Camshaft and Adjuster - Left Cyl. Head, Removal & Installation

Camshafts and camshaft adjuster - left cylinder head, removing and installing

Note: There are fundamental differences between installation procedure of timing chain on left cylinder head and right cylinder head. Observe different procedures.

Special tools and equipment
^ Retainer for chain tensioner 3366
^ Sealant:, Refer to Parts Supplier

Removing
^ Engine in vehicle

- Remove toothed belt.
- Remove camshaft sprocket.





- Unscrew idler wheel (arrow).
- Loosen nuts -1-.
- Remove bolts -2- and take out rear toothed belt guard.





- Unplug electrical connector (arrow) from Valve -2- for camshaft adjustment -N208-.
- Remove left cylinder head cover.





- Unplug connector (arrow) from Camshaft Position (CMP) Sensor 2 G163-.
- Remove Hall sender housing.
- Remove Hall sender rotor and washer.
- Rotate crankshaft approximately 45° counter-clockwise by turning securing bolt for toothed belt sprocket so that none of the pistons are at TDC.





- Re-check TDC position of camshafts.
^ The marks on the two camshafts must be in line with (arrows) on bearing caps.

If old drive chain is being re-installed:
- Clean chain and camshaft sprockets opposite two (arrows) on bearing caps and mark installation position with colored marks.





^ The distance between the two (arrows) (and thus between colored markings) is 15 rollers on chain.

Note: Do not mark chain with a center punch or by making a notch or similar.





Continued:

- Hold camshaft adjuster in position with retainer for chain tensioner 3366.

Note: If retainer for chain tensioner is tightened excessively, this can damage camshaft adjuster.





- Mark sequence and positions of all bearing caps as shown in illustration - regardless of existing identification markings.
- To mark bearing caps, clean them first and use a waterproof felt pen.
- Unscrew bolts securing camshaft adjuster -10-.
- Remove bearing cap 1.
- Remove bearing caps 2, 4, 6, 8 and 9 and place them in correct order on a clean surface.
- Loosen off bearing caps 3, 5 and 7 of intake and exhaust camshafts alternately and diagonally, and remove.
- Take out both camshafts together with camshaft adjuster.

Installing
- Install new bolts for camshaft bearing caps and camshaft adjuster.
- Replace semi-circular sealing plug.
- Remove all remaining sealant from cylinder head and bearing caps.





- Replace rubber/metal gasket for camshaft adjuster and apply a thin coat of sealant to shaded area.
^ Sealant:, Refer to Parts Supplier

- Install drive chain on camshaft sprockets as follows:





If old drive chain is being re-installed:

^ Install chain so that colored markings are in line (arrows).





If new drive chain is being installed:

^ The distance between notches -A- and -13- on camshafts must be 15 rollers on chain. The illustration shows exact positions of 1st and 15th rollers on sprockets.

Continued:
- Insert camshaft adjuster into chain (2nd mechanic required).
- Position camshafts together with chain and camshaft adjuster on cylinder head.
- Oil running surfaces of both camshafts.

Note: Dowel sleeves for bearing caps and camshaft adjuster must be installed in cylinder head.





- Install bearing caps 3, 5 and 7 in accordance with identification markings.
- Tighten bearing caps 3, 5 and 7 of intake and exhaust camshafts in stages and in diagonal sequence.
- Secure camshaft adjuster -10-
- Remove holder for chain tensioner 3366.
- Check correct setting of camshafts:





^ The two markings on camshafts must be in line with two arrows on bearing caps (arrows).

Note: If necessary, turn camshafts slightly backward and forward so that both markings are aligned correctly.





- Apply a thin coat of sealant to shaded areas on double bearing cap and on outer bearing cap next to camshaft adjuster, and install bearing caps.
^ Sealant, Refer to Parts Supplier

- Install remaining bearing caps.
- Install new intake and exhaust camshaft oil seals
- Carefully knock in sealing cap with a suitable lever or bar.
- Rotate crankshaft approximately 45° clockwise by turning securing bolt for toothed belt sprocket to bring it back to TDC position, and secure crankshaft by screwing in clamping bolt.

The remaining installation steps are carried out in reverse sequence - note following points:
- Install toothed belt (adjust valve timing).
- Install cylinder head cover.

Notes:
^ Wait about 30 minutes after installing camshafts before starting engine. The hydraulic valve compensating elements must settle (otherwise valves will strike pistons).
^ After working on valve gear, turn engine carefully at least 2 full rotations by hand to ensure that none of the valves make contact when starter is operated.

- Install lock carrier with attachments.

- Install front bumper:
- Install air filter housing
- Top up coolant.
- Adjust headlights:





Tightening torques