CAMSHAFT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo]

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Warning

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.4 DI Turbo].)

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

2.  Remove the following parts:

(1)  Engine cover

(2)  Splash shield (RH)

(3)  Drive belt (See DRIVE BELT REPLACEMENT [MZ-CD 1.4 DI Turbo].)

(4)  Remove the coolant reserve tank with the hoses and pipes still connected (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

3.  Remove the wiring harness and wiring harness bracket from the upper timing belt cover.

4.  Set the cooler hose out of the way (With A/C). (See REFRIGERANT LINE REMOVAL/INSTALLATION.)

5.  Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

6.  Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

7.  Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

8.  Disconnect the fuel pressure sensor / glow plug / fuel injector connector.

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9.  Disconnect the EGR valve connector.

10.  Set the EGR valve and EGR cooler as a single unit out of the way. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

11.  Set the fuel return hose out of the way.

12.  Remove the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

13.  Disconnect the MAP sensor hose (cylinder head cover side).

14.  Remove in the order indicated in the table.

15.  Install in the reverse order of removal.

16.  Start the engine.

17.  Inspect the following and adjust if necessary.

(1)  Pulley and belt for runout and contact

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1	Cylinder head cover (See Cylinder Head Cover Removal Note.) (See Cylinder Head Cover Installation Note.)
2	Camshaft pulley (See Camshaft Pulley Removal Note.) (See Camshaft Pulley Installation Note.)
3	Camshaft oil seal (See Camshaft Oil Seal Installation Note.)
4	Camshaft housing (upper) (See Camshaft Housing (Upper) Removal Note.) (See Camshaft Housing (Upper) Installation Note.)
5	Camshaft

Cylinder Head Cover Removal Note

1.  Remove the cylinder head cover installation bolts in the order shown in the figure.

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Camshaft Pulley Removal Note

Note

•  Install the SSTs so that they are level with the camshaft pulley without allowing them to contact each other.

1.  Lock the camshaft using the SSTs.

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2.  Remove the camshaft pulley installation bolt.

Camshaft Housing (Upper) Removal Note

1.  Remove the camshaft housing (upper) installation bolts in the order shown in the figure.

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Camshaft Housing (Upper) Installation Note

1.  Clean the mating surfaces of the camshaft housing (lower) and camshaft housing (upper) with Loctite 7070 or equivalent.

2.  Apply the sealant to the mating surface of the camshaft housing (lower).

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Caution

•  Install the camshaft housing (upper) within four min of applying the sealant.

3.  Align the camshaft housing (upper) to the camshaft housing (lower) using the SSTs.

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4.  Tighten the camshaft housing (upper) installation bolts in two steps in the order shown in the figure.

Camshaft Oil Seal Installation Note

1.  Apply clean engine oil to a new camshaft oil seal.

2.  Install the camshaft oil seal using the SST.

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Camshaft Pulley Installation Note

Note

•  Install the SSTs so that they are level with the camshaft pulley without allowing them to contact each other.

1.  Lock the camshaft using the SSTs.

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2.  Tighten the camshaft pulley installation bolt.

Cylinder Head Cover Installation Note

1.  Tighten the cylinder head cover installation bolts in the order shown in the figure.

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