In this case, first replace the fastening
screws for the camshaft controller for cylinder bank 5-8 as described in Step 2 and
then replace the affected camshaft controller  Technical Information 'AH0800 Replacing
camshaft controller'.

NOTICE
Improper handling of the camshaft controller
•

Damage to the camshaft controller



Do not use any degreasing liquid cleaning agents.



Clean the threaded bore and contact surface of the camshaft controller only using a clean,
lint-free cloth.



Blow out the threaded bore with compressed air if necessary.
1.4

Clean the threaded bore and contact surface on the camshaft controller  Replacing
fastening screw on cyl. 1–4 -2- using a clean, lint-free cloth. Then remove any remaining
engine oil from the threaded bore using compressed air.

1.5

Screw in new fastening screw  Replacing fastening screw on cyl. 1–4 -1-, Part No.
999.067.803.30, on the camshaft controller  Replacing fastening screw on cyl. 1–4 -2and tighten with the torque wrench 9768 - Electronic torque wrench, 2 - 100 Nm/1.5 74 ftlb. using the two-step tightening procedure:
•
•

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Step 1: Tightening torque 6 Nm (4.5 ftlb.) +0.5 Nm (+0.5 ftlb.)
Step 2: Torque angle 60° +5°

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Information
The tightening torque for the fastening screws for the camshaft controller achieved
using the two-step tightening procedure must be 8 – 14 Nm/6 – 10.5 ftlb..
Once the two-step tightening procedure is complete, the torque will be displayed on the electronic torque wrench display.
If this tightening torque is not reached, the relevant fastening screw must be removed
again. Then clean the threaded bore again, screw in a new fastening screw, Part No.
999.067.803.30, and tighten using the prescribed two-step tightening procedure.
If the resultant tightening torque of 8 – 14 Nm/6 – 10.5 ftlb. is not reached several
times, the relevant camshaft controller must be replaced.
In this case, first replace the fastening screws for the camshaft controller for cylinder
bank 5–8 as described in Step 2 and then replace the affected camshaft controller 
Technical Information 'AH0800 Replacing camshaft controller'.
1.6

After screwing in the fastening screw  Replacing fastening screw on cyl. 1–4 -1- to the
prescribed tightening torque, mark it with a water-resistant marker.

1.7

Remove adhesive tape or cloth from the contact area of the tool on the camshaft.

1.8

To replace the other fastening screws on the camshaft controller on cylinder bank 1–4, turn
the engine at the vibration balancer 180° in rolling direction and then repeat Steps
1.2 to 1.7 until you have replaced all fastening screws.

NOTICE
Loosening several fastening screws on the camshaft controller at the same time
•

Damage to the camshaft controller

•

Adjustment of valve timing for camshaft drive

•

Damage to the valve drive



Replace fastening screws for the camshaft controller individually, one at a time

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Replace fastening screws  Fastening screws for
camshaft controller on cyl. 5–8 -1- for the camshaft
controller on cylinder bank 5–8  Fastening screws
for camshaft controller on cyl. 5–8 -2-.

Fastening screws for camshaft
controller on cyl. 5–8
2.1

Use the tool 9714 - socket-wrench insert
to turn the engine at the vibration balancer
in rolling direction until one of the fastening
screws  Turning engine to assembly
position, cyl. 5–8 -1- for the camshaft
controller  Turning engine to assembly
position, cyl. 5–8 -2- on cylinder bank 5–8
is at the same height as the flattened area on
the mounting saddle for the intake camshaft.

Turning engine to assembly
position, cyl. 5–8
Information
For easy access and to prevent damage to the cylinder head or valve drive, the threaded
joint on the camshaft controllers must be loosened and tightened using the prescribed Torx

Jan 12, 2018
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socket-wrench insert. The use of this Torx socket-wrench insert ensures that the tool can be
fitted correctly on the screw heads.
2.2

Cover the contact surface  Covering
contact surface -A- on the camshaft with
adhesive tape or a clean, lint-free cloth
to prevent damage to the camshaft when
replacing the fastening screws using the Torx
socket-wrench insert  Covering contact
surface -1-.

Covering contact surface
2.3

Unscrew and remove fastening screw 
Replacing fastening screw on cyl. 5–8 -1for the camshaft controller  Replacing
fastening screw on cyl. 5–8 -2- using the
prescribed Torx socket-wrench insert.
Information
If one or more fastening screws for the
camshaft controller have already become
loose and can be unscrewed and removed
by hand, the camshaft controller must be
replaced;  Technical Information 'AH0800
Replacing camshaft controller'.

Replacing fastening screw on cyl. 5–8

NOTICE
Improper handling of the camshaft controller
•

Damage to the camshaft controller



Do not use any degreasing liquid cleaning agents.



Clean the threaded bore and contact surface of the camshaft controller only using a clean,
lint-free cloth.

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Blow out the threaded bore with compressed air if necessary.
2.4

Clean the threaded bore and contact surface on the camshaft controller  Replacing
fastening screw on cyl. 5–8 -2- using a clean, lint-free cloth. Then remove any remaining
engine oil from the threaded bore using compressed air.

2.5

Screw in new fastening screw  Replacing fastening screw on cyl. 5–8 -1-, Part No.
999.067.803.30, on the camshaft controller  Replacing fastening screw on cyl. 5–8 -2and tighten with the torque wrench 9768 - Electronic torque wrench, 2 - 100 Nm/1.5 74 ftlb. using the two-step tightening procedure:
•
•

Step 1: Tightening torque 6 Nm (4.5 ftlb.) +0.5 Nm (+0.5 ftlb.)
Step 2: Torque angle 60° +5°

Information
The tightening torque for the fastening screws for the camshaft controller achieved
using the two-step tightening procedure must be 8 – 14 Nm/6 – 10.5 ftlb..
Once the two-step tightening procedure is complete, the torque will be displayed on the electronic torque wrench display.
If this tightening torque is not reached, the relevant fastening screw must be removed
again. Then clean the threaded bore again, screw in a new fastening screw, Part No.
999.067.803.30, and tighten using the prescribed two-step tightening procedure.
If the resultant tightening torque of 8 – 14 Nm/6 – 10.5 ftlb. is not reached several
times, the relevant camshaft controller must be replaced;  Technical Information
'AF0200 Replacing camshaft controller'.

3

Jan 12, 2018
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2.6

After screwing in the fastening screw  Replacing fastening screw on cyl. 5–8 -1- to the
prescribed tightening torque, mark it with a water-resistant marker.

2.7

Remove adhesive tape or cloth from the contact area of the tool on the camshaft.

2.8

To replace the other fastening screws on the camshaft controller on cylinder bank 5–8, turn
the engine at the vibration balancer 180° in rolling direction and then repeat Steps
2.2 to 2.7 until you have replaced all fastening screws.

Complete the engine Technical Information 'AH0800 Concluding work'.

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Replacing camshaft controller
Additional parts required for replacing the camshaft controllers:

Parts Info:

Part No.

Designation
– Use

Qty.

94810505123

Camshaft controller
– Intake camshaft

1 or 2 ea.
(as required)

94810525400

Hexagon round-head bolt, M12 x 1.5 x 110
– Intake camshaft controller
– Sprocket for outlet camshaft

4 ea.

90012311830

Sealing ring, A 22 x 27
– Chain tensioner

1 ea.

Additional tools required for replacing the camshaft controllers:

Tools:

Information
Due to the limited amount of space between the radiator frame and vibration balancer at the
crankshaft, the locking pin 9595/1cannot be used in some cases for securing the crankshaft in TDC
position of cylinder 1.
In this case, an M8 screw with a length of 50 to 60 mm, e.g. Part No. 900.385.071.01 or
999.073.411.01, must be used instead of the locking pin.
•
•
•
•

9595/1 - Locating pins
9678/1 - Staking tool
9683/1 - Auxiliary chain tensioner
Torque wrench, 20 – 100 Nm (15 – 74 ftlb.), e.g. VAS 5820 - Torque wrench, 20-100 Nm
(15-74 ftlb.)

Work
Procedure:
NOTICE
Improper handling of crankshafts
•

Risk of damage to the timing system



Never turn the crankshaft against the rolling direction or when the chain tensioner is removed.



Only turn the engine at the crankshaft.



After working on the camshaft, reset valve timing.



Observe general warning notes and working regulations.

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1

Turn the crankshaft at the vibration balancer using
the tool 9714 - socket-wrench insert so that the
staking bore  Staking bore 45° before TDC -2of the vibration balancer is approx. 45°  Staking
bore 45° before TDC -3- in front of the lower staking
point  Staking bore 45° before TDC -1- on the
timing-case cover.

2

Remove chain tensioner for the timing chain 
Workshop Manual '153619 Removing and installing
chain tensioner'.

3

Staking bore 45° before TDC
Remove affected camshaft controller and install new
camshaft controller  Workshop Manual '158419 Removing and installing camshaft controller'.

4

9683/1 - Auxiliary chain tensioner must then be installed on the engine.

5

Set timing of the valve drive  Workshop Manual '150516 Setting valve timing'.
Tighten the central screws for the camshaft controllers and the fastening screws for the sprockets
for the outlet camshaft using the prescribed tightening procedure.
Central screw for camshaft controller:
•
•
•
•
•
•
•

Initial tightening, Step 1: Tightening torque 10 Nm (7.5 ftlb.)
Initial tightening, Step 2: Tightening torque 30 Nm (22 ftlb.)
Initial tightening, Step 3: Torque angle 100°
Loosening process, Step 1: Torque angle 90°
Loosening process, Step 2: Torque angle 360°
Final tightening, Step 1: Tightening torque 30 Nm (22 ftlb.)
Final tightening, Step 2: Torque angle 135°

Fastening screw for sprockets for outlet camshaft:
•
•
•
6

Step 1: Tightening torque 10 Nm (7.5 ftlb.)
Step 2: Tightening torque 50 Nm (37 ftlb.)
Step 3: Torque angle 90°

Remove auxiliary chain tensioner and install chain tensioner with a new sealing ring  Workshop
Manual '153619 Removing and installing chain tensioner'.

Concluding work
Work Procedure: 1

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Install spark plugs on both cylinder banks  Workshop Manual '287055 Removing and installing
spark plugs'.

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Information
The space available for loosening and tightening the fastening screws for the cylinder head
cover may be restricted depending on vehicle equipment.
Always use the tools recommended in the Workshop Manual for carrying out repairs.
2

Install cylinder head covers on both cylinder banks  Workshop Manual '158219 Removing and
installing cylinder head cover'.

3

Install oil mist separator on cylinder bank 5-8  Workshop Manual '105519 Removing and installing
oil separator'.

4

Install bar ignition modules on both cylinder banks  Workshop Manual '282020 Removing and
installing bar ignition modules'.

5

Install engine cover on both cylinder banks  Workshop Manual '108319 Removing and installing
engine cover (design cover)'.

6

Install cross panel in engine compartment at the left and right  Workshop Manual '508119
Removing and installing cross panel'.

7

Install secondary-air pump  Workshop Manual '266519 Removing and installing secondary-air
pump'.

8

Install torque support  Workshop Manual '103719 Removing and installing torque support'.

9

Install DME control unit  Workshop Manual '247019 Removing and installing DME control unit'.
On vehicles with anti-theft protection for engine control module (I-no. KE2), use new shear
bolts, Part No. N 91146801.

10 Install cowl panel cover  Workshop Manual '664419 Removing and installing cowl panel cover'.
11 Install rear profile seal for front hood  Workshop Manual '553319 Removing and installing front lid
seal'.
12 Install engine compartment trim panel at the left and right  Workshop Manual '700219 Removing
and installing front trim panel (engine compartment)'.
13 Install wiper arms  Workshop Manual '922519 Removing and installing wiper arm'.
14 Enter the campaign in the Warranty and Maintenance booklet.
References:

 Workshop Manual '1001IN Tightening torques, tightening sequences, assembly overviews for engine'
 Workshop Manual '103719 Removing and installing torque support'
 Workshop Manual '105519 Removing and installing oil separator'
 Workshop Manual '108319 Removing and installing engine cover (design cover)'