Replacing Right Camshaft

(intake or exhaust side as applicable) Cylinder bank 1-4

Remove both cylinder head covers.
Remove all spark plugs.

Remove fan coupling with fan wheel.
Unscrew and remove splash guard.







Remove all oil lines to left and right cylinder head.

Removal
Removal of camshaft is described separately from installation. Assembly sequence for removal and installation is different.







Crank engine at central bolt in direction of rotation until the first cylinder is in TDC position.







Unfasten the accessible three screws in the exhaust and intake camshaft on cylinder bank 5-8 approx. 1/2 a turn.







Crank engine once engine wise up to TDC position of first cylinder.







NOTE: When camshaft screw connection is unfastened, brace camshaft on hex head.


CAUTION! Do not damage the cylinder head.
Machine open-end wrench accordingly if necessary.







Unfasten remaining three screws in exhaust and intake camshafts in cylinder bank 5-8 approx. 1/2 a turn.

Remove top right timing case cover.







Remove sprocket on right intake camshaft (cylinder bank 1-4).
Secure chain to prevent it from dropping.







Rotate engine into 45° before TDC setting.


NOTE MARKINGS!
Crank engine at central bolt against direction of rotation until gap in increment gear fits in special tool 11 3 440.







Unfasten sprocket wheel screw connection.







To relieve load on chain, compress chain tensioner.







Lock chain tensioner with special tool 11 3 420.







Lift off both sprockets complete with chain.







Move camshafts on cylinder bank 1-4 into installation position.
Rotate exhaust and intake camshafts with special tool 11 3 430.







Recesses in camshafts point approx. 30 - 40° upwards from plane of cylinder head.







Check installation position with special tool 11 2 430.


NOTE: Cylinder designation 1-4 on special tool 11 2 430 point upwards.







Uniformly untighten bearing covers on camshafts for cylinder bank 1-4 in 1/2 turn steps from outside edge to inside.

Remove bearing covers and place to one side in orderly fashion. Lift out camshafts.

Installation
Installation of camshaft is described separately from removal. Assembly sequence differs between removal and installation.







Camshaft designation:
(1) Hex head on exhaust camshaft 1-4 between cylinders 1 and 2.
(2) Hex head on intake camshaft 1-4 between cylinders 3 and 4.







Install camshafts.
Recesses in camshafts point approx. 30 - 40° upwards from plane of cylinder head.







Check installation position with special tool 11 2 430.


NOTE: Cylinder lettering 1-4 on special tool 11 2 430 points upwards.







CAUTION! Do not confuse camshaft bearing covers of cylinders 1 4 and 5-8.


NOTE: The exhaust camshaft bearing covers are legibly marked
A 1 - A 5 from the intake side.







NOTE: The intake camshaft bearing covers are legibly marked with E 1 - E 5 from the intake side.







Fit bearing covers.
Evenly tighten down bearing covers on camshafts for cylinder bank 1-4 in 1/2 turn steps from outside to inside.
Tightening torque:
M6 screw = 10 Nm
M7 screw = 15 Nm
M8 screw = 20 Nm






Secure special tool 11 3 430 to camshaft.







Rotate camshafts until marker bores face upwards.
(1) Exhaust camshaft 1-4.
(2) Intake camshaft 1-4.







Fit special tool 11 2 445 /441 to camshafts on cylinder bank 1-4.







Fit special tool 11 2 446 /442 to camshafts on cylinder bank 5-8.







Align all camshafts with open-end wrench in such a way that special tools 11 2 445 /441/446 1442 locate without gap against cylinder heads.


CAUTION! Do not damage the cylinder head.
Machine open-end wrench accordingly if necessary.







Fit special tool 11 2 443 to special tool 11 2 445 /441 and secure with special tool 11 2 444 using the spark plug thread.







Fit special tool 11 2 443 to special tool 11 2 446 /442 and secure with special tool 11 2 444 using the spark plug thread.







Fit secondary sprocket wheels with chain to camshafts on cylinder bank 1-4. Align long bores centrally. Remove special tool 11 3 420 from chain tensioner.







Install screws in exhaust camshaft on cylinder bank 1- and fit flush.







Rotate engine from 45° before TDC position engine-wise until in TDC position.
Hold crankshaft in TDC position with special tool 11 2 300.


CAUTION! Remove special tool 11 2 300 before switching on the engine.







Fit sprocket with sensor pin (1) to intake camshaft on cylinder bank 1-4 with arrow in cylinder axis pointing upwards and long bores aligned centrally.
Insert screws and fit flush.







Fit special tool 11 2 400 to right cylinder head (cylinder bank 14).








Install special tool 11 3 390 in special tool 11 2 400.
Tighten tensioning rail by turning the adjusting screw 0 the special tool 11 3 390 with special tool 00 9 250 to 1.3 Nm.



NOTE: If installation tolerance is unfavorable, attach special tool 00 9 250 from underside.


Tighten sprockets in following order:
Three screws on left exhaust camshaft, all screws on right exhaust camshaft, three screws on left intake camshaft, all screws on right intake camshaft.







Remove special tools 11 2 444 /443 /441/445.







Remove special tools 11 2 444/443/442/446.







Remove special tool 11 2 300.
Turn over engine once.
Tighten down remaining three screws in exhaust and intake camshafts on cylinder bank 5-8.







Relieve load on special tool 11 3 390 and remove with special tool 11 2 400.
Assemble engine.