NOTE: After each removal of the gear during assembly, it is necessary to check and, if necessary, adjust the position of the pump-injector pistons.
NOTE: The workflow described below and the components shown are for the first bank of cylinders. The differences from the second bank of cylinders are minor and do not require description.
Removal
Remove the engine and gearbox.
Remove the intake manifold flap and the crankcase ventilation hose of the corresponding cylinder.
Remove the soundproofing cover and the cylinder head cover of the corresponding cylinder head.
Check the working surfaces of the rocker arm axle for signs of wear or damage.
Disconnect the water pipe under the tandem and fuel pump.
Remove the vibration damper.
Use counter support T10172 with bolts T10172/1.
Screw the T10195 crankshaft stopper to the end of the crankshaft. While doing this, pay attention to the position of the installation pin.
After this, carefully rotate the crankshaft until the T10195 crankshaft stopper protrusion enters the calibration holes (fig. 2.185).
Remove the appropriate pump.
1st row of cylinders: tandem pump.
2nd row of cylinders: fuel pump.
Disconnect the oil feed line to the turbocharger.
Insert the T10211 key as shown in Figure 2.186 and loosen the adapter ring of the central connector of the unit injectors.
Remove the G40-C Hall sensor (only for 1st row of cylinders).
Remove the outer cover of support A, install the clamping device T10199 on the camshaft gear and tighten the device bolts to a torque of 40 Nm.
Loosen the camshaft gear mounting bolt B using the T10198 socket wrench and remove it together with the tandem pump drive mechanism (fig. 2.187).
Loosen the T10199 clamping fixture bolts and remove it.
Unscrew the compensation piston in the removable axis of the compensation pad (fig. 2.188).
Unscrew the removable head of the pump-injector from the T10055 puller.
Screw the T10055 puller into the guide axle as shown in Figure 2.189, and gently tap the axle in the direction of the arrow.
Remove the outer (on the checkpoint side) compensation pad from its socket. If necessary, knock it off with light blows of a plastic hammer (fig. 2.190).
Remove the camshaft gear.
Now remove the compensation gear and the inner compensation pad.
Remove the diamond washer from the camshaft console (fig. 2.191).
Installation
Clean the contact surfaces of the bearing caps from any remaining sealant.
Lubricate the guide surfaces of the compensating pad bushing with oil.
NOTE: If there is noticeable wear or deposits on the guide surface of the compensating lining bushings, they must be replaced.
Hook the inside (on the engine side) compensation pad A at the bottom first (if necessary, guide with your finger through the hole in the compensation piston) and finally slide it onto the sleeve at the top (fig. 2.192).
Install a new diamond washer onto the camshaft bracket.
Bring the lower compensation pad (on the checkpoint side) into position and set the compensation gear in phase (fig. 2.193) towards the checkpoint.
When installing, rotate the camshaft gear so that the marking (fig. 2.194) on the drive gear coincided with the upper edge of the mounting surface.
Secure the knot by carefully inserting (as evenly as possible) locking axle by hand.
CAUTION: There is a risk that the gear block cover may slide to the side and not fit onto the guide axle, or that it may become skewed when the axle is pushed in.
Insert the guide sleeve into the compensation pad on the gearbox side.
Carefully remove the locking axle, making sure that the already adjusted compensation pads remain in the correct position.
Install the compensation pad on the gearbox side with the inscription facing the gearbox. If necessary, support it with light blows of a plastic hammer on the guide bushing.
Check the correct fit of the compensation pads with your finger through the hole in the compensation piston.
The compensating gear must be centered so that the holes on the four pads and on the gear coincide with each other (fig. 2.195).
Lubricate the guide axle, then push it in by hand, applying force evenly. The correct fit of the locking axle can be determined by a noticeable gap to the hole in the main cylinder head (fig. 2.196).
Install the tandem or fuel pump drive.
Install the bearing caps flush with the edge of the cylinder head using AMV 176 501 sealant and secure them.
Install a new compensation piston.
Install the T10199 clamp and tighten the camshaft gear bolt.
Tightening torques
| Threaded connection | Tightening torque, Nm |
| Bolts, nuts | |
| M6 | 10 |
| M8 | 20 |
| M10 | 45 |
| M12 | 60 |
| Except: | |
| Compensating piston | 110 |
| Camshaft gear bolt | |
| Stage 1 | 60 |
| Stage 2 | 150 |
| EtalZ | 1/4 turn (180°) |
| Support cover bolt | 8 + turn 1/4 turn (90°) |
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