Camshafts
Camshafts
Special tools, testers and auxiliary items required
• Ignition Coil Puller (T40039)
• Assembly Tool (T10352) and Assembly Tool (T10352/1)
• Counter Hold Tool (T10355)
• Locking Pin (T40011)
• Thrust Piece (T10174)
• Drift (T40196)
• Spacers (T40191)
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 18) Cover ] Valvetrain Overview must be replaced.
• During installation, cable ties must be installed at the same location.
- Remove the engine cover - arrows -.
- Remove the bolts - arrows - and air guide.
- 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 on the ignition coil connector strip.
- Disconnect the connectors - arrows - from the camshaft adjuster actuators.
- Release the connector - arrows - and disconnect all the connectors at the same time from the ignition coils.
- Remove the ignition coils using the (T40039).
- Remove the camshaft adjuster actuators - arrows -.
- 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 noise insulation.
- Remove the right noise insulation - arrows -.
- Remove the frame for the noise insulation.
- 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 timing chain guard upper section.
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 - arrow -.
• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.
The engine could be destroyed.
• The (T40196) may be installed only in the shown positions.
- Install the (T40196) as illustrated.
- Turn the crankshaft 2 complete turns in the direction of engine rotation.
• The engine must be back at "TDC".
- Remove the (T40196).
- Mark the camshaft timing chain and the cylinder head - arrows - to match the marking on the chain sprockets - 1 - with a waterproof marker.
- Remove the plug - arrow -.
- Lift the chain tensioner locking wedge by inserting a scriber or a suitable screwdriver into the hole in the chain tensioner direction of - arrow 1 -.
- Turn the crankshaft opposite the engine direction of rotation - arrow direction 2 - and secure it with a (T40011).
• The intake camshaft switches in the engine direction of rotation.
• The intake camshaft switches in the engine direction of rotation.
- Remove the bolt - 1 - and guide the tensioning rail - 2 - downward.
- Remove the upper guide track - 3 - 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.
- Remove the high pressure pump.
- Remove vacuum pump.
- Remove the cylinder head cover bolts in sequence - 1 to 6 -.
- Remove the cylinder head cover.
- Remove the camshafts.
Risk of contaminating lubricating system and bearing.
• Cover open parts of the engine.
- Make sure that no dirt or sealant residue can get into the cylinder head.
Installing
• For the correct tightening specifications, refer to => [ Valvetrain Overview ] Valvetrain Overview.
• Sealing surfaces must be completely free of oil and grease.
• The pistons must not be positioned at TDC.
• Make sure that all roller cam followers make contact correctly on the valve stem ends.
• Silicone sealant, refer to the Electronic Parts Catalog (ETKA).
• Note the expiration date of the silicone sealant.
• The cover must be installed within 5 minutes after application of the silicone sealant.
- 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.
- Lubricate the running surfaces of both camshafts.
Danger of eye injury.
• Wear protective goggles.
- Install the camshaft with the (T40191) as illustrated, move the spacers into the correct position if necessary.
• If necessary, use a second set of (T40191) or (T40191/1).
- Install the camshafts into the cylinder head; the markings - arrows - must be located as shown in the illustration.
- Check the alignment - arrows - of the camshafts.
- Cut the tube nozzle at the front marking (nozzle diameter: approximately 2 mm).
- Apply the silicone sealant on the clean sealing surface of the cylinder head cover as illustrated - arrows -.
• Thickness of sealant bead: 2 to 3 mm.
• The cylinder head cover must be installed within 5 minutes after application of silicone sealant.
• 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 Electronic Parts Catalog (ETKA).
- Mount the cylinder head cover on the cylinder head.
- Replace the cylinder head cover bolts.
- 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.
• The marked links of the camshaft timing chain must be positioned on the markings on the chain sprockets.
- Turn the intake camshaft in direction of - arrow - with the wrench and install the camshaft timing chain. The markings on the camshaft timing chain and on the cylinder head - arrows - must line up with the markings on the chain sprockets - 1 -.
- Mount the bearing bracket and the bolts - arrows - hand-tight.
- Remove the (T40011).
- Tighten the bolts - arrows -. Refer to => [ Camshaft Timing Chain Overview ] Camshaft Timing Chain Overview.
- Install the control valve => [ (Item 6) Control Valve ] Camshaft Timing Chain Overview.
- Install the vacuum pump.
- Install the high pressure pump.
Assemble in reverse order of disassembly.