Camshaft, Removing And Installing: Installing

• The crankshaft must not be at "TDC".
• Replace bolts that were tightened with an additional turn after removing them.
• Check the O-ring in the Tank Ventilation Pressure Sensor 1 -G950- for damage. Refer to OVERVIEW - CRANKCASE VENTILATION .

-- If removed, install the roller rocker lever and the hydraulic lifter as instructed by the markings. Refer to Figure.

-- Make sure all the roller rocker levers lie correctly on the ends of the valve stems and are clipped onto the respective hydraulic lifters.

In the case that the crankshaft has been turned in the meantime:

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-- Turn the crankshaft on the hex fitting -2- to "TDC" point.

• In "TDC" point the flattened position -1- is in an imaginary vertical line between the camshaft chain sprockets.

-- Then turn the crankshaft 90° counter-clockwise out of "TDC".

-- Cover the open engine components with a clean cloth.

-- Remove the sealant residues at the cylinder head using a blade scraper (width at least 40 mm).

-- Remove any sealant residue from the groove on the cylinder head cover as well as on the sealing surfaces.

-- Clean any oil or grease off the sealing surfaces.

-- Bring the pin of the cam adjustment actuator into the installation position. Refer to Installing .

-- Coat the camshaft contact surfaces with engine oil.

-- Align the exhaust camshaft centrally to the roller rocker lever.

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-- Position the exhaust camshaft in the cylinder head and turn the lobes -arrows- from cylinder 4 upward.

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-- Insert the intake camshaft in the cylinder head cover.

• The spacers must be pushed away from the chain sprocket -arrows-.

-- With the intake camshaft installed push the front and rear sliding bar ends to each other -arrows-.

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-- Align the intake camshaft in the "TDC" point.

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• The marking -arrow A- must align with the locating tab -arrow B- on the cylinder head cover.

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-- Apply sealant to the clean sealing surfaces of the cylinder head cover -arrows- as shown.

• Sealant bead thickness: 1.5 to 2.5 mm

-- Secure the camshaft and place the cylinder head cover with the camshaft on the cylinder head, at the same time pay attention to the alignment pins.

-- Lightly press on the cylinder head cover by hand and at the same time slightly push the camshafts back and forth in direction of -arrows- until the cylinder head cover lays on the cylinder head >>without tension<<.

-- Tighten the bolts in multiple steps. Refer to Figure.

• Pay attention that the cylinder head cover is not tilted.
• Remove the excess sealant leaking from tightening.

-- Turn the intake camshaft with the Assembly Tool: T40427  in the direction of -arrow B- until the marks -1- and -2- align.

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-- Push the Camshaft Lock: T40271/3  into the chain sprocket splines in direction of -arrow A-.

-- Turn the exhaust camshaft using the Assembly Tool: T40427  in direction of -arrow B-, until the marking -2- of the exhaust camshaft is shifted by half a tooth clockwise to the marking -1- on the cylinder head cover.

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-- Push the Camshaft Lock: T40271/4  into the chain sprocket splines in direction of -arrow A-.

-- Turn the crankshaft on the hex fitting to the "TDC point".

• The flattened surface -1- must be on top.

-- Remove the Vibration Damper Assembly Tool - Knurled Nut: T10531/4  and the Vibration Damper Assembly Tool - Turning Over Tool: T10531/3  .

Install in reverse order of removal. Note the following:

• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Electronic Parts Information (ETKA).
• Check the O-ring in the crankcase ventilation hose for damage. Refer to OVERVIEW - CRANKCASE VENTILATION .

-- Install the camshaft timing chain. Refer to CAMSHAFT TIMING CHAIN, REMOVING AND INSTALLING .

-- Install the vacuum pump. Refer to VACUUM PUMP, REMOVING AND INSTALLING .

-- Install the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Install the oil separator. Refer to OIL SEPARATOR, REMOVING AND INSTALLING .

-- Install the ignition coils. Refer to IGNITION COILS, REMOVING AND INSTALLING .

-- Install the upper timing chain cover. Refer to UPPER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Connect the coolant hoses with the connector coupling. Refer to Fig 3.

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .