eyewear
• Sealant, refer to the electronic parts catalog ETKA
Removing
• Cylinder head installed.
- Remove the engine cover - arrows -.
- Remove the toothed belt from the camshaft toothed belt gear and the high pressure pump toothed belt gear. Refer to => [ Toothed Belt ] Toothed Belt.
- Remove cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.
- Remove bolts - 1 - and remove the camshaft toothed belt gear.
- Remove bolt - 1 - for the camshaft hub while counterholding it with the (T10051).
- Remove the bolt approximately 2 turns.
- Mount the (T10052) on the camshaft hub and install the bolts - 1 - in the hub.
- To remove the camshaft hub, install the bolt - 2 - and counterhold it on the hex (30 mm) on the puller.
- Remove the hub from the camshaft cone.
- Remove vacuum pump.
- Loosen the guide frame bolts and nuts in the sequence - 24 to 1 -.
- Remove the bolts and carefully loosen the frame from the bonding.
- Mark the camshafts so they can be installed later and remove them.
Installing
• Tightening specifications, refer to => [ Valvetrain Assembly Overview ] Service and Repair.
Danger of destroying the axial bearing in the bearing bracket.
• The camshafts must be installed only with the (T40094) as follows.
Risk of contaminating lubricating system and bearing.
• Cover open parts of engine.
Risk of eye injury.
• Wear safety glasses.
- Using a rotating plastic brush, remove any remaining sealant from the cylinder head and guide frame.
- Clean the sealing surfaces; they must be free of oil and grease.
- Oil running surfaces of both camshafts.
Set up the (T40094) as follows:
- Secure the (T40094/9) and (T40094/10) (with (T40094/11)) to the base plate as illustrated. Remove the attached brackets if necessary.
- Mount the bracket (T40094/1) on position - F - and bracket (T40094/2) on position - A -.
- Install the intake camshaft into the (T40094/1) and (T40094/2).
- Turn the intake camshaft so that it can be locked with the straight-edge in the TDC position - arrow -.
• The recess - arrow 2 - for the cylinder head bolt must face outward.
- Install the exhaust camshaft into the (T40094/9) and (T40094/10).
- Secure the exhaust camshaft with the (T40094/11).
• The tab - 1 - in the cover must fit in the groove - 2 - in the camshaft.
- Mount the tensioning tool (T40096/1) on the teeth of the exhaust camshaft so that one arm of the clamping device engages in one sprocket half.
• The wider arm must engage into the wider half of the sprocket.
- Tension the tensioning tool with the thumb wheel until the tooth faces align.
- Slide the intake camshaft toward the exhaust camshaft until the splines mesh - arrows -.
- Mount the frame on the camshafts.
• All the camshaft bearings must lie on the camshafts.
- Mount the (T40095) and secure the camshafts inside the frame as illustrated.
- Remove the (T40094/11).
• Note the expiration date of the sealing compound.
- Cut the tube nozzle at the front marking (nozzle diameter approximately 2 mm).
Risk of contaminating camshaft bearing with excess sealant.
• Do not apply sealant beads thicker than indicated.
- Apply a bead of sealant on the clean sealing surfaces on the cylinder head as illustrated.
• Sealant bead thickness: 2 to 3 mm.
• Placing the guide frame in place and tightening it should occur without interruption, since the sealant begins to harden immediately.
• After installing the guide frame, let the sealant harden for approximately 30 minutes.
- Remove the camshafts together with the frame, the (T40095) and the tensioning tool (T40096/1) from the (T40094) and carefully install the cylinder head.
- Install the bolts and nuts for the frame in the following sequence - 1 through 24 - by hand.
• The guide frame must be in contact with the entire contact surface of the cylinder head.
- Tighten the bolts and nuts => [ Guide Frame Tightening Specifications and Sequence ] Service and Repair.
- Remove the (T40095) and the (T40096/1).
The rest of the installation is in reverse order of removal, note the following:
- Install the camshaft seal. Refer to => [ Camshaft Seal ] Service and Repair.
- Install the new cover - 15 - => [ Cap ] Service and Repair on the cylinder head 1 to 2 mm deep with a suitable thrust piece.
- Install the vacuum pump.
- Install cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover
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 the crankshaft at least 2 turns.