Camshaft: Service and Repair

Camshafts

Special tools, testers and auxiliary items required

• Impact Puller (T10133/3) from the Tool Set (T10133)

• Locating Pins (T40116)

• Locking Pin (T40069)

• Hand drill with plastic brush attachment

• Protective goggles

• Sealant, refer to the Parts Catalog

Removing

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

- To remove the camshafts in the left cylinder head, remove the vacuum pump.

- To remove the camshafts in the right cylinder head, remove the high pressure pump and pump motor housing.

- Remove the bolt - arrows - and the camshaft adjuster valves.






- Disconnect the electrical connector - 1 - on the camshaft position sensor.






• Ignore - arrow -.

- Loosen the guide frame bolts in the following sequence: - 21 to 1 -.






• Proceed in the same way with the right guide frame.

- Remove the bolts, carefully loosen the guide from out of the bond and place is on a soft surface.

- Remove the (T40133) - arrows -.






- Mark the camshafts and then remove them.

Installing






Tightening specifications:

• => [ Cylinder Head Overview ] Cylinder Head Overview

• => [ Camshaft Guide Frame Tightening Specifications and Sequence ] Valve Train Overview

• Replace the seals and sealing plugs.

• Secure crankshaft - 1 - in TDC position using (T40069).

• The hydraulic adjusting elements and roller rocker lever are inserted.

Risk of contaminating lubricating system and bearing.

• Cover open parts of the engine.

Danger of eye injury.

• Wear protective goggles.

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

- Clean any oil or grease off the sealing surfaces.

- Check the screen - arrow - for dirt; clean it if necessary.






- Oil running surfaces of both camshafts.

- Insert the camshafts in the guide frame.






• The placement of the camshafts must be exactly within the axial bearings - arrows - of the guide frame.

• The compression ring ends - 1, 2 and 3 - must face up or down. They must never face sideways.

- Rotate the guide frame with the camshafts inserted while holding them securely in the frame.

- Rotate the camshafts until the threaded holes - arrows - face upward.






- Check if the camshafts still lie in the guide frame axial bearings.

- Install the (T40133) in both cylinder heads and tighten - arrows - to 25 Nm.






• Note the expiration date of the sealing compound.






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

- Rotate the guide frame again.






The lubrication system could be plugged with excess sealant.

• Do not apply sealant beads thicker than indicated.

- Apply sealant beads - 4 through 8 - to the clean sealing surfaces on the guide frame as shown in the illustration.

• Thickness of sealant beads: 2.0 mm.

- Apply sealant beads - 1 through 3 - to the clean sealing surfaces on the guide frame as shown in the illustration.

• Thickness of sealant beads: 2.5 mm.

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

- Place the guide frame on the cylinder head.






- Insert the (T40116) in the guide frame and cylinder head.

- Tighten the camshaft guide frame bolts. Refer to => [ Camshaft Guide Frame Tightening Specifications and Sequence ] Valve Train Overview.






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

- Clean the hole in the cylinder head of any oil and grease.






- Coat the outer circumference of the sealing plug - arrow - with sealant; sealant, refer to the Parts Catalog.

- Drive in the sealing plugs until they are flush.

- Remove the (T40116) with the (T10133/3).






Install in reverse order of removal paying attention to the following:

- Install the high pressure pump motor housing and the high pressure pump.

- Install the vacuum pump.

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

Risk of damaging valves and piston heads after working on valve train.

• 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.