Removal
The cylinder head is installed. Remove the toothed belt. Remove the locking pin "3359". Unscrew the bolts "1" and remove the camshaft gear from the hub.
Loosen the hub nut "1" by holding it with the "T10051" support. Loosen the bolt by about 2 turns.
Place the puller "T10052" on the hub and screw in bolts "1". Remove the hub from the camshaft, holding the puller's hexagon with a 30 key and screwing in bolt "2". Remove the cylinder head cover.
First unscrew the outer and then the inner bolts of the balance shaft, and remove it. Remove the tandem pump. Remove covers "2" and "3". Crosswise unscrew covers "1" and "4"
Instructions. Bearing cover "4" is marked like bearing cover "5". Make sure that the camshaft bearing shells are not mixed up. Using a waterproof marker, mark the location of the shells on the camshaft on the back of the shells.
Remove the camshaft.
Installation
Installation in reverse order, taking into account the following: the crankshaft gear must be locked using the crankshaft stopper "T10050". The marks on the toothed belt gear and the crankshaft stopper "arrow" must be opposite each other. In this case, the stopper journal must enter the hole of the sealing flange.
Instructions: Make sure that used camshaft bearing shells are not mixed up (take into account the markings). When installing the camshaft, ensure that the retaining protrusions of the liners in the bearing caps and cylinder head are correctly seated.
Lubricate the working surfaces of the camshaft with engine oil. Bring the camshaft to the TDC position of the first cylinder: the cams of the first cylinder of the camshaft should be facing up "arrows". Crosswise tighten the covers "2" and "3".
Apply a thin, even layer of sealant to the surface of bearing caps "1" and "4". Make sure that the sealant does not get into the "arrow" grooves or onto other surfaces. Install and tighten bearing caps "1" and "4". Bearing cap "4" must be flush with the outer edge of the cylinder head, otherwise the tandem pump may become unsealed. Install the camshaft seal. Install the balance shaft and tighten the inner bolts first, then the outer bolts of the shaft in several steps. Place the hub on the camshaft. Tighten the bolt, holding it with the "T10051" support. Install the camshaft gear on the hub. The "arrow" toothed segment on the camshaft timing belt gear must face up.
Do not screw in bolts "1" completely. Secure the camshaft hub with locking pin "3359". Install the timing belt (adjust valve timing). Install the tandem pump. If the balance shaft or the ball head bolts and adjusting bolts have been replaced, the unit injectors must be adjusted. Install the cylinder head cover.
Instructions: After installing the camshaft, the engine must not be started for approximately 30 minutes. The hydraulic tappets must be settled (otherwise the valves will touch the pistons). After working on the valve mechanism, turn the engine by hand at least 2 turns to make sure that none of the valves are in contact with the piston.
Tightening torques
- Bearing cap to cylinder head: 8 Nm + 90° 1)
- Balance shaft to cylinder head: 20 Nm + 90° 1)
- Hub to camshaft: 100 Nm
1) Replace the bolts
Valve sizes
| Size | Inlet valve | Exhaust valve |
| a mm | 35.95 | 31,45 |
| b mm | 6,980 | 6,956 |
| with mm | 89,95 | 89,95 |
| α° | 45 | 45 |
Instructions. It is prohibited to process the valves. Only lapping is allowed.