Contents: Removal the camshaft drive gear ↓ Removal the injector body seal ↓ Removal the cylinder head cover ↓ Removal the camshaft oil seal cover ↓ Removal camshafts ↓ Removal the camshaft oil seal ↓ Installing the camshaft oil seal ↓ Setting the piston of cylinder No.1…↓ Installing the camshaft ↓ Installing camshaft #2 ↓ Installing the camshaft oil seal…↓ Installing the camshaft drive gear ↓ Installing the cylinder head cover ↓ Installing High Pressure Fuel Line #1 ↓
Fig. 2.364. Components of camshafts
Removal the camshaft drive gear
Fig. 2.365. Unscrewing the gear mounting bolt
Using SST, remove the pinion mounting bolt (fig. 2.365).
Remove the camshaft drive gear.
Note: Remove the gear by tapping it lightly with a plastic hammer and remove the key.
Remove the high pressure fuel lines.
Remove the vacuum pump assembly.
Removal the injector body seal
Fig. 2.366. Removing the injector housing seals
Using a screwdriver, remove the 4 injector housing seals (fig. 2.366).
Removal the cylinder head cover
Fig. 2.367. Cylinder head cover fastening bolts
Remove 10 mounting bolts, remove the cylinder head cover and gasket (fig. 2.367).
Remove the fuel return line assembly.
Remove the injectors as an assembly.
Note: Since each injector has its own fuel injection characteristics, the removed injectors must be arranged in a certain order so that the injectors can be installed in their original locations during assembly.
Removal the camshaft oil seal cover
Remove 4 mounting bolts.
Fig. 2.368. Removing the camshaft oil seal cover
Separate the oil seal cover by inserting a screwdriver between the oil seal cover and the camshaft bearing cover (fig. 2.368).
Removal camshafts
Fig. 2.369. Sequence of unscrewing the bearing cap bolts
In several steps, evenly loosen and unscrew the 15 bearing cap mounting bolts, acting in the sequence shown in Figure 2.369.
Remove 5 bearing caps and camshaft.
Remove camshaft No.2 and camshaft bearing housing.
Removal the camshaft oil seal
Fig. 2.370. Removing the camshaft oil seal
Remove the seal using a screwdriver and hammer (fig. 2.370).
Installing the camshaft oil seal
Fig. 2.371. Pressing in the camshaft oil seal
Using the SST mandrel and a hammer, press the new seal until its surface is flush with the edge of the seal cover (fig. 2.371).
Apply general purpose grease to the edge of the new seal.
Note: The seal seating surface must be free of sand, dirt and other foreign particles.
Setting the piston of cylinder No.1 to TDC of the compression stroke
Fig. 2.372. Setting the piston of cylinder No.1 to TDC of the compression stroke
Turn the crankshaft by the pulley mounting bolt and install the timing gear so that the dot mark on it occupies a position 90° before TDC, as shown in Figure 2.372.
Note: If the timing gear is installed at a different angle, the piston crown may contact the valve head.
Installing the camshaft
Fig. 2.373. Installing the camshaft bearing housing into the cylinder head
Install the camshaft bearing housing into the cylinder head (fig. 2.373).
Note: Due to the small axial clearance of the camshaft, the camshaft must be held strictly horizontally during assembly. If the camshaft is not positioned horizontally, the cylinder head or camshaft may be damaged. To avoid this, follow the steps below.
Install the camshaft.
Lubricate the camshaft cams and gear, as well as the camshaft bearings, with engine oil.
Fig. 2.374. Direction of installation of cylinder caps No.3 and No.4
Install the intake camshaft onto the camshaft bearing housing so that the tops of the cams of cylinders No.3 and No.4 are directed downwards, as shown in the figure (fig. 2.374).
Installing camshaft #2
Install camshaft #2.
Lubricate the camshaft cams and gear, as well as the camshaft bearings, with engine oil.
Fig. 2.375. Alignment of marks on camshaft gears
Engage the gears of the exhaust and intake camshafts, aligning the marks on the gears (fig. 2.375).
Turn the exhaust camshaft down onto the bearing housing while engaging the gears.
Install the camshaft bearing caps.
Remove any remaining old sealant (FIPG) from the camshaft bearing cap #5.
Fig. 2.376. Places of sealant application
Apply sealant to the bearing cap No.5 of the camshaft as shown in Figure 2.376.
Fig. 2.377. Bearing cap installation diagram
Install the 5 bearing caps in place (fig. 2.377).
Fig. 2.378. Sequence of tightening the bearing cap bolts
In several stages, evenly tighten the 15 bearing cap mounting bolts, acting in the sequence shown in Figure 2.378.
Tightening torque: 20 Nm.
Installing the camshaft oil seal cover
Remove any remaining old sealant (FIPG).
Be careful not to let oil get on the mating surfaces of the oil seal cover and the cylinder block.
Thoroughly clean all parts from any remaining sealant.
Clean the mating surfaces with solvent.
Fig. 2.379. Places of sealant application
Apply sealant to the oil seal cover as shown in Figure 2.379.
Trim the tip of the sealant packaging so that the hole diameter is 2-4 mm.
After applying the sealant, install the parts within 3 minutes and fix them within 15 minutes.
Immediately remove the tip from the tube, then close the tube with the cap.
Secure the oil seal cover with 4 bolts. Tighten the 4 bolts evenly in several stages.
Tightening torque: 8.8 Nm.
Installing the camshaft drive gear
Install the gear key into the camshaft groove.
Aligning the groove in the gear with the key on the shaft, install the gear on the camshaft.
Using SST, tighten the pinion mounting bolt.
Tightening torque: 88 Nm.
Install the timing belt drive.
Check the valve timing.
Check the valve clearances.
Adjust the valve clearances.
Install the camshaft position sensor.
Install the injectors as an assembly.
Install the fuel return line assembly.
Installing the cylinder head cover
Remove any remaining old sealant (FIPG).
Fig. 2.380. Places of application of sealant on the cylinder head
Apply sealant to the cylinder head as shown in Figure 2.380.
Install the gasket on the cylinder head cover.
Install the cylinder head cover and secure with 10 bolts.
Tightening torque: 13 Nm.
Install 4 new injector body seals.
Install the vacuum pump assembly.
Installing High Pressure Fuel Line #1
Remove the plastic bag from the injector and the vinyl tape from the Common Rail fuel rail.
Note: Tubes should be installed with the engine cooled to room temperature or below.
Fit the high pressure fuel line.
Using SST, tighten the high pressure fuel pipe to common rail fuel rail fastening nut.
Tightening torque: 31 Nm with SST, 34 Nm without SST.
Note: Use a torque wrench with a lever length of 30 cm.
Note: After installation, make sure the high pressure fuel pipe is not deformed and is installed correctly. If the pipe is deformed or cannot be installed correctly, replace the pipe with a new one.
Using SST, tighten the high pressure fuel line to injector retaining nut.
Tightening torque: for used tubes – 42 Nm with SST, 46 Nm without SST.
For new tubes: 31 Nm with SST, 34 Nm without SST.
Install the 2 upper high pressure fuel pipe clamps and secure with 2 nuts.
Tightening torque: 5.0 Nm.
Note: Installation of fuel pipes No.2, 3, 4 is carried out in the same way as installation of pipe No.1.
Note: Install the remaining components in the reverse order of removal.