Contents: Removal ↡ Installation ↡
The camshaft is removed upwards with the cylinder head installed.
Attention! If the timing parts are to be used again, they must be installed in their original places. To avoid confusion, a special box for storing them should be made.
Removal
1. Disconnect the negative (–) cable from the battery.
Attention! This will erase the radio's anti-theft code.
2. Remove the air cleaner cross pipe.
3. Unscrew the cylinder head cover.
4. Set the engine to the top dead center of ignition. To do this, crank the engine until the markings on the camshaft housing and the crankshaft pulley match. Note: the top dead center (TDC) is the highest position that the piston reaches when moving in the cylinder. It is necessary to distinguish between the dead center of ignition, after which the piston compresses the intake air, and simply the top dead center, after which the piston pushes out the combustion gases.
5. Set the gearbox to idle and, using a sprocket secured to the central bolt of the crankshaft pulley, turn the crankshaft in the direction of engine rotation, i.e. clockwise. Turn until the "O.T." (TDC) mark on the belt pulley is positioned under the pointer.
Caution! Do not rotate the engine in the opposite direction. Never turn it by the camshaft gear mounting bolt.
6. At the same time, the markings (arrows) on the camshaft flange and on the first bearing cap must match. If these markings do not match, the crankshaft should be turned one more full revolution.
7. Remove the chain tensioner.
8. Vehicles with height control: Unscrew the oil injection pump and set it aside with the hoses attached. Remove the O-ring and drive disc.
Caution: Do not loosen the two Allen bolts that secure the cover. These bolts have through threads that are visible between the cover and the crankcase.
9. Mark the position of the timing gear and control chain relative to each other using varnish or a graver, after wiping this area on the chain and camshaft gear with a rag.
10. Secure the camshaft gear by inserting a pin or large screwdriver into one of the holes in the gear.
11. Unscrew the mounting bolt, remove the timing gear. In cars with height adjustment, remove the drive sleeve.
Caution! The control chain must remain engaged with the crankshaft and fuel pump gears. Otherwise, the valve timing will change, which may cause engine failure.
12. Set the control chain aside and secure it to the cylinder head with wire.
13. Mark the position of the camshaft bearing caps with varnish.
14. Unscrew the camshaft bearing caps.
Caution! To avoid damage to the camshaft, the unscrewing sequence must be strictly followed.
15. First, unscrew both bolts on camshaft bearings 1, 3 and 5 (white arrows). Then loosen both bearing cap bolts 2 and 4 one by one and gradually (respectively by 1/2 turn and by one turn), until the opposition is removed (black arrows).
16. Pull the camshaft upwards.
17. Remove the washer (arrow) for axial fixation of the camshaft from the cylinder head and check its condition; replace if necessary.
18. Pull out the disc plunger using a rubber siphon (d 30 mm), e.g. HAZET 735-2.
Warning! Do not use a magnetic siphon for this operation: this will magnetize the sliding surfaces of the pusher, and subsequently tiny metal shavings may settle on them, which will damage the pushers and cams. You can make a siphon yourself using a household wall hook and a suction cup.
Caution: Before removing, thoroughly clean the surface of the plunger.
Installation
Attention! Install only the camshaft with index "13". The index is stamped next to the TDC position mark on the camshaft flange.
1. Thoroughly clean the camshaft and bearing caps with cleaning gasoline and lubricate with oil, clean the mating surfaces of the sealing gaskets.
2. Insert the camshaft axial locking washer into the groove of the cylinder head.
Attention! If a new camshaft is installed or the cylinder head has been machined, then after bolting the bearing caps, the camshaft must be checked for smooth rotation.
3. Lubricate the new camshaft with engine oil and insert it into the cylinder head.
Attention! The plate tappets remain dismantled.
4. Install the camshaft bearing caps in accordance with the given markings and tighten evenly to a torque of 25 Nm. Rotate the camshaft while doing this.
5. To rotate the camshaft, screw in a bolt with an internal hexagon M 10x30 (01) instead of the mounting bolt.
6. If the camshaft is difficult to turn, loosen the bearing cap bolts individually until the jammed area is found.
7. Remove the camshaft and measure the seat of this bearing. Bearing journal diameter: 30.934–30.950 mm.
8. If the old camshaft is being installed, it should be checked for runout.
9. Lubricate the tappets with engine oil and install.
Attention! Install the tappets in the same places as before disassembly.
10. Lubricate the camshaft and place it in the cylinder head so that the TDC mark (arrow) is directed vertically upwards. Pay attention to the tightness of the axial lock washer.
11. Install bearing caps 2 and 4 and tighten lightly with bolts by hand. Then tighten the mounting bolts one turn at a time and finally tighten to 25 Nm.
12. The remaining bearing caps can be installed in any order. Tightening torque: 25 Nm.
13. Unscrew the camshaft gear from the cylinder head and install the control chain so that the applied markings match.
14. Place the timing gear on the camshaft flange. Center the timing gear using the dowel pin.
15. On vehicles with height adjustment, lubricate and install the steering sleeve.
16. Tighten the timing gear to 25 Nm and finally tighten the bolt with an open-end wrench by 90° (1/4 turn). When tightening the timing gear, use a screwdriver or pin as a counter support.
17. Install the chain tensioner.
18. Install the oil injection pump, if removed, and tighten it to the flange to 10 Nm, after installing the drive disc and a new O-ring.
19. Set the engine to TDC ignition position and check that the markings on the crankshaft pulley and camshaft flange (arrows) match.
20. Install the cylinder head cover and tighten its mounting bolts to a torque of 10 Nm. Before doing this, check the sealing gasket for damage and replace it if necessary.
21. Install the air filter cross pipe.
22. Connect the battery ground (–) cable.
23. Set the time on the clock.
24. Set the radio anti-theft code.
25. Warm up the engine and check the cylinder head cover for leaks.