05-220 Removal and installation of camshaft
Operation no. of operation texts and work units or standard texts and flat rates 05-6292 |
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Turbo engine: | |
Boost air pipe | remove, install. |
Engine 601 in model 202 | |
Air cleaner cross pipe | remove, install. |
Cylinder head cover (125) | remove, install, 10 Nm. |
Engine | position on ignition TDC of No. 1 cylinder. The engine must not be turned by the camshaft timing gear bolt. |
Chain tensioner (224) | remove, install, replace sealing ring (237) |
With self-levelling suspension: Drive of the pressure oil pump (400) |
remove, install (05-437). |
Camshaft timing gear (188) | mark at timing chain (210). Remove, install camshaft timing gear. Different bolts (190) and washers (189). Hexagon bolt, 65 Nm, bihexagonal head bolt, 25 Nm/90° angle of rotation. When assembling the camshaft timing gear ensure that the straight pin (187) is not pushed out rearwards. |
Camshaft bearing cap (80, 81, 82) | remove, install, note sequence, hexagon bolts (84) and washers (84a), 25 Nm. Note slackening and tightening diagram! |
Camshaft (185) | remove, install. Check for ease of movement. |
Lock washer (186) | check. |
Valve tappet (203) | remove, install, check. |
After installation | allow engine to run, check for leaks. |
Data
Bearing position/engine | 601 | 602 | 603 | |
Camshaft timing gear seat | 0.025 | 0.025 | 0.025 | |
2nd and 4th bearing position | 0.030 | - | - | |
|
Permitted eccentricity | 3rd bearing position | 0.050 | - | - |
of center bearing pins and camshaft gear seat | 2nd and 5th bearing position | - | 0.030 | - |
when locating the camshaft in the outer | 3rd and 4th bearing position | - | 0.050 | - |
bearing positions | 2nd and 6th bearing position | - | - | 0.030 |
3rd and 5th bearing position | - | - | 0.045 | |
4th bearing position | - | - | 0.060 | |
Scleroscope hardness of cam | 70-82 | 70-82 | 70-82 | |
Camshaft code numbers
The code number is stamped on the flange
next to the TDC notch (arrow).
TDC marking (arrow) and code number
P05-2263-13
1) Repair camshaft with 0.5 mm larger bearing dia.
2) Engine 601.913 in model 202
3) Engine 602.982 in model 210
Engine | Thread for sprocket wheel | Camshaft code number |
601 | M10 | 05, 06, 081) |
M11 | 10, 121), 132) | |
602, 603 | M10 | 07, 091) |
M11 | 11, 131) 163) | |
Washer for camshaft timing gear bolt
A modified washer with larger outer diameter (c) has been installed since 12/86 to prevent the camshaft timing gear bolt from loosening.
A 1st version
B 2nd version
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Camshaft timing gear bolt
As of 11/88 the camshaft timing gear bolt has been changed from a M10 hexagon bolt to a M11 12-point necked down bolt on all engines.
Tightening torques
Hexagon bolt (A) 65 Nm
12-point necked down bolt (B)
Pre-torque 25 Nm
Tightening angle 90°
Note modified plain washer!
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Use the plain washer (A) for the hexagon bolt, and plain washer (B) for the 12-point necked down bolt.
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Use carrier (A) for previous hexagon bolt, carrier (B) for bihexagon necked down bolt.
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Tightening torques and tightening angles Nm
Hexagon bolts on cylinder head cover | 10 | |
Hexagon bolts on camshaft timing gear | 65 | |
12-point bolt on camshaft timing gear | initial torque | 25 |
tightening angle | 90° | |
Hexagon bolts on camshaft bearing cap | 25 | |
Special tools
001 589 66 21 00
001 589 72 21 00
Commercially available tools and testers
Designation | e.g. Make | Order no. |
Rubber suction cup, dia. 30 mm | Hazet Postfach 100461 | 795-3 |
Removal
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Turbo engine:
1 Remove boost air pipe.
Engine 601 in model 202
2 Remove air cleaner cross pipe.
3 Remove cylinder head cover.
4 Position engine on ignition TDC of no. 1 cylinder (arrow).
Do not turn engine by the camshaft timing gear bolt. Do not turn engine backwards.
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5 Remove chain tensioner (05-310).
With self-levelling suspension
6 Remove pressure oil pump (05-437).
7 Align camshaft timing gear and timing chain.
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8 Unscrew hexagon bolt or 12-point head bolt on camshaft timing gear, whilst holding the camshaft with a mandrel.
9 Remove camshaft timing gear and allow timing chain to sag.
Note
The timing chain is prevented from twisting when the timing case cover is assembled.
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Note different bolt and washer.
10 It is absolutely essential to observe the following sequence during removal and installation in order to avoid damage to the camshaft:
Engine 601
Unscrew both hexagon bolts on camshaft bearing caps 1, 3 and 5 (light arrows).
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Slacken both hexagon bolts on camshaft bearing caps 2 and 4 alternately in increments of one turn respectively until counterpressure is reduced (dark arrows).
Engine 602
Unscrew both hexagon bolts on camshaft bearing caps 1, 2 and 6 (light arrows).
Slacken both hexagon bolts on camshaft bearing caps 3, 4 and 5 in increments of one turn respectively, until counterpressure is reduced (dark arrows).
P05-0203-13
Engine 603
Unscrew both hexagon bolts on camshaft bearing caps 1, 5 and 6 (light arrows).
Slacken both hexagon bolts on camshaft bearing caps 2, 3, 4 and 7 in increments of one turn respectively, until counterpressure is reduced (dark arrows).
11 Remove camshaft upwards.
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12 Remove lock washer for axial location (arrow) and check condition.
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13 Pull out valve tappet with rubber suction cup.
14 Check condition of valve tappet (visual check), replace, if required.
Install valve tappet in the same position again.
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Installation
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15 Insert lock washer for axial fixing (arrow) in cylinder head.
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16 Lubricate camshaft and place on the cylinder head so that the TDC marking (arrow) points vertically upwards.
17 Install camshaft bearing caps. Note marking on bearing caps.
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Assemble camshaft bearing cap bolts (dark arrows) and tighten up alternately in increments of one turn respectively in accordance with tightening diagram, see work step 10.
Engine 601; camshaft bearing caps 2 and 4
Engine 602; camshaft bearing caps 3, 4 and 5
Engine 603; camshaft bearing caps 2, 3, 4 and 7
The remaining camshaft bearing caps (light arrows) can then be assembled at random.
Tightening torque 25 Nm.
18 Install camshaft sprocket according to marking and tighten. Check straight pin to ensure it is correctly fitted.
Tightening torques and tightening angle
Hexagon bolt 65 Nm,
12-point head bolt 25 Nm, 90°
19 Install chain tensioner (05-310).
P03-2140-13
If car fitted with level control:
20 Install pressurized oil pump (05-437).
21 Position engine to ignition TDC of cylinder 1 and check markings (arrows).
22 Install cylinder head cover. Tightening torque 10 Nm.
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Turbo engine:
23 Install boost air pipe.
Engine 601 in model 202
24 Install air cleaner cross pipe.
After installation:
25 Run engine and check for leaks.