Setting Camshafts (Timing) - Engine Removed
Setting Camshafts (Timing) - Engine Removed
Tools
Item A - D:
Item A - B:
Setting The Camshafts (Timing)
Preliminary work:
- Camshafts installed.
- Spark plugs removed.
1. Unscrew camshaft sprockets. To undo the screw connection, the camshaft adjusting elements (inlet shaft) must be countered using special tool holding wrench No. 9653 and the sprocket wheels (exhaust shaft) must be countered using special tool holding wrench No. 9653/1.
2. Fit auxiliary chain tensioner for both cylinder banks. Unscrew two hexagon-head bolts M6 on each chain tensioner cover and remove the covers with the chain tensioner. Subsequently screw on both auxiliary chain tensioners and then apply pretension using the hexagon-head bolt until the first ring on the piston just disappears from view.
3. Fit dial gauge. A dial gauge is affixed to the first cylinder on cylinder bank 1 - 3 using the universal dial gauge holder. Extend the probe of the dial gauge until it is certain that measurement on the piston crown is possible.
4. To set the timing, the respective cylinder side must be positioned to overlapping TDC. For this purpose, turn the engine at the belt pulley of the crankshaft (in operating direction) until the maximum defection (reversing point) is attained on the dial gauge. The cams of the 1st cylinder point towards each other -Figure 4.1-, the cams of the 4th cylinder point away from each other (each points towards cylinder head outer wall) -Figure 4.2-.
Figure 4.1: Position of the camshafts on overlapping of cylinder 1
-1- Exhaust camshaft
-2- Inlet camshaft
Figure 4.2: Position of the camshafts on overlapping of cylinder 4
-2- Inlet camshaft
-1- Exhaust camshaft
NOTE: Camshaft adjusting element must be positioned to the left-hand stop. Use special tool holding wrench No. 9653
5. Turn camshaft adjusting element of the inlet camshafts to its left stop. Use special tool holding wrench No. 9653 to turn the actuating element of the inlet camshaft counter-clockwise until it meets the stop.
NOTE: Tighten the screws for the adjustment device only slightly. It must be possible to move the frame easily by hand.
6. Fit adjustment devices. Use two screws to fasten the frame of both staking tools at the end of the cylinder bank (clutch side) on the sealing surface for the valve cover. Tighten screws by hand only.
7. Insert holding keys. Insert the holding keys No. 9661/1 into the frame according to their identification and then fasten them with two fastening screws to prevent them from dropping.
Adjustment device of cylinder bank 1 - 3
Adjustment device of cylinder bank 4 - 6
8. Set camshafts on cylinder side 1 - 3 (cams of both camshafts point towards each other on cylinder. To do this, use a suitable open-ended wrench (a/f 30) to turn the hexagon on the camshafts until the holding key of the staking tool easily enters the slot of the camshaft. Fix holding keys with both hexagon-head bolts.
Correctly set camshafts
NOTE: Camshaft adjusting element must be positioned to the left-hand stop! Use special tool holding wrench No. 9653
9. Tighten sprocket wheels. Check whether the actuating element of the inlet camshaft is still on the left stop. Subsequently tighten the sprockets of the inlet and exhaust camshafts with initial tightening of 30 Nm (22 ftlb.). When doing so, counter the sprockets using the appropriate special tools holding wrench No. 9653 or holding wrench No. 9653/1. Subsequently remove the holding keys No. 9661/1 and tighten the exhaust camshaft with a 90 degrees torque angle and the inlet camshaft with a 170 degrees torque angle. Counter camshafts with the appropriate special tools.
10. Turn the engine on the belt pulley of the crankshaft by 360 degree clockwise so that the second cylinder side can be set. (Observe maximum defection of dial gauge indicator or TDC position).
11. Set cylinder side 4 - 6 in the same way as side 1 - 3 (cams of both camshafts on cylinder 4 point away from each other).
NOTE: Camshaft adjusting element must be positioned to the left-hand stop! Use special tool holding wrench No. 9653
12. Tighten sprocket wheels. Check whether the actuating element of the inlet camshaft is still on the left stop. Subsequently tighten the sprockets of the inlet and exhaust camshafts with initial tightening of 30 Nm (22 ftlb.). When doing so, counter the sprockets using the appropriate special tools holding wrench No. 9653 or holding wrench No. 9653/1. Subsequently remove the holding keys No. 9661/1 and tighten the exhaust camshaft with a 90 degrees torque angle and the inlet camshaft with a 170 degrees torque angle. Counter camshafts with the appropriate special tools.
13. Check the timing. Turn engine on belt pulley of crankshaft clockwise by 720 degree.
14. Refit the holding keys and check the timing on both cylinder sides.
15. Remove the adjustment devices and the dial gauge if timing is set correctly, otherwise repeat the setting.
16. Remove the auxiliary chain tensioner. To do this, relieve the auxiliary chain tensioner and loosen the two fastening screws.
17. Reinstall chain tensioner. Insert the chain tensioner into the chain housing in accordance with its identification1 then fit the chain tensioner cover with a new seal. Tighten the hexagon-head bolts M6 to 10 Nm (7.5 ftlb.).
18. Clean sealing surface for the camshaft housing cover.
19. Install camshaft housing cover. Apply a silicone bead of a maximum 1.5 mm -Figure- (drying time of sealant approx. 5 mm). Put on the camshaft housing cover and tighten the 15 fastening screws from the inside with tightening torque.
Tightening torque of hexagon-head bolt M6 (8.8) 10 Nm (7.5 ftlb.)
20. Install solenoid hydraulic valve for valve lift adjustment. Put on holder with both hexagon-head bolts M6 x 25 and tighten the screws with tightening torque.
Tightening torque of hexagon-head bolt M6 (8.8) 10 Nm (7.5 ftlb.)
21. Fit the closure cap and the oil extraction pump with new 0-rings. Tighten the hexagon-head bolts: 3 M6 x 20 for the closure cap and 3 M6 x 35 for the oil extraction pump to tightening torque.
Tightening torque of hexagon-head bolt M6 (8.8) 10 Nm (7.5 ftlb.)
22. Fit four new closure caps (green) for camshaft housing cover in dry state.
23. Install spark plugs.
Tightening torque of new spark plug 30 Nm (22 ftlb.); used spark plugs 25 Nm (19 ftlb.)
24. Install ignition coils. Insert ignition coils in spark-plug recess. Position 2 pan-head screws (hexagon socket) M6 X 25 and tighten with tightening torque. Connect cable plug.
Tightening torque of pan-head screw M6 10 Nm (7.5 ftlb.)
NOTE: Replace fastening nuts for holder of turbocharger
25. Cylinder bank 1 - 3: Install fuel collection pipe with injection valves and holder for turbochargers.
26. Cylinder bank 4 - 6: Fit holder for turbochargers and install bypass flap control box on turbocharger.
Tightening torque of fastening nut M8 25 Nm (19 ftlb.)
27. Install coolant guide housing.
28. Install generator.
29. Install the oil container.
NOTE: Replace fastening nuts for flange of turbocharger rear mufflers.
30. Install rear mufflers.
Tightening torque of fastening nut M8 25 Nm (19 ftlb.)