Right Cylinder Head Camshaft, Removing And Installing

Special tools and workshop equipment required 

• Puller - Toothed Belt Pulley T10320
• Camshaft Fitting Tool T40094A
• Camshaft Fitting Tool T40095
• Camshaft Fitting Tool T40096
• Pry Lever 80-200
• Wrench - Pin Type 3036
• Hand drill with plastic brush attachment
• Protective eyewear
• Sealant.

Removal

-- Remove the affected camshaft timing chain from the camshaft, refer to CAMSHAFT TIMING CHAINS, REMOVAL FROM CAMSHAFTS .

-- Remove the right cylinder head cover. Refer to RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Remove the union nuts -1- and -2-.

-- Remove the screws -arrows- and then move the fuel rail to the side with the hoses still attached.

-- Free up the wiring harness -arrow- using the Pry Lever 80-200.

-- Loosen the guide frame bolts and nuts in the sequence -17 to 1-.

-- Carefully remove the bearing bracket and camshafts.

Installation 

• Tightening specifications, refer to CYLINDER HEAD OVERVIEW  and COOLANT PIPES OVERVIEW .

-- Remove the sealant residue on the cylinder head and guide frame and the upper section of the oil pan, for example using a rotating plastic brush.

-- Clean the sealing surfaces; they must be free of oil and grease.

-- Lubricate the running surfaces of both camshafts.

Set up the Camshaft Fitting Tool T40094A as follows:

-- Install the Bracket T40094/2 in -B-.

-- Install the Bracket T40094/1 in -C-.

-- Install the exhaust camshaft -1- into the Bracket T40094/1 and Bracket T40094/2.

-- Turn the exhaust camshaft so that it can be locked with the straight-edge in the "TDC" position -arrow-.

-- Place the intake camshaft -2- into the Camshaft Fitting Tool T40094A.

• The securing pin -3- must engage in the groove on the intake camshaft.

-- Mount the Camshaft Fitting Tool T40096 onto the teeth of the intake camshaft so that one arm of the clamping device engages in one sprocket half.

-- Tension the clamping devise with the thumbwheel until the tooth faces align.

-- Push the exhaust camshaft -1- toward the intake camshaft -arrows- until the splines engage.

-- Make sure the camshaft is positioned correctly:

• The notches -arrows- on both camshafts must face upward.

-- Place the bearing brackets -1- on both camshafts.

• All the camshaft bearings must lie on the camshafts.

-- Mount the Camshaft Fitting Tool T40095 onto the camshafts by aligning the pliers and tension with the knurled nuts -2-.

-- Tension the camshafts by tightening the nuts -3-.

-- Make sure the alignment pins -arrows- are in the cylinder head. Insert any missing alignment pins.

-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1.5 mm).

-- Turn the guide frame around.

-- Apply sealant beads -arrows- to the clean sealing surfaces on the guide frame as shown in the illustration.

• The grooves of sealing surface must be completely filled with sealant.
• The sealant beads must be 1.5 to 2.0 mm above the sealing surface.

-- Mount the guide frame together with both camshaft and the Camshaft Fitting Tool T40095 to the cylinder head.

-- Tighten the guide frame bolts, refer to Figure.

-- Remove the Camshaft Fitting Tool T40095 and Camshaft Fitting Tool T40096.

Install in reverse order of removal. Note the following:

-- Install the fuel rail and the high pressure lines. Refer to HIGH PRESSURE LINES, INSTALLING .

-- Install the right cylinder head cover. Refer to RIGHT CYLINDER HEAD COVER, REMOVING AND INSTALLING .

-- Install the new cover with a suitable drift so that it is flush.

-- Install the camshaft timing chains. Refer to CAMSHAFT TIMING CHAINS, REMOVAL FROM CAMSHAFTS .