Camshaft Gear/Sprocket: Service and Repair
WM 158419 Removing and installing camshaft controller
Tools
Technical values
Preliminary work
1. Remove the timing-case cover at the top.-> 153319 Removing and installing timing-case cover on V6 DFI engines - section on "Removing"
2. Set crankshaft to compression TDC for cylinder 1 =>
TDC for cylinder 1
Removing camshaft controller
Information
- Always check all components, such as timing chains, sprockets, locking pins and chamfers for wear or damage. Always replace faulty components.
- Always replace all fastening screws for the sprockets.
- Before removing the timing chains, mark the running direction with a colored pen.
- Maintain the same timing chain running direction during re-installation.
- Never use a prick punch or file for marking.
Information
Fix camshaft in place
- To loosen the fastening screws on the camshaft controller, counter the relevant camshaft with an open-ended wrench (a/f 27).
- To prevent damage, remove the camshaft guide.
Component overview of timing chains
1. Relieve the timing chain.
1.1. Unscrew the chain tensioner -9-.-> 153619 Removing and installing chain tensioner on V6 DFI engines - section on "Removing" Service and Repair.
1.2. Detach upper guide rail -23- by unscrewing the fastening screw -21-. Do not remove the guide rail.
1.3. Lift up the timing chain at the camshaft controllers and remove it from the camshaft controllers -4 and 25-.
2. Remove camshaft controllers.
Camshaft hexagon
2.1. Remove outlet camshaft controller -4- by unscrewing the fastening screw -22-. Counter the camshaft at the hexagon => Camshaft hexagon with an open-ended wrench when doing this.
2.2. Remove intake camshaft controller -25- by unscrewing the fastening screw -22-. Counter the camshaft at the hexagon => Camshaft hexagon with an open-ended wrench when doing this.
Installing camshaft controller
NOTICE
Incorrect handling of camshaft controllers
- Risk of engine damage
- Risk of damage to components
-> Do not turn the engine without camshaft controllers.
-> Counter the camshafts at the hexagon when tightening the camshaft controllers.
Information
- Pay attention to marking and allocation of camshaft controllers to camshafts!
- Do not interchange camshaft controllers!
- Always replace all fastening screws for the sprockets.
1. Install camshaft controllers. Guide the timing chain around the components at the same time.
1.1. Check the position of the camshafts.
Camshaft bar T10068A must fit into the grooves on the intake and outlet camshafts => Camshaft bar at the same time.
Cylinder 1 must be set to compression TDC. ->
Camshaft bar
1.2. Secure drive gear wheel for high-pressure pump using adjusting tool T10363. -3-. Make sure that the marking -1- on the drive cam for the high-pressure pump is pointing straight up. Fit adjusting tool with a fastening screw and tighten hand-tight -2-.
Securing drive gear wheel for DFI high-pressure pump
1.3. From now on, read and follow the details and instructions for setting the timing.
Information
Tips for fitting the camshaft controllers:
- The two camshaft controllers (identified by "24E" on the intake side and "32A" on the outlet side) can be screwed onto the camshaft mounting in one position only because of a dowel pin.
- Turn the sensor wheel 1 on the removed intake camshaft controller as far as it will go to the right. Hold the controller at this position. It must be possible to fit the controller easily on the intake camshaft with the camshaft roller chain set "tightly" and then tighten it hand-tight.
- The outlet camshaft controller is locked in "idle state". As a result, the sensor wheel will not turn when you set the timing. If the locking mechanism is not engaged (locked) in "idle state", the controller must be turned in both directions by hand until it locks. If this is not possible, replace the camshaft controller.
- There must be exactly 16 rollers between the markings on the camshaft controllers "24E" and "32A" and the markings must be flush with the FSI marking.
1.4. Turn sensor wheel -1- on the intake camshaft controller as far as it will go to the right. Then position intake camshaft controller on the camshaft and fix in place with the fastening screw. The fastening screw must always be replaced.
Sensor wheel on intake camshaft controller
Component overview for timing chains
Place timing chain over the sprocket on the intake camshaft controller -25-.
Make sure that the timing chain is tensioned correctly between the intake camshaft controller and the drive gear wheel for the high-pressure pump.
1.4.1. Counter the camshaft at the hexagon with an open-ended wrench => Camshaft hexagon.
Tighten fastening screw -22- with a torque wrench=> Tightening torque: 60 Nm (44 ftlb.) and then tighten further to => Torque angle: 90°.
Camshaft hexagon
1.5. Place outlet camshaft controller on the camshaft. Place timing chain over the sprocket on the outlet camshaft controller -4-. Fix the outlet camshaft controller in place with the fastening screw -22-. The fastening screw must always be replaced.
1.5.1. Counter the camshaft at the hexagon -arrows- with an open-ended wrench (a/f 27).
Tighten the fastening screw with a torque wrench=> Tightening torque: 60 Nm (44 ftlb.) and then tighten further to => Torque angle: 90°.
2. Tension the timing chain.
2.1. Fit tensioning rail -8- for the chain tensioner on the timing chain.
2.2. Fit guide rail -23- on the timing chain and fit the screw -21-. => Tightening torque: 23 Nm (17 ftlb.).
2.3. Sealing ring -10- on the chain tensioner -9- must always be replaced.
2.3.1. Then tighten the chain tensioner with a torque wrench.=> Tightening torque: 40 Nm (30 ftlb.).
2.4. Camshaft bar T10068A must now be removed.
2.5. Adjusting tool T10363 must be removed from the drive gear wheel for the high-pressure pump.
3. After you have fitted the timing chain, turn the crankshaft twice and check the timing. Adjust the timing if necessary.
Subsequent work
1. Install the timing-case cover at the top.-> 153319 Removing and installing timing-case cover on V6 DFI engines- section on "Installing"
2. Install intake-air distributor. -> 244619 Removing and installing intake-air distributor - section on "Installing" Service and Repair