Camshafts

Camshafts

Special tools, testers and auxiliary items required

• Retainer (3036)

• Puller (T10320)

• Camshaft Fitting Tool (T40094)

• Camshaft Fitting Tool (T40095)

• Camshaft Fitting Tool (T40096)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Sealant, refer to the Parts Catalog

Removing

- Remove the affected camshaft timing chain from the camshafts. Refer to => [ Camshaft Timing Chain, Removing from Camshafts ] Camshaft Timing Chain, Removing from Camshafts.

Left Cylinder Head

- Remove the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

- Remove the high pressure pump toothed belt. Refer to => [ High Pressure Fuel Pump Toothed Belt ] High Pressure Fuel Pump Toothed Belt.

- Using the retainer (3036) , loosen the center bolt - 1 - for the toothed belt pulley approximately two turns.






- Remove the toothed belt pulley using the puller (T10320).






Continuation for Both Sides






- Remove the left or right cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

- Loosen the guide frame bolts and nuts in sequence - 18 through 1 -.

• Be careful of the roller rocker arms and the hydraulic lash adjusters when removing the camshafts.

- Carefully remove the guide frame and the camshafts.

Installing

Only install the camshafts using the camshaft fitting tool (T40094) as described below. Otherwise the axial bearing in the guide frame will be destroyed and the cylinder head will have to be replaced.

Wear protective eyewear.

- Remove any sealant residue on the cylinder head and guide frame using a rotating plastic brush.

Make sure that no sealant residue enters the cylinder head and bearings.

- Clean the sealing surfaces, they must be free of oil and grease.

- Oil the journal surfaces of the camshafts.

Assemble the camshaft fitting tool (T40094) as follows:






Left Cylinder Head

- Insert the bracket (T40094/2) in location - A -.

- Insert the bracket (T40094/1) in location - D -.

Right Cylinder Head

- Insert the bracket (T40094/2) in location - B -.

- Insert the bracket (T40094/1) in location - C -.

Continuation for Both Sides






• The following procedure describes the left cylinder head.

• The procedure is performed in the same order for the right cylinder head.

- Insert the exhaust camshaft - 1 - in the brackets (T40094/1) and (T40094/2).

- Rotate the camshaft so it can be secured in the Top Dead Center (TDC) position with the straight edge - arrow -.

- Install the camshaft fitting tool (T40096) on the camshaft splines so each of the arms on the tool engages in half of the sprocket.

- Tighten the tool using the knurled knob until the tooth faces align.

- Insert the intake camshaft - 2 - in the camshaft fitting tool (T40094).






• The pin - 3 - must engage in the groove on the camshaft.

- Slide the exhaust camshaft - 1 - toward the intake camshaft until the splines mesh.

- Make sure the camshaft is positioned correctly:






• The notches - arrows - on both camshafts must face upward.

- Place the guide frame - 1 - on the camshafts.






• All the camshaft bearings must lie on the camshafts.

- Install the camshaft fitting tool (T40095) onto the camshafts by aligning the tool and tensioning using the knurled knobs.

- Tension the camshafts by tightening the nuts.

- Make sure the alignment pins - arrows - are in the cylinder head. Insert any missing alignment pins.






• Note the expiration date of the sealant.






- Cut the sealant tube nozzle at the front mark (nozzle diameter approximately 1.5 mm).

• The illustration shows the guide frame without the camshafts.






- Turn the guide frame over.

The lubrication system could be plugged with excess sealant.

• Do not apply sealant beads thicker than specified.

- Apply sealant beads - arrows - to the lean sealing surfaces of the guide frame as shown in the illustration.

• The grooves - arrows - in the sealing surface must be completely filled with sealant.

• The sealant beads must be 1.5 to 2.0 mm above the sealing surface.

• Sealant beads must not be thicker than specified, otherwise the extra sealant can enter the camshaft bearings.

• The guide frame must be installed within 5 minutes after application of the sealant.

The engine could be damaged.

• Make sure all the roller rocker arms are seated correctly on the valve stem tips and the adjusters.

- Place the guide frame on the cylinder head immediately with both camshafts and the camshaft fitting tool (T40095).






• After installing the guide frame, the sealant must dry for approximately 30 minutes.

- Hand tighten the guide frame bolts/nuts equally, in sequence - 1 through 18 -.

• The guide frame must be touching the entire contact surface of the cylinder head.

- Tighten the guide frame bolts/nuts in sequence - 1 through 18 - until they are seated.

- Remove the camshaft fitting tools (T40095) and (T40096).

Further installation is in the reverse order of removal. Note the following:

• Do not start the engine for approximately 30 minutes after installing the camshafts. The hydraulic lash adjusters must seat themselves (otherwise the valves will seat themselves on the pistons).

• After working on the valvetrain, carefully rotate the engine by hand at least 2 full revolutions to ensure that valves do not strike the pistons when starting.

- Install the left or right cylinder head cover. Refer to => [ Cylinder Head Cover ] Cylinder Head Cover.

Left Cylinder Head

- Replace the camshaft seal. Refer to => [ Camshaft Seal ] Service and Repair.

- Install the high pressure pump toothed belt. Refer to => [ High Pressure Fuel Pump Toothed Belt ] High Pressure Fuel Pump Toothed Belt.

- Install the upper intake manifold. Refer to => [ Upper Intake Manifold ] Upper Intake Manifold.

Right Cylinder Head

- Replace the front cover on the cylinder head.

- Drive the new cover in using a suitable drift until it is flush.

Continuation for Both Sides

- Install the camshaft timing chain. Refer to => [ Camshaft Timing Chain ] Camshaft Timing Chain.

Tightening Specifications