Camshaft: Service and Repair
Camshafts
Special tools, testers and auxiliary items required
• Puller (T40001)
• Retainer (3036)
• Sealant remover (commercially available)
• Sealant, refer to the electronic parts catalog ETKA
Removing
• Sealing surfaces on guide frame at bottom and on cylinder head at top must not be worked.
• Camshaft bearings are integrated in the cylinder head and guide frame. Before removing guide frame, tension on toothed belt must be released.
• Replace the camshaft seal and cover when the guide frame is removed.
- Removing camshaft adjuster. Refer to => [ Camshaft Adjuster ] Camshaft Adjuster.
- Toothed belt, removing. Refer to => [ Toothed Belt ] Toothed Belt.
- Loosen the camshaft toothed belt sprocket bolt with the (3036).
- Remove the camshaft toothed belt sprocket with the (T40001) and the claws (T40001/6) and (T40001/7).
- Remove the rear toothed belt guard bolts - arrows -.
- Tilt the rear toothed belt guard away from the cylinder head slightly.
- Loosen the guide frame bolts in the following sequence: - 6 to 1 -.
- Remove the bolts and carefully remove the guide frame and lay it on a soft surface on the workbench.
- Remove the camshafts with the drive chain from the cylinder head and lay on a clean surface.
Installing
• Tightening specifications, refer to => [ Guide Frame Tightening Specifications
and Sequence ] Valvetrain Overview.
• Replace guide frame bolts.
Risk of contaminating lubricating system and bearing.
• Cover open parts of engine.
- Remove reside on the cylinder head and guide frame with sealant remover (commercially available).
- Clean the sealing surfaces; they must be free of oil and grease.
- Make sure all of the roller rocker levers lie on the valve stem ends correctly.
- Lubricate the running surfaces of both camshafts.
- Place the drive chain on the chain sprockets for the removed camshaft as follows:
• Cams - A - of cylinder 4 must face each other.
• The notches - arrows - on both camshafts must align.
• The side surfaces of the notches must be exactly vertical.
- Place the camshafts in the cylinder head and the chain tensioner together with the drive chain.
- Check the camshaft "TDC" position again:
• Cams - A - of cylinder 4 must face each other.
• The notches - arrows - on both camshafts must align.
• The side surfaces of the notches must be exactly perpendicular to the cylinder head.
• Note the expiration date of the sealing compound.
- Cut the tube nozzle at the front marking (nozzle diameter approximately 1.0 mm).
The lubrication system could be plugged with excess sealant.
• Do not apply sealant beads thicker than specified.
- Apply an even and light bead of sealant in the clean groove on the guide frame.
• The guide frame must be installed within 5 minutes after applying the sealant.
- Tighten the guide frame bolts. Refer to => [ Guide Frame Tightening Specifications
and Sequence ] Valvetrain Overview.
- Check the camshaft "TDC" position:
• It must be possible to insert the (T10252) as far as the stop.
• Rotate the camshafts back and forth slightly if necessary to insert the (T10252).
• Ignore - arrows -.
- Remove the (T10252).
- Drive the cover => [ (Item 25) Cover ] Valvetrain Overview in approximately 1 to 2 mm with the thrust piece (3334).
The rest of the installation is performed in reverse order of removal, noting the following:
Risk of damaging valves and piston crowns.
• If camshafts are being rotated, crankshaft may not rest with any piston at "TDC".
• The engine must be no more than warm to touch.
- Install the camshaft seal. Refer to => [ Exhaust Camshaft Seal ] Service and Repair.
- Tighten the rear toothed belt guard. Refer to => [ Toothed Belt Drive Overview ] Toothed Belt Drive Overview.
- Insert the fitting key in the camshaft and make sure it is seated correctly.
- Installing camshaft adjuster. Refer to => [ Camshaft Adjuster ] Camshaft Adjuster.
- Install toothed belt (adjust timing) => [ Installing (Adjusting
valve timing) ] Toothed Belt.