Camshafts

Camshafts

Special tools, testers and auxiliary items required

• Assembly Tool (T10352)

• Counter Hold Tool (T10355)

• Locking Pin (T40011)

• Lever (T40243)

• Locking Tool (T40267)

• Camshaft Clamp (T40271)

• Locking Pin (T10060 A)

• Ignition Coil Puller (T40039)

• Polydrive Bit and Drive Socket (T10070)

• Thrust Piece (T10174)

Removing

• 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.

• If the cylinder head cover was removed, then the cover - item 15 - => [ (Item 15) Cap ] Valvetrain Overview must be replaced.

• During installation, cable ties must be installed at the same location.

Removing

- Remove the engine cover - arrows -.






- Remove the cover for the air guide; to do this, disengage the side clips- arrows -.






- Unclip the lower air guide, to do this, disengage the clips - arrows -.






- Remove both the lower air guide and the air guide hose.

- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).






- Remove the air guide hose - 2 -.

- Remove the bolt - 4 - and the air filter housing.

• Ignore - 3 -.

- Remove the bolts - arrows -.






- Lift the clamps - 1 and 2 - and remove the air guide pipe.

- Disconnect the connector from the camshaft adjustment valve 1 (N205) - 1 -.






- Remove the bolts - arrows - and then the camshaft adjustment valve 1.

- Remove the bolts - 1 through 5 - and the upper timing chain guard.














The control valve has a left thread.

- Remove the control valve using the (T10352) or (T10352/1) in direction of - arrow - depending on the version.

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






- Rotate the vibration damper using the (T10355) into the TDC position.






• The notch on the vibration damper and the marking on the lower timing chain guard must be opposite one another - arrow -.

• The markings - 1 - on the camshafts must point upward.

- Mark the camshaft timing chain and the cylinder head - arrows - to match the marking on the chain sprockets - 1 - with a waterproof marker.






- In addition, mark the camshaft timing chain to the camshaft timing chain guide rail - 2 - with a permanent marker.

- Remove the plug - arrow -.






- Remove the bolts - arrows -.






- Remove the bolt - arrow -.






Two Different Chain Tensioners may be Installed Depending on the Version:






Version 1

- Install the (T40243) - arrows -.

- Insert a scriber or a suitable screwdriver into the opening for the chain tensioner in the direction of - arrow 1 - to lift up the locking wedge for the chain tensioner, slowly press down the (T40243) and hold it in the direction of - arrow 2 -.

- Secure the chain tensioner using (T40011).






Version 2






- Install the (T40243) - arrows -.

- Press the chain tensioner locking ring - arrow - together and slowly press and hold the (T40243) in the direction of - arrow -.

- Secure the chain tensioner with the (T40267).






All






- Remove the (T40243).

- Bolt the (T40271/2) to the cylinder head and push the chain sprocket splines in the direction of - arrow 2 -. If necessary, turn the intake camshaft with a wrench in the direction of the - arrow 1 -.

- Remove the bolt - 1 - and guide the tensioning rail - 2 - downward.






- Attach the (T40271/1) to the cylinder head.






- Turn the exhaust camshaft with the wrench in the direction of the - arrow 1 - and slide the (T40271/1) in the chain sprocket splines in the direction of the - arrow 2 -.

- Mark the camshaft sprocket to the (T40271/1) and the (T40271/2) - arrow -.






- Remove the upper guide track - 1 - by unlocking the latch with a screwdriver and pushing the guide track forward.

- Remove camshaft timing chain from chain sprockets.


Risk of damaging valves and piston crowns.

• If the camshaft timing chain was removed from the cylinder head, then the crankshaft may not be turn further.

- Turn the intake camshaft with a wrench in the direction of - arrow 1 -, slide the (T40271/2) out of the chain sprocket splines if the direction of - arrow 2 - and bring the camshaft into the rest position.






- Turn the exhaust camshaft with a wrench in the direction of - arrow 1 -, slide the (T40271/1) out of the chain sprocket splines if the direction of - arrow 2 - and bring the camshaft into the rest position.






- Disconnect the connector on the ignition coils and free up the wiring harness.

- Remove the ignition coils with the (T40039).






- Disconnect the crankcase ventilation hoses - 1 and 2 -.






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

- Disconnect the lines - 1 and 3 -.






- Disconnect the connector - 2 - from the Camshaft Position (CMP) sensor (G40).

- Remove the high pressure pump.

- Remove vacuum pump.

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






- Remove the cylinder head cover.

- Remove the camshafts.


Risk of contaminating lubricating system and bearing.

• Cover open parts of engine.

Installing

• Tightening specifications, refer to => [ Valvetrain Overview ] Valvetrain Overview.

• Sealing surfaces must be completely free of oil and grease.

• Make sure that all roller cam followers make contact correctly on valve stem ends.

• Silicon sealant, refer to the Parts Catalog.

• Note the expiration date of the silicone sealant.

• The cover must be installed within 5 minutes after the silicone sealant has been applied.

- Remove any sealant residue on the cylinder head using the flat blade scraper.


Danger of eye injury.

• Wear protective goggles.


Risk of contaminating lubricating system and bearing.

• Cover open parts of engine.

- Remove any sealant out of the groove in the cylinder head cover as well as from any sealing surface using, for example, a rotating plastic brush.






- Clean sealing surfaces, must be free of oil and grease.

- Cut the tube nozzle at the front marking (nozzle diameter: approximately 2 mm).






- Lubricate the running surfaces of both camshafts.

New Camshafts

- Transfer the self-made markings from the old camshafts to the new camshafts.

All

- Place the camshaft into the cylinder head; the recesses - arrows - must be perpendicular to each other.






- Replace the cylinder head cover bolts.

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






• Thickness of sealant bead: 2 to 3 mm.

• The cylinder head cover must be installed within 5 minutes after the silicone sealant has been applied.

• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

• Note the expiration date of the sealing compound.

Sealant, refer to the Parts Catalog.

- Tighten the bolts in several steps, tightening sequence, refer to => [ Cylinder Head Cover Tightening Sequence ] Valvetrain Overview.

• Make sure the cylinder head cover is not tilted.

• Drive the cap - 1 - in without sealing using the (T10174).






• -a-: 1 to 2 mm







When rotating the crankshaft, make sure the timing chain cannot damage any other components.

- Rotate the vibration damper using the (T10355) into the TDC position - arrow -.

• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

- Turn the intake camshaft in the direction of the - arrow 1 - until the markings - 3 - align with the (T40271/2).






- Slide the (T40271/2) into the chain sprocket splines in the direction of - arrow 2 -.

- Turn the exhaust camshaft in the direction of - arrow 1 - until the markings - 3 - align with the (T40271/1).






- Slide the (T40271/1) into the chain sprocket splines in the direction of the - arrow 2 -.

- Position the markings on the chain links - arrows - at the chain sprockets - 1 - to install the camshaft timing chain.






- Install the upper glide track - 2 -.

- Turn the exhaust camshaft in the direction of the - arrow 1 -, slide out the (T40271/1) from the chain sprocket splines in the direction of the - arrow 2 - and release the camshaft.






- Remove the (T40271/1).

- Move the tensioning rail - 2 - up and install the bolt - 1 -.






- Turn the intake camshaft in the direction of - arrow 1 -, slide out the (T40271/2) from the chain sprocket splines in the direction of - arrow 2 - and release the camshaft.






- Remove the (T40271/2).

- Check the valve timing. The camshaft timing chain and cylinder head - arrows - must align with the markings on the chain sprocket - 1 -.






- The markings for the camshaft timing chain and the camshaft timing chain glide track - 2 - must be opposite one another.

- The notch on the vibration damper must be opposite the marking on the lower section of the timing chain guard - 3 -.

- Mount the bearing bracket and the bolts - arrows - hand-tight.






- Remove the (T40011) or the (T40267) , depending on the version.

- Tighten the bolts - arrows -. Refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.

- Install the bolt - arrow -.






- Install the control valve - item 6 - => [ (Item 6) Control Valve ] Camshaft Timing Chain Overview.

- Install the vacuum pump.

- Install the high pressure pump.

Assemble in reverse order of disassembly.