Part 2

Removing and installing camshafts (includes setting timing)

16. Tighten adjusting screw -arrow- on the staking tool to the specified torque by turning it clockwise.





Tightening adjusting screw on staking tool

-> Tightening torque: 10 Nm (7.5 ftlb.)

17. Turn the crankshaft clockwise (running direction of engine) to the TDC marking at the vibration damper.
17.1. This position is marked TCD 1/4 on the surface.
17.2. Fix in place using a long locating pin 9595/1 -1-.





TDC marking on cylinder 1/4 on vibration damper

18. Tighten central screws on sprocket and camshaft controller to the prescribed initial tightening torque.





Central screws on camshaft timing gears

18.1. Tighten central screw on sprocket -1- initially and counter with a holding wrench 9775 while doing this.

-> Initial tightening: 30 Nm (22 ftlb.)

18.2. Tighten central screw on camshaft controller -2- initially and counter with a long open-ended wrench (a/f 32) at the driver -3- while doing this.

-> Initial tightening: 35 Nm (26 ftlb.)

19. Staking tool 9772 must now be removed.
19.1. Loosen the adjusting screw. A creaking noise is completely normal due to the tension in the tool.
19.2. Unscrew fastening screws on the cylinder head and remove the tool.
20. Tighten central screws on the sprocket and camshaft controller to the prescribed final torque using a torque angle wrench.





Outlet sprocket threaded joint

20.1. Tighten central screw on sprocket and counter with a holding wrench 9775 -1- while doing this.

-> Torque angle: 60 degrees





Camshaft controller threaded joint

20.2. Tighten central screw on camshaft controller and counter with a long open-ended wrench (a/f 32) -1- while doing this.

-> Torque angle: 120 degrees

Installing camshafts, setting timing - cylinder bank 1-3

Notice
Dirt and contamination
^ Risk of damage to units or components

-> Protect components from dirt and contamination.
-> Clean or replace dirty components.

Caution
Timing chains positioned incorrectly
^ Too much wear on sprockets and timing chains
^ Engine damage

-> Perform a visual inspection to check the position of the timing chains on the tensioning and guide rails.

Information
Before final tightening (torque angle) of the central screws, the special tool staking tool 9772 must be removed.

Information
Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:
^ Torx screws: (E..) for external Torx, (T..) for internal Torx.
^ Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

1. Continue to turn the crankshaft clockwise (running direction of engine) to 60 degrees before TDC at the vibration damper.
1.1. This position is marked U 3/6 on the surface.





Position U 3/6 (60 degrees before TDC)

1.2. Fix in place using a long locating pin 9595/1 -1-.
2. Turn the engine on the assembly support until cylinder bank 1-3 is at the top.
3. Fit lower part of bearing saddle -1-.





Lower part of bearing saddle 1-3

3.1. Check position of oil bores and position and fit the component on the dowel sleeves.
4. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
4.1. Check that all bucket tappets are installed correctly.
5. Fit the outlet camshaft and sprocket.





Outlet camshaft and sprocket (view of cylinder bank 1-3)

5.1. Check that the friction plate is fitted in the sprocket.





Friction plate in sprocket

5.2. Screw in the central screw but make sure that the sprocket can still turn slightly.
5.3. Lift the timing chain and position the camshaft and sprocket at the overlapping position of cylinder 1. The cams must be facing downwards at an angle with respect to the cylinder head wall and the camshaft must lie loosely in the bearing positions.
5.4. Another feature is the data matrix code marking on the reconditioned surface next to the dihedron -inset-. These markings must be facing the observer at overlapping position.





Marking on camshafts 1-3 at overlap

Information
The outlet sprocket must be positioned correctly in order to build up the pressure of the high-pressure pump correctly when starting the engine.

6. After fitting the outlet camshaft, the sprocket must be aligned as follows with the driver for the high pressure pump.
6.1. Cylinder head positioned vertically: The sprocket -1- must be positioned towards the top left using the deeper recess on the driver (15 mm) -2- at approx. 15 degrees with respect to the sealing face of the cylinder head.





Driver for high-pressure pump prepositioned

7. Fit the intake camshaft.
7.1. Check that the friction plate is fitted on the shaft.





Position of friction plate on intake camshaft

7.2. Lift the timing chain and engage and secure the camshaft controller. Guide the intake camshaft into the controller and set it to the overlapping position of cylinder 4. The cams must be facing downwards at an angle with respect to the spark-plug recess and the camshaft must lie loosely in the bearing positions.





Intake camshaft with camshaft controller

7.3. The square marking on the camshaft must be facing the observer.
7.4. Screw in the internal Torx central screw (T55, M12 x 1.5 x 110) by hand until the controller can still turn.
8. Check cam position of cylinder 1 before fitting the bearing saddle and bearing covers. The cams must be facing the cylinder head wall and must point downwards at an angle.
8.1. Check the position of the outlet sprocket again (position of driver for high-pressure pump).





Guide pins on tensioning and guide rails

9. Use a torch to check that the timing chains are on the tensioning and guide rails between the guide pins -arrow-.
10. Oil the bearing surfaces of the camshafts with new engine oil. When rebuilding the engine, apply a light coating of Optimol Optipit grease (Part No. 000.043.204.17) on the bearings.
11. Fit bearing saddle and bearing covers.
11.1. Fit bearing saddle and bearing covers and observe markings.
11.2. Fit four external Torx screws (E10, M6 x 55) on the bearing saddle.
11.3. Fit two external Torx screws (E10, M6 x 37) on each of the bearing covers.
11.4. Fit and tighten screws according to the specified tightening sequence.

=> Initial tightening torque for bearing covers and bearing saddle: 5 Nm (3.5 ftlb.)

=> Final tightening torque angle for bearing covers and bearing saddle: 50 degrees





Tightening sequence for mounting camshafts 1-3

12. Check axial bearing clearance by pulling and pressing on the camshaft controller and sprocket.
12.1. There must be perceptible clearance because otherwise the shafts will have to be fitted again.
13. Screw in and tighten chain tensioner with anew seal.

=> Tightening torque for chain tensioner: 80 Nm (59 ftlb.)

Set the timing, cylinder bank 1-3: Essentially, the timing for cylinder bank 1-3 is set in the same way as for cylinder bank 4-6.

14. Check cam position for cylinder 1 and markings again.





Cam position for cylinder 1 at overlap





Marking on camshafts 1-3 at overlap

15. The adjusting device is positioned on the reconditioned dihedron of the camshafts -arrows-.





Position of dihedron of camshafts 1-3

15.1. Check the position of the intake and outlet side.





Fitting position of staking tool for cylinder bank 1-3

A - A = Outlet
E - E = Intake
1 - Staking tool
2 - Staking guide

16. Fit special tool staking tool 9772 on the cylinder head and camshafts.
16.1. Secure on the cylinder head with four M6 x 25 screws and tighten screws hand-tight only.





Staking tool screws for cylinder bank 1-3

17. Tighten adjusting screw on the staking tool by turning it clockwise.

=> Tightening torque for adjusting screw: 10 Nm (7.5 ftlb.)





Tightening adjusting screw on staking tool

18. Turn the crankshaft clockwise (running direction of engine) to the TDC marking at the vibration damper.
18.1. This position is marked TCD 1/4 on the vibration damper.
18.2. Fix in place using a long locating pin 9595/1.





TDC marking on cylinder 1/4 at vibration damper

19. Check position of the outlet sprocket -1-.
19.1. The driver must now be positioned towards the top left with the deeper recess on the driver (15 mm) -2- at approx. 45 degrees with respect to the sealing face of the cylinder head.





Positioning driver for high-pressure pump

19.2. If this is not the case, the outlet camshaft must be re-aligned once again with the sprocket.
20. Tighten central screws on sprocket and camshaft controller to the prescribed initial tightening torque.





Central screws on camshaft timing gears

20.1. Tighten central screw on sprocket -1- initially and counter with a holding wrench 9775 while doing this.

=> Initial tightening torque for central screw on outlet sprocket: 30 Nm (22 ftlb.)

20.2. Tighten central screw on camshaft controller -2- initially and counter with a long open-ended wrench (a/f 32) at the driver -3- while doing this.

=> Initial tightening torque for central screw on camshaft controller: 35 Nm (26 ftlb.)

21. Remove special tool staking tool 9772.
21.1. Loosen the adjusting screw. A creaking noise is completely normal due to the tension in the tool.
21.2. Unscrew fastening screws on the cylinder head and remove the tool.
22. Tighten central screws on the sprocket and camshaft controller to the prescribed final torque using a torque angle wrench.
22.1. Tighten central screw on sprocket and counter with a holding wrench 9775 -1- while doing this.

=> Final torque angle for central screw on outlet sprocket: 60 degrees





Outlet sprocket threaded joint

22.2. Tighten central screw on camshaft controller and counter with a long open-ended wrench (a/f 32) -1- while doing this.





Camshaft controller threaded joint

=> Final torque angle for central screw on camshaft controller: 120 degrees

23. Then check the position of the camshafts on both sides again (pay attention to overlapping position).
23.1. It must be possible to screw in the adjusting screw by hand at the staking tool 9772.
23.2. Remove the tool and complete the engine.

Subsequent work

1. Install cylinder head cover.
2. Fit cover for positive crankcase ventilation.
2.1. Fit cover for cylinder bank 1-3 -1- with a new O-ring and moulded seal and secure with three external Torx screws (E10, M6 x 25) -4-.





Cover on positive crankcase ventilation 1-3

2.2. Fit cover for cylinder bank 4-6 -1- with a new O-ring and secure with two external Torx screws (E10, M6 x 25) -3-.





Cover on positive crankcase ventilation 4-6

-> Tightening torque: 13 Nm (9.5 ftlb.)

3. Install high-pressure pump.

-> Tightening torque: 13 Nm (9.5 ftlb.)

4. Install vacuum pump.

-> Tightening torque: 13 Nm (9.5 ftlb.)

5. Fit spark plugs.
6. Fit bar ignition modules.
6.1. Fit and tighten one internal Torx (T30) countersunk screw (M6 x 16) on each.

-> Tightening torque: 10 Nm (7.5 ftlb.)

6.2. Plug in cable plugs for bar ignition modules, hall sender and solenoid hydraulic valve (VVS) and screw on two ground cables for each.

-> Tightening torque: 10 Nm (7.5 ftlb.)

7. Fit heat shield.
7.1. Insert and tighten four external Torx screws (M6 x 12).

-> Tightening torque: 10 Nm (7.5 ftlb.)

8. Fit holder for rear silencer.
8.1. Insert and tighten four external Torx screws (M8 x 20).

-> Tightening torque: 23 Nm (17 ftlb.)

9. Fit exhaust manifolds with a new seal.
9.1. Insert and tighten nine external Torx screws (M8 x 21) on each. Observe tightening sequence.

-> Tightening torque: 23 Nm (17 ftlb.)

10. Install rear silencer.
11. Install engine carrier.
12. Install the engine.