Removal
1. Disconnect the ground wire from the battery.
2. Drain the coolant.
3. Remove the ventilation hose connecting the air filter and the cylinder head cover.
4. Remove the air filter.
5. Remove the timing belt covers.
6. Remove the cylinder head cover and camshaft angle sensor.
7. Remove the bolt and pulley from the camshaft.
8. Remove the bolts and bearing caps, camshaft, rocker arms and clearance compensators.
Warning! Removing and installing injectors and high-pressure fuel pump:
- 1. The fuel system is exposed to high pressure (1350 bar).
- 2. Never work on the fuel system while the engine is running or within 30 seconds after it has stopped.
- 3. Always take safety precautions.
- 4. Ensure absolute cleanliness.
- 5. Prevent fuel injectors from falling.
Examination
Rocker arms
1. Check the ease and smoothness of the roller rotation.
2. Check the roller surface. Replace it if there are dents, damage or evidence of jamming.
3. Check the working end of the valve stem. If the end of the valve stem is worn or cracked, replace the valve.
Camshaft
1. Inspect the camshaft journals for uneven wear, cracks or damage.
2. Check the camshaft lobes for wear or damage. Measure the height of each camshaft lobe at two points.
- Nominal height of intake cams: 34.697 mm
- Nominal height of exhaust cams: 34.570 mm
- Minimum permissible height of intake cams: 34.197 mm
- Minimum permissible height of exhaust cams: 34.070 mm
Installation
1. Install the camshaft onto the cylinder head.
Caution: Before installation, apply a thin layer of clean engine oil to all sliding surfaces of the camshaft.
2. Install the camshaft bearing caps.
3. Make sure the camshaft rotates easily by hand. After checking, remove the bearing caps and camshaft, and then install the rocker arms.
4. Make sure that the dowel pin on the pulley side of the camshaft is facing up.
5. Tighten the bearing cap bolts to the specified torque in a specific sequence in two or three stages. Tightening torque: 26.5 – 29.5 Nm.
Caution: Tighten the cover mounting bolts evenly.
6. Using the special tool, press in the camshaft oil seal. Before pressing the seal in, lubricate the outer surface of the seal with engine oil. Insert the oil seal into the front end of the camshaft and install it by tapping the tool with a hammer until it is fully seated.
7. Install the camshaft pulley and secure it with the bolt. Tightening torque: 120–140 Nm.
8. Install the cylinder head cover.