Camshafts

Camshafts

Special tools, testers and auxiliary items required

• Retainer (3036)

• Puller (T10320)

• Camshaft Insertion Tool (T40094)

• Camshaft Insertion Tool (T40095)

• Camshaft Insertion Tool (T40096)

• Hand Drill with Plastic Brush Attachment

• Protective Eyewear

• Sealant

Removing

- Remove the affected camshaft timing chain from the camshafts. Refer to => [ Camshaft Timing Chains, Removing from Camshafts ] Camshaft Timing Chains, 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 (3036), loosen the central bolt - 1 - for the toothed belt drive sprocket approximately two turns.





- Remove the toothed belt drive gear using (T10320).





Continuation for Both Sides





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

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

• Be careful of the roller rocker levers and the adjusters when removing the camshafts.

- Carefully remove the guide frame and the camshafts.

Installing

CAUTION!
Only install the camshafts with the (T40094) as described below. Otherwise the axial bearing in the guide frame will be destroyed and the cylinder head will have to be replaced.

CAUTION!
Wear safety glasses.

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

CAUTION!
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 (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.

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

- Tighten the (T40096) with the knurled bolt until the tooth faces align.

- Install the intake camshaft - 2 - in the (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.

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





• All the camshaft bearings must lie on the camshafts.

- Align the grips and tighten with the knurled nuts to install the (T40095) on the camshafts.

• Note that the intake and exhaust camshafts have different shapes.

- Cut the 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.

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

• The grooves - arrows - of 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 extra sealant can enter the camshaft bearings.

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

- Make sure all the roller rocker levers are seated correctly on the valve stem ends and the adjusters.

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





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

- Tighten the guide frame bolts by hand evenly in sequence - 1 through 18 -.

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

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

- Remove the (T40095) and the (T40096).

The rest of the installation is performed in reverse order of removal, noting the following:

• After installing the camshafts, the engine may not be started for approximately 30 minutes. The hydraulic adjusting elements must seat themselves (otherwise the valves will seat themselves on the pistons).

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

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 with a suitable drift until it is flush.

Continuation for Both Sides

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

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

Tightening Specifications