Removing and installing camshafts

AR05.20-S-6992A

9.9.11

ENGINE 111 in MODEL 638

S05.20-3000-09

1 Exhaust camshaft wheel

2 Timing chain

3 Slide rail

4 Intake camshaft wheel

5  Open-end wrench

6 Camshaft cap

7 Exhaust camshaft

8 Intake camshaft

9 Chain tensioner

	Removing, installing
1	Remove the slide rail in the cylinder head		AR05.10-S-8432A
2	Position the piston of the 1st cylinder at 30° after the PMS	Rotate the engine by the crankshaft	AR01.00-S-0120A
		 At 30° of the igniton PMS in the 1st cylinder the camshafts can be rotated without the valves touching the bottom of the piston
3	Mark the camshaft wheels (1) and (4) with colour respect to the timing chain (2) (arrows)	 Installation: Fit the timing chain so that the coloured marks of the timing chain and the wheels of the camshaft coincide, if necessary
		check the basic position of the camshafts, if necessary, after checking	AR05.20-S-6010A
		correct the adjustment of the camshafts	AR05.20-S-6020A
4	Remove the chain tensioner (9)	 Installation: Dismantle the chain tensioner and assemble it again as described	AR05.10-S-7800A
5	Remove the exhaust camshaft wheel (1)		*000589011000
			*BA05.20-N-1001-01A
		 Installation: Install the exhaust camshaft wheel (1) with the timing chain (2) fitted Replace the screws of the camshaft wheel, use them only once
6	Lift the timing chain (2) from the intake camshaft wheel (4)
7	With the aid of the open-end wrench (5) rotate the camshafts (7) and (8) freeing them from tension	  The camshafts are likely to break, so rotate them until the point when, if possible, the base circles of the cams rest on the hollow tappets (the camshafts are to a great extent free from tension in their bearings)	*104589010100
8	Remove the camshaft bearing cap		*000589011000
		  Installation: Install camshaft bearing caps at the same point 	*BA05.20-N-1002-01A
	Marking of camshaft bearing caps	Engine 111	AH05.20-N-6992-01A
9	Take out the camshafts (7) and (8)	 Installation: Lubricate the valve tappets and the camshaft bearings. Fit the camshafts (7) and (8) in the bearings so that, if possible, the basic circles of the cams are supported on the hollow tappets Pay attention to the assignment of the camshafts
	Camshaft code number and assignment	Engine 111, 112, 113	AH05.20-N-0100-01A
		Camshaft code numbers	*BE05.20-N-1001-01A
		Camshaft code numbers repair camshaft	*BE05.20-N-1002-01A
		Timing of inlet valve at 2 mm valve and new timing chain	*BE05.20-N-1001-02A
		Timing of exhaust valve at 2 mm valve and new timing chain	*BE05.20-N-1002-02A
10	Installation in reverse order

Test values characterstics numbers of the camshaft

Number	Designation		Engine 111.948	Engine 111.978


BE05.20-N-1001-01A	Index figure of the camshaft	Intake	16	16
		Exhaust	24	17
BE05.20-N-1002-01A	Re-conditioned camshaft	Intake	19	19
		Exhaust	25	20

Test values timing phases

Number	Designation			Engine 111.948	Engine 111.978


BE05.20-N-1001-02A	Timing phase intake valve at 2 mm valve stroke and new timing chain	opens after the PMS	°KW	11–15	11–15
		closes after PMI	°KW	12–16	12–16
BE05.20-N-1002-02A	Timing phase exhaust valve at 2 mm valve stroke and new timing chain	opens before the PMI	°KW	15–19	18.5–22.5
		closes before PMS	°KW	15–19	13–17

 Camshaft

Number	Designation			Engine 111.948/ 978


BA05.20-N-1001-01A	Camshaft sprocket/flange shaft to camshaft	1st stage	Nm	20
		2nd stage	°	60
BA05.20-N-1002-01A	Camshaft bearing cap to cylinder head		Nm	21

104 589 01 01 00

000 589 01 10 00

Internal Torx set

Open-end wrench

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