Timing Component Alignment Marks: Locations
Installing camshafts, adjusting timing - engine removedATTENTION: Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.
Identification of housings of camshafts:
^ Inlet camshaft:
^ Thrust bearing: "E" and matching number on cylinder head/cylinder head cover
^ Housing of bearing sleeve: only matching number
^ Outlet camshaft:
^ Thrust bearing on sprocket: "1A" and matching number on cylinder head/cylinder head cover
^ 2nd Thrust bearing: "2A" and matching number on cylinder head/cylinder head cover
1. To remove the play from the timing chain drive, turn the crankshaft by means of the pulley or vibration balancer clockwise (running direction of engine to 60° before TDC : marking U6 on pulley or vibration balancer coincides with fixing bore in crankcase. Fix with locating pin 9595/ 1.
Assembly of cylinder bank - 6
2. Turn the engine on the assembly support until cylinder bank -6 stands vertically upwards.
3. Oil the bearing surfaces of the camshafts with new engine oil.
4. Insert inlet camshaft - 6. Pull the timing chain out of the chain housing of the cylinder head with a welding wire and position on the ring gear of the camshaft adjuster, at the same time inserting the camshaft at overlapping TDC of cylinder (the cams of cylinder point towards the bulkhead of the flat-base tappet housing -arrows-).
Note: Make sure that the bearing sleeve on the inlet camshaft is positioned correctly.
5. The bearing sleeve of the inlet camshaft must be positioned so that the centrally bored blind hole points vertically upwards -arrow- (the rib of the cylinder head should also be at the centre in relation to the bearing sleeve). In this position, the dowel pin in the bearing bore of the cylinder head will fit precisely into the opposite off-centre blind hole bore. Any other bores are through-holes for guiding the oil.
6. Insert exhaust camshaft - 6. Lay the timing chain on the flange for the sprocket, then insert the camshaft at overlapping TDC of cylinder (the outlet cams of cylinder point towards the cams of the inlet camshaft -arrows-).
7. Insert exhaust camshaft sprocket in the timing chain and position on camshaft flange. The four threaded bores in the camshaft flange must be covered by the slots of the sprocket in the clockwise running direction of the engine approximately half way -arrows-.
8. Oil the bearing surfaces of the camshafts with new engine oil.
Note: Do not interchange the thrust bearings of the inlet and exhaust camshafts during assembly; observe identification markings.
9. Insert three thrust bearings and one housing -arrows- for the bearing sleeve of the camshafts together with the guide rail for the timing chain.
10. Insert eight housing screws (Torx): six M6 35 -1- and two M6 40 -2- for camshaft bearing and guide rail. Tighten screws evenly and just finger-tight.
Adjust timing, cylinder bank - 6
11. Align both camshafts. The small circular cut-outs must point upwards -arrows-.
12. Using special tool adjusting gauge 9686, fix camshafts (if necessary with the gauge twisted) with an M8 screw (e.g. hexagon-head bolt M8 ). The flat tool face points upwards. Screw in fastening screw by hand.
13. Screw the housing screws of the inlet and exhaust camshafts and the auxiliary screw of the adjustment gauge alternately by approx. another 90° until the specified tightening torque is reached. Tightening Torque: 7.5 ft. lb.
14. Insert guide rail screw with a new O-ring and tighten (hexagon socket M6, a/f 5) Grease O-ring with Optimol MP3. - Tightening torque: 7.5 ft. lb.
15. Fit chain tensioner, side - 6 (hexagon socket a/f 14). Fit chain tensioner with new aluminium sealing ring and tighten. Tightening Torque: 59 ft. lb.
Note: Position crankshaft above the pulley or vibration balancer before final adjustment of the timing to the TDC marking.
16. Turn the crankshaft by means of the pulley or vibration balancer clockwise (running direction of engine to TDC mark: marking U6 on pulley or vibration balancer coincides with fixing bore in crankcase. Fix with locating pin 9595/ 1.
17. Insert four Torx screws M6 to sprocket of exhaust camshaft and tighten evenly in diagonally opposite sequence. Tightening Torque: 10.5 ft. lb.
18. Tighten the central screw of the camshaft adjusting device. Fit special tool retaining tool 9685 on hexagon of intermediate piece of the central screw. Screw in the central screw gently by hand so that the loose contact block just touches the fitting bore of the oil suction pump. Fix the hexagon-head bolt to the contact block.
Note: Before final tightening (torque angle) of the central screw, the special tool adjusting gauge 9686 must be removed.
19. Tighten the central screw in two stages. Initial tightening to the specified toque. - Initial tightening: 37 ft. lb.
20. Remove special tool adjustment gauge 9686. Undo the M8 screw and remove gauge.
21. Apply final tightening to central screw with torque angle wrench. - Final tightening torque angle: 110°
Assembly of cylinder bank 1 -3
22. Turn the engine on the assembly support until cylinder bank 1 -3 stands vertically upwards.
23. Turn the crankshaft by means of the pulley or vibration balancer clockwise (running direction of engine further still until the marking U6 on pulley or vibration balancer coincides with fixing bore in crankcase (60° before TDC). Fix with locating pin 9595/ 1.
24. Oil the bearing surfaces of the camshafts with new engine oil.
25. Insert inlet camshaft 1 - 3. Pull the control chain out of the chain housing of the cylinder head with a welding wire and position on the toothed ring of the camshaft adjuster. Then insert the camshaft at overlapping TDC of cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head -arrow-).
Note: Make sure that the bearing sleeve on the inlet camshaft is positioned correctly.
26. The bearing sleeve of the inlet camshaft must be positioned so that the centrally bored blind hole points vertically upwards -arrow- (the rib of the cylinder head should also be at the centre in relation to the bearing sleeve). In this position, the dowel pin in the bearing bore of the cylinder head will fit precisely into the opposite off-centre blind hole bore. Any other bores are through-holes for guiding the oil.
27. Insert exhaust camshaft 1 - 3. Lay the control chain on the flange for the chain sprocket, then insert the camshaft at overlapping TDC of cylinder 1 (the cams of cylinder 1 point diagonally downwards towards the outside of the cylinder head).
28. Insert exhaust camshaft sprocket in the timing chain and position on camshaft flange. The four threaded bores in the camshaft flange must be fully visible on the left at the slotted curves of the sprocket-arrows- so that the Torx screws M6 12 can still be positioned to fasten the sprocket.
Note: Do not interchange the thrust bearings of the inlet and exhaust camshafts during assembly; observe identification markings.
29. Insert three thrust bearings and one housing -arrows- for the bearing sleeve of the camshafts together with the guide rail for the timing chain.
30. Insert eight housing screws (Torx): six M6 35 -1- and two M6 40 -2- for camshaft bearing and guide rail. Tighten screws evenly and just finger-tight.
Timing for side 1 - 3
Note: Position crankshaft above the pulley or vibration balancer before final adjustment of the timing to the TDC marking.
Note: Before final tightening (torque angle) of the central screw, the special tool adjusting gauge 9686 must be removed.
31. Final timing adjustment for cylinder bank 1 - 3 is analogous to that for cylinder bank - 6.
32. Fit chain tensioner for side 1 -3 (hexagon a/f 32) before turning crankshaft to the TDC mark. Fit chain tensioner with new sealing ring and tighten. Tightening Torque: 59 ft. lb.
After adjusting the timing, this should be re-checked.
33. Turn the engine 360° at the crankshaft and fix at the TDC mark. Check camshaft position of cylinder bank -6 using the adjusting gauge 9686. Then turn a further 360° and check the camshaft position of cylinder bank 1 - 3.
Subsequent work for installing camshafts
1. Insert solenoid hydraulic valves and new gaskets for the spark-plug recesses. Fit new O-rings into both solenoid hydraulic valves and insert into the bores in the cylinder head. Grease O-rings with Optimol MP3.
2. Install cylinder head cover.
3. Fit oil suction pump (1 - 3) and tandem pump ( - 6) with new, micro-self-locking Torx screws M6. Replace O-rings and grease with Optimol MP3. - Tightening torque: 7.5 ft. lb.
4. Fit new plastic cap dry on cylinder head. Tap in with a plastic hammer.
5. Fit ground strap to cylinder head -6 with Torx screw M8 20 and tighten. Tightening Torque: 17 ft. lb.
6. Insert each ignition coil into its spark plug recess, fit two M6 25 Torx socket screws and tighten. Tightening Torque: 7.5 ft. lb.
7. Fit retainer plates and holders for the solenoid hydraulic valves. Tightening Torque: 7.5 ft. lb.
8. Fit holder for rear muffler. Fit and tighten two Torx screws M8 30 intake side and two Torx screws M8 25 exhaust side. Fit cable plugs for ignition coils and solenoid hydraulic valves, fixing cable in the sheetmetal clips. Tightening Torque: 17 ft. lb.
9. Fit and tighten cover plate with two Torx screws M6. Tightening Torque: 7.5 ft. lb.
10. Connect two cable plugs to the oil temperature switch for cylinder bank - 6.