Contents: Removal ↡ Installation ↡
Caution! If the valve control parts are to be reused, they must be installed in the same locations. To avoid confusion, it is recommended to make a suitable panel for their storage. The camshafts are removed upwards with the cylinder head installed.
Removal
1. Disconnect the battery ground cable.
Caution: Disconnecting the battery will cancel the radio's anti-theft code.
2. Remove the front cover.
3. Set the first cylinder 20° below TDC.
4. Note: In this position (20° below TDC), the camshafts can be turned with the control chain removed so that the valves do not touch the piston base.
5. Remove the cylinder head cover.
6. Remove the chain tensioner.
7. Use paint to mark the position of the timing chain relative to both timing chain gears. To do this, draw a line through the chain and sprocket.
8. Unscrew the exhaust camshaft gear using a T40 socket wrench while holding the camshaft at the hexagon. Remove the camshaft gear.
9. Remove the timing chain from the intake camshaft gear.
10. Turn the camshafts with an open-end wrench until all major cam circles are in contact with the tappets. This allows the camshafts to sit in the bearings without tension.
Caution! Camshafts are very sensitive to breakage.
11. Unscrew the camshaft bearing cap.
12. Loosen all the bolts of this bearing cap crosswise, first by 1/2 turn, then all the bolts by 1 turn and then completely loosen them.
13. Remove the bearing cap.
14. Remove the camshafts.
Installation
1. Thoroughly clean all mounting parts with cleaning gasoline, clean the sealing surfaces.
2. Lubricate the camshafts, tappets and bearing locations with engine oil.
3. Install the camshafts so that, if possible, all major cam circles are in contact with the tappets.
Caution! The intake camshaft can be installed with or without the camshaft gear. If the camshaft is replaced, pay attention to the correct alignment. The camshaft index is located at the second bearing on the camshaft.
4. Install the camshaft bearing caps in the proper sequence.
5. Number the bearings and camshaft caps in order from 1 to 10.
6. Tighten the bearing caps alternately to a tightening torque of 20 N·m.
7. Place the control chain on top of the intake camshaft gear and the sliding bar.
Caution! For 2.2L engine: Turn the camshaft adjuster near the intake camshaft gear (75) to the "spat" (late) position as far as it will go in the direction of camshaft rotation.
8. Install the exhaust camshaft gear into the timing chain and tighten it with a new flange bolt to 20 Nm. Then tighten the bolt in the same direction with an open-end wrench by 90°.
9. Check that the markings on the camshaft gears and the control chain, applied during dismantling, match.
10. Install the chain tensioner.
11. Install the cylinder head cover.
12. Install the front cover.
13. Connect the battery ground (–) cable.
14. Set the time on the clock.
15. Set the radio anti-theft code.