Removing Camshaft Housing - Engine Removed

Removing Camshaft Housing - Engine Removed

Tools

Item A - D:

Component Overview And Tightening Torques













Removing The Camshaft Housing
The following preliminary work must be carried out:
- Remove engine.
- Remove rear muffler.
- Remove the oil container.
- Remove generator.
- Remove coolant guide housing.

1. Cylinder bank 1 - 3: Undo fuel collection pipe with injection valves and remove holder for turbochargers.
2. Cylinder bank 4 - 6: Undo holder for turbochargers and remove bypass flap control box on turbocharger.
3. Remove ignition coil. Remove electrical plug of the ignition coils, unscrew 2 cylinder screws (hexagon socket) M6 x 25 of each and pull ignition coils out of spark-plug recess.
4. Remove 2 closure caps (green, plastic) between camshaft housing cover and cylinder head (clutch side). To do so, puncture the closure cap in the middle and lever out using a small slotted screwdriver.







5. Remove oil extraction pump and closure cap. The oil extraction pump flange must be held with a wrench when the oil line on the pump is loosened. Subsequently unscrew the three fastening screws of the oil extraction pump and the three fastening screws of the closure cap, then lever off the two components.
6. Remove solenoid hydraulic valve for valve lift adjustment. To do so, remove plug, unscrew both hexagon-head bolts M6 x 25 and remove with the holder. Subsequently remove the valve.







7. Remove camshaft housing cover. Unscrew the 15 hexagon - head bolts M6 and remove the camshaft housing cover. If this is stuck, it can be loosened by gently tapping with a plastic hammer.
8. Check engine position. The cylinder side which is to be worked on must be positioned to overlapping TDC so that the camshaft can be removed without tension. For cylinder bank 1 - 3, this means: the cams of the exhaust and inlet shaft of cylinder 1 point towards each other -Figure 8.1-, for cylinder bank 4 - 6: the cams of the exhaust and inlet camshaft of cylinder 4 point away from each other (each points towards the cylinder head outer wall) -Figure 8.2-.

Figure 8.1: Overlapping TDC of cylinder 1







-1- Exhaust camshaft
-2- Inlet camshaft

Figure 8.2: Overlapping TDC of cylinder 4







-2- Inlet camshaft
-1- Exhaust camshaft

9. Remove chain tensioner. To do this, unscrew the two fastening screws of the chain tensioner cover and remove the cover. Then remove the chain tensioner.







10. Remove guide rail for timing chain. Remove the three fastening screws on the short guide rail between the camshaft sprockets and remove the guide rail.







11 Remove camshaft sprockets. The timing chain must not be loaded when the screw connection of the camshaft sprockets is loosened. To remove the sprocket wheels, the actuating element of the inlet camshaft must be countered using special tool holding wrench No. 9653, and the sprocket wheel of the exhaust camshaft must be countered using special tool holding wrench No. 9653/1.







NOTE:
- Only remove oil guide housing from the camshaft if the camshaft has to be replaced
- The pan-head screws of the oil guide housing can fall into the crankcase when unscrewing, the use of a magnetic socket wrench insert is therefore recommended.







- The oil guide housing of cylinder 1 - 3 and 4 - 6 differ in height.

12. Remove oil guide housing. Heat the three hexagon socket head bolts using a hot-air gun, unscrew and remove the housing. The fastening screws are microencapsulated and therefore must be replaced.







13. Remove camshaft bearing cap. To do so, uniformly unscrew the hexagon-head bolts of the relevant bearing covers from the inside. Remove the bearing covers in the specified order.







14. Remove camshaft bearing covers. Lift the bearing covers up and off. The bearing covers must not be confused.







15. Remove thrust bearing cover. Unscrew the hexagon-head bolts and remove the thrust bearing cover up and off.







16. Lift camshafts up and out.

WARNING: Do not confuse the flat-base tappets.

The flat-base tappets have been run in in their housing. Therefore, they must not be interchanged or soiled.

17. Remove the flat-based tappets. Pull the flat-based tappets upwards out of the camshaft housing. In order to avoid confusing the individual flat-based tappets, they should be placed on a prepared sheet of paper as shown in the diagram.







18. Remove the camshaft housing. Unscrew and remove the 18 hexagon-head bolts in the order specified. Then remove the camshaft housing.