Camshaft: Service and Repair
Camshafts and camshaft adjusters, removing and installing
Special tools and equipment
T10055 Extractor:
T40029 Locating pin:
^ Drill with plastic brush attachment
^ Protective glasses
^ Sealants
Removing
- Toothed belt, removing.
- Remove respective camshaft gears.
- Remove combination valve for Secondary Air Injection.
Right cylinder head
- Disconnect electrical harness connectors -1- and -2- at Camshaft Position (CMP) sensor -G40- and Camshaft Position (CMP) sensor 3 -G300-.
- Unscrew bolts -1- and remove bracket with idler roller.
- Unscrew bolts -2- and remove toothed belt guard at right rear.
Left cylinder head
- Unscrew bolts -1- and -2- and remove toothed belt guard at left rear.
All
- Remove T40030 camshaft adjuster gauge from camshafts.
- Unscrew bolts -1- to -6- and remove housing for camshaft adjustment valves.
- Unscrew bolts -1- to -6- and remove housing for Camshaft Position (CMP) sensor.
- Loosen bolts of guide frame in sequence of numbers and follow arrows.
- Press off guide frame with M6 bolts (arrows).
- Carefully remove guide frame.
WARNING: Wear protective glasses.
- Using rotating plastic brush, remove remaining sealant from cylinder head and guide frame.
- Clean sealing surfaces so they are completely free of any oil or grease.
Installing
Note: Replace gaskets and O-rings.
^ Crankshaft aligned using T40026 locking pin
- Oil camshaft journal surface.
Left cylinder head
- Insert camshaft into cylinder head as depicted in illustration.
^ Cams at cylinder 5 point downward evenly (arrows).
Right cylinder head
- Insert camshaft into cylinder head as depicted in illustration.
^ Cams at cylinder 3 point upward evenly (arrows)
All
- Cut tube nozzle at front marking (jet diameter approximately 1 mm).
Note: Sealant bead must be applied according to exact specifications, otherwise excess sealant could get into the camshaft bearings.
- Apply sealant to clean sealing surface of guide frame as depicted in illustration.
^ Thickness of sealant bead: Approximately 1.2 mm
^ Distance of sealant bead to camshaft bearings at specified locations -1- to -8-: at least 5 mm
^ In addition, sealing surfaces around spark plug holes obtain a sealant ring each, -9- to -11-
- Immediately set guide frame in place and align using T40029 locating pin.
Note:
^ Setting in place and tightening the guide frame should occur without interruptions since the sealant starts to harden immediately.
^ After installing guide frame, allow sealant to dry for approximately 30 minutes.
- Tighten bolts of guide frame in sequence of numbers and follow arrows uniformly by hand.
^ Guide frame must make full contact with cylinder head surface
- Tighten bolts of guide frame to final tightening torque (10 Nm).
- Using T10055 extractor, remove T40029 locating pin from cylinder head.
Left cylinder head
- Insert T40030 camshaft adjuster gauge at camshafts.
- Spread T40030 camshaft adjuster gauge with threaded shaft (tightening torque 10 Nm) until it is seated without axial play.
Right cylinder head
- Install camshaft gear of exhaust camshaft.
- Turn exhaust camshaft (arrow -1-) and intake camshaft (arrow -2-) 30° in direction of arrow at same time...
- ...until cams (arrows) of cylinder 3 at intake and exhaust camshafts are as shown in illustration.
- Insert T40030 camshaft adjuster gauge at camshafts.
- Remove exhaust camshaft gear again.
All
- Install Camshaft Position (CMP) sensor housing and tighten bolts -1- to -6-.
- Check whether piston rings at camshafts are installed and whether piston ring ends are engaged with each other.
Note: If ends of installed piston are not of the locking type (cannot be locked together):
^ Always orient the rings so that the gaps (of all three rings) are at the top of the camshaft prior to installation of the camshaft adjustment housing.
With all ring gaps aligned at the top of camshaft:
^ Install camshaft adjustment housing using a gentle side to side motion (do not rock top to bottom).
- If necessary, engage ends of installed piston rings (arrows), as depicted in illustration.
Note: If the camshaft sealing rings are being replaced, they must be removed from camshaft adjustment housing before installation, using T40017 lever. Installing camshaft sealing rings.
- Install camshaft adjustment housing and tighten bolts -1- to -6-.
- Installation is reverse of removal, noting the following:
- Install combination valve for Secondary Air Injection.
- Install toothed belt (adjust timing).
Note:
^ After installing camshafts, do not start engine for at least 30 minutes. The hydraulic valve lifters have to settle (otherwise valves will strike the pistons).
^ After working on the valvetrain, carefully rotate engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.
Tightening torques
