Withdrawal
1. Disconnect the wire «masses» from the battery.
2. Drain the coolant.
3. Remove the ventilation hose connecting the air filter and cylinder head cover.
4. Remove the air filter.
5. Remove casings of a gear belt.
6. Remove the cylinder head cover and camshaft angle sensor.
7. Turn out a bolt and remove a pulley from a camshaft.
8. Turn out bolts and remove covers of bearings, a camshaft, yokes and gap compensators.
Warning! Removal and installation of injectors and high pressure fuel pump:
- 1. The fuel system is subjected to high pressure (1350 bar).
- 2. Never work on the fuel system while the engine is running or within 30 seconds of stopping it.
- 3. Always take precautions.
- 4. Ensure absolute cleanliness.
- 5. Avoid dropping fuel injectors.
Examination
Rocker arms
1. Check the ease and smoothness of the rotation of the roller.
2. Check the surface of the roller. Replace it if it is dented, damaged, or jammed.
3. Check the working end of the valve stem. If the valve stem end is worn or riveted, replace the valve.
Camshaft
1. Check the camshaft journals for uneven wear, cracks or damage.
2. Check the camshaft lobes for wear or damage. At two points, measure the height of each camshaft lobe.
- Nominal intake lobe height: 34.697 mm
- Nominal height of exhaust cams: 34.570 mm
- Minimum allowable intake cam height: 34.197 mm
- Minimum allowable exhaust cam height: 34.070 mm
Installation
1. Install the camshaft on the cylinder head.
Attention! Before installing, apply a thin film of clean engine oil to all sliding surfaces of the camshaft.
2. Install the camshaft bearing caps.
3. Make sure the camshaft can be easily rotated by hand. After checking, remove the bearing caps and camshaft and then install the rocker arms.
4. Be convinced that the adjusting pin in an end face of a camshaft from a pulley is directed upwards.
5. In a certain sequence, in two or three stages, tighten the bearing cap bolts to the required torque. Tightening torque: 26.5 - 29.5 Nm.
Attention! Tighten the cover bolts evenly.
6. Using the special tool, press in the camshaft oil seal. Lubricate the outer surface of the seal with engine oil before pressing the seal. Insert the oil seal on the front end of the camshaft and install it by hitting the tool with a hammer until it is completely installed.
7. Install the camshaft pulley and secure it with a bolt. Tightening torque: 120–140 Nm.
8. Install the cylinder head cover.