Remove and Install Camshaft

REMOVING CAMSHAFT
Valve Timing Components:
1 Camshaft 248°- S 38 Z
2 Plug for camshaft oil bore
3 Circlip
4 Cylindrical pin - different for intake and exhaust sprockets. New standard pin for "E" and "A" can be installed retroactively.
5 Sprocket - intake "E"
6 Sprocket - exhaust "A"
8 Lock plate
9 Bolt M 6x16
10 Adapter for distributor rotor
11 Intake valve - 37 mm (1.457") diameter Oversize valves with larger stem diameter are available.
12 Exhaust valve - 32 mm (1.260") diameter Oversize valves with larger stem diameter are available.
13 Spring retainer, lower
14 Valve stem seal
15 Valve spring - 42.5 mm (1.673") long Double spring set can be installed retroactively together with new spring retainers.
16 Spring retainer, upper
17 Valve collets
18 Tappet
19 Shims from 3.00 to 4.25 mm (0.118 to 0.167")

- Remove cylinder head cover.
- Remove fan cowl and fan.




- Remove distributor cap (1).
- Unscrew distributor rotor (2).
- Unscrew adapter (3).
- Remove cover (4).

Installation Note: Check 0-ring (5), replacing if necessary. Torque cap to 4 + 1 Nm (3 + 0.75 ft lb.).




- Take off distributor housing and cover.

Installation Note: Check 0-rings, replacing if necessary.




- Unscrew end cover.

Installation Note: Replace gasket.




- Unscrew guide rails.




Installation Note: Center guide rail with a feeler gage blade.




- Turn crankshaft with Special Tool 11 3 020 to set cylinder 1 to TDC - cyl. 6 overlaps.

CAUTION: Never crank the engine after removing the timing chain.




- Remove chain tensioner, Remove and Install Chain Tensioner Piston.
- Open lockplates and unscrew sprockets.




- Mount Special Tool 11 3 010 on timing case.
- Turn shaft (6) up to the stop - camshaft is held down for removal of bearing caps.
- Unscrew camshaft bearing caps.




- Release arrest and relax the camshaft.
- Remove Special Tool 11 3 010.
- Mark camshafts "E" (intake), "A" (exhaust) and remove.

NOTE:
Intake and exhaust camshafts are identical.
Used camshafts must be installed in the same position.




Installation Note:
- With Crankshaft at TDC, install camshaft so that each groove faces up and in - TDC #1 position.




- Mount Special Tool 11 3 010 on timing case. Hold camshaft in TDC position with Special Tool 11 3 020 and turn shaft (6) up to the stop - camshaft is held down for installation of bearing caps.




- Install camshaft bearing caps on timing case according to the lettering.




- Tighten the timing chain in opposite direction of engine rotation and place on the intake sprocket "E" first.
- Install lockplate and tighten sprocket. Torque to 10 ± 1 Nm (7.5 ± .75 ft lb).




Installation Note:
- Install exhaust sprocket "A".
- Insert adapter (7).
- Install lockplate and tighten sprocket. Torque to 10 ± 1 Nm (7.5 ± .75 ft lb).




- Install chain tensioner, Remove and Install Chain Tensioner Piston.

- Crank engine once in direction of rotation and recheck the timing.
- Crankshaft in TDC
- One each camshaft groove faces in
- One each camshaft groove faces cast boss on bearing cap.
- Lock sprocket mounting bolts with the lock plates.
- Adjust valve clearance, Valve Clearance.




Cam distance "N".