Removal and Replacement

Camshaft Replacement (Part 1 Of 2):

Camshaft Replacement (Part 2 Of 2):

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

REMOVAL
1. Remove cylinder head cover. Service and Repair
2. Position piston of cylinder 1 to ignition TDC
- Rotate engine at the crankshaft.
- Do not turn engine at the bolt of the camshaft sprocket.
- DO NOT turn engine backwards.

NOTE: Markings of camshaft/camshaft bearing caps (arrows) should be aligned

3. Lock inlet camshaft (6)
- Insert the locking pin (1), through the 1st camshaft bearing cap into the hole in the inlet camshaft sprocket (2).
4. Install lock (7) for crankshaft/starter ring gear, refer to Installing/Removing Crankshaft Retaining Lock. [1][2]Procedures
5. Mark camshaft sprocket (5) relative to timing chain

NOTE: When carrying out work which does not involve rotating the crankshaft, connect camshaft sprocket (5) and timing chain with cable strap.

6. Remove chain tensioner (10). [1][2]Procedures
7. Detach camshaft sprocket (5) from the exhaust camshaft (7) and take off
- Pay attention to dowel pin (3) (arrow).
- Take off camshaft sprocket (5) with timing chain installed on.
8. Bolt camshaft housing onto cylinder head as follows:





- Remove camshaft bearing caps 2 and 5.
- Bolt down camshaft housing with 2 7x41 mm bolts (arrows)
The camshaft housing must be bolted to the cylinder head in order to avoid damage (leaks at seals between camshaft housing and cylinder head) when removing the camshafts

NOTE:
^ Bolts may remain installed.
^ Pay attention to marking of camshaft bearing caps

9. Unbolt camshaft bearing caps as follows:





- Remove bearing caps 1, 4 and 7. DO NOT remove caps 3 and 6 yet.





- Remove caps 3 and 6 in multiple steps of one turn of each bolt until pressure is relieved

CAUTION: The camshafts must not twist while camshaft caps are being loosened

Camshaft Replacement (Part 1 Of 2):

Camshaft Replacement (Part 2 Of 2):

10. Remove inlet and exhaust camshafts (6, 7)
11. Remove bushes of shaft trim panel (12)

INSTALLATION
1. Install bushes of shaft trim panels (12)
- Replace seals.
- The lug on the bush of the shaft trim cover (arrow) should be aligned with the guide notch in the camshaft housing.
2. Position inlet and exhaust camshafts (6, 7) noting the following:

CAUTION:
^ The camshafts are very sensitive to fracturing.
^ Ensure that they are installed free of stress

- Lubricate bucket tappets and camshaft bearing points.
- Check that bucket tappets operate freely.
- Pay attention to matching of camshafts.
The camshaft code numbers are indicated on the thrust collar of the axial bearing.
- Align inlet and exhaust camshafts at the axial bearing (arrows).
- Install camshafts so that the two holes (13) in the camshaft sprockets are opposite each other and the markings of camshaft (arrows) and camshaft bearing caps are aligned.
3. Install camshaft bearing caps, noting the following:
- Pay attention to marking of camshaft bearing caps
- Install camshaft bearing caps (8) at the same point in the EXACT reverse order.
- Tighten bearing cap bolts evenly in steps each of one turn.
Tighten to: 15 Nm
4. Lock inlet camshaft (6)
- Insert the retaining pin (1) through camshaft bearing cap 1 into the hole in the inlet camshaft gear (2).
- When the inlet camshaft is blocked, the piston of cylinder 1 must be at ignition TDC.
5. Install camshaft gear (5) onto exhaust camshaft (7)
- Replace bolts of camshaft gear (4).
- Pay attention to dowel pin (3) (arrow).
- Install on camshaft gear (5) with timing chain installed.
Tighten to: 18 Nm
6. Install chain tensioner (10)
- Replace seal of chain tensioner (11)
6. Install remaining parts to engine
7. After assembling, check start of delivery of injection pump, refer to Powertrain Management.