Removing And Installing Camshafts - Up To Model Year 2002: Notes
REMOVAL AND INSTALLATION PROCEDURE FOR CAMSHAFTS (UP TO MODEL YEAR 2002)
| No. | Designation | Qty. | Removal | Installation |
|---|---|---|---|---|
| 1 | Hexagon-head bolt M6 x 30 | 23 | Tightening torque 13 Nm (7.0 ft.lb.) | |
| 2 | Cylinder head cover | 1 | Protect sealing surface from damage | Apply silicone type 1209 from the Drei Bond company on sealing surface. The pairing number of the cylinder head/bearing saddles/cylinder head cover must agree. |
| 3 | Camshaft closure cap | 3 | Remove emerging silicone material. Fit cap dry. Using a plastic hammer, drive in the cap as far as it will go. | |
| 4 | Tensioning screw (tensioning screw is already fitted as a transport lock on new chain tensioners) | 1 | Remove tensioning screw once both camshaft bearing saddles have been fastened. | |
| 5 | Pan-head screw M6 x 35 | 4 | Fit holding-down device (special tool 9611) before loosening the pan-head screws. | Fit holding-down device (special tool 9611) before tightening the pan-head screws. |
| 6 | Bearing saddle for exhaust camshaft | 1 | Observe code (A) and pairing number | |
| 7 | Bearing saddle for inlet camshaft | 1 | Observe code (E) and pairing number | |
| 8 | Pan-head screw with captive washer M6 x 95 | 3 | Tightening torque 10 Nm (7.0 ft.lb.) | |
| 9 | Tensioning element for camshafts | 1 | Relieve with the special tool, tensioning screw 9632, before removal of the camshafts. | Remove tensioning screw 9632 only after the camshafts or tensioning element has been fastened on the cylinder head. |
| 10 | Timing chain | 1 | ||
| 11 | Exhaust camshaft | 1 | Check for wear (scoring), observe identification | |
| 12 | Inlet camshaft | 1 | Check for wear (scoring), observe identification | |
| 13 | Valve tappet | 12 | Do not interchange; store in suitable place | Check for wear (scoring) |
| 14 | Pan-head screw with captive washer M6 x 35 | 15 | ||
| 15 | Guide for valve tappets | 1 | Tightening sequence: tighten from the inside to the outside. Check for wear (scoring) | |
| 16 | Hexagon-head bolt M6 x 16 | 1 | ||
| 17 | Shield (fitted only on cylinder head 1 - 3) | 1 | Fit before installing guide for valve tappets | |
| 18 | Pan-head screw with captive washer M6 x 35 | 1 | Fit before installing the shield | |
| 19 | Pan-head screw with captive washer M6 x 35 | 3 | ||
| (20) | Cylinder-head screw M10 x 234 | 12 | Always replace, or replace by cylinder-head screw M10 x 230 (10.9) | |
| 20 | Cylinder-head screw M10 x 230 (10.9) | 12 | Can be re-used | |
| 21 | Cylinder head | 1 | Ensure sealing surfaces are protected from damage; use suitable pad. | Compare pairing numbers with cylinder head cover and bearing saddles. Cylinder heads are identified with 1 - 3 or 4 - 6. |
| 22 | Cylinder-head gasket | 1 | Always replace. The gaskets are identified by Zyl. 1 - 3 or Zyl. 4 - 6 and the corresponding part number. When they are fitted, the cylinder head identification or the part number must face downward toward the exhaust side. |
NOTE:
- Magnetized tools or magnets must not be used when removing and installing valve tappets (flat-base tappets).
- A suitable removal tool is a rubber suction cup, for example.