REMOVAL & INSTALLATION
See Figure 1
The following procedure covers camshaft removal and installation with the cylinder head on or off the engine. If the cylinder head has been removed, follow Steps 7-9 then skip to Step 12.
- Drain the cooling system. Remove the air cleaner assembly and disconnect the negative battery cable.
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
- Remove the spark plug wires from the plugs, disconnect the retainer from the valve cover and position the wires out of the way. Disconnect rubber vacuum lines as necessary.
- Remove all drive belts. Remove the alternator mounting bracket-to-cylinder head mounting bolts, position bracket and alternator out of the way.
- Disconnect and remove the upper radiator hose. Disconnect the radiator shroud.
- Remove the fan blades and water pump pulley and fan shroud. Remove cam belt and valve covers.
- Align engine timing marks at TDC for No. 1 cylinder. Remove cam drive belt.
- Remove the rocker arms (camshaft followers).
- Remove the camshaft drive gear and belt guide using a suitable puller. Remove the front oil seal with a sheet metal screw and slide hammer.
- Remove the camshaft retainer located on the rear mounting stand by unbolting the two bolts.
- Jack up the front of the vehicle and support on jackstands. Remove the front motor mount bolts. Disconnect the lower radiator hose from the radiator. Disconnect and plug the automatic transmission cooler lines.
- Position a piece of wood on a floor jack and raise the engine carefully as far as it will go. Place blocks of wood between the engine mounts and crossmember pedestals.
- Remove the camshaft by carefully withdrawing toward the front of the engine. Caution should be used to prevent damage to cam bearings, lobes and journals.
- Check the camshaft journals and lobes for wear. Inspect the cam bearings, if worn (unless the proper bearing installing tool is on hand), the cylinder head must be removed for new bearings to be installed by a machine shop.
Right click on the image and select option "open image in new web" if the image is not seen full or its very small to see.-----------
- Camshaft installation is in the reverse order of service removal procedure. Coat the camshaft with a heavy SF (or better) grade oil before sliding it into the cylinder head. Install a new front seal. Apply a coat of sealer or teflon tape to the cam drive gear bolt before installation. After any procedure requiring removal of the rocker arms, each lash adjuster must be fully collapsed after assembly, then released. This must be done before the camshaft is turned.
- Refill cooling system. Start engine and check for leaks. Roadtest the vehicle for proper operation.
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Removing the camshaft seal
The abbreviation VVT stands for: Variable Valve Timing.
Note! Crankshaft or camshafts must not, under any circumstances, be rotated more than is listed below. Failure to follow these instructions may cause damage to the valves.
Remove:
the cable from the battery negative terminal.
the charge air pipe over the engine.
Seal the openings.
the upper camshaft belt cover.
the cover over the ignition coils.
lift the solenoid valves away from the air cleaner (ACL) cover.
the air intake hose for the turbocharger (TC) from the air cleaner (ACL) cover.
Put to one side.
the upper torque rod bracket.
the camshaft position (CMP) sensor housing.
the trigger wheel.
the rear cover for the intake camshaft.
the servo reservoir and the expansion tank.
Lift up and place on top of the engine.
Note! Take care not to spill servo oil from the bleed hole in the cap.
Place paper wipe around the reservoir and then cover with a plastic bag as protection.
Spilled servo oil is highly inflammable.
3 nuts for the cable duct at the right suspension turret.
Lift the duct away from the screws.the auxiliaries belt.the front camshaft belt cover.
Position the engine according to the marking
Raise the car.Remove:
the right front wheel.
the nuts for the cover in the fender liner.
Install the upper camshaft belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.Turn the crankshaft a further 1/4 of a turn clockwise, then back counter-clockwise until the markings correspond.The markings are illustrated.
Remove the upper camshaft belt cover.Removing the camshaft belt
Slacken off the belt tensioner.Slacken off the belt tensioner center screw slightly.
Hold the center screw still and turn the tensioner eccentric clockwise with a 6 mm (15/64") Allen key to "10 o'clock".Remove the camshaft belt from the belt tensioner, camshaft pulley and idler pulley.Removing the timing gear pulley with the variable valve timing (WT) unit Use camshaft adjustment tool:
Install camshaft adjustment tool 999 5452 at the rear edge of the camshafts.
First screw in the part of the tool intended for the exhaust camshaft.
Install the adjustment tools
Screw the camshaft adjustment tools together
Carefully turn the exhaust camshaft clockwise with the camshaft adjustment tool until the intake camshaft tool can be applied.
Screw the camshaft adjustment tools together.
Remove the timing gear pulley
Remove
Exhaust camshaft pulley:
The plug at the front edge of the variable valve timing (WT) unit (TORX 55).
The center screw from the variable valve timing (WT) unit (TORX 55).
Carefully pull out the timing gear pulley with the variable valve timing (WT) unit.
Intake camshaft pulley:
Remove the screws and remove the timing gear pulley.
Replace the camshaft seal
Replacing the camshaft seal:
Carefully press in tool 999 5651 between the sealing ring and the camshaft.
Carefully pry out the seals.
Install a new seal:
Grease the new seal.
Install the new seal for the intake camshaft using drift 999 5719.
Install the new seal for the exhaust camshaft using drift 999 5718.
Secure the crankshaft position
Install the adjustment tool.
Pull the charge air pipe forward
Remove the 3 starter motor screws for the starter motor mounting.
Place the starter motor to one side.
Remove the blind cover plug and the sealing washer.
Turn the crankshaft clockwise slightly to avoid the camshaft adjustment tool being in the wrong position.
Install camshaft adjustment tool: 999 5451.
Ensure that the camshaft adjustment tool reaches down to the cylinder block.
Turn the crankshaft back counter~ockwise until it stops against the drift.
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Reinstall
Install the variable valve timing (VVT) unit with the toothed belt pulley:
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing (VVT) unit.
Press the timing gear pulley and variable valve timing (VVT) unit on to the camshaft.
Install the center screw which secures the variable valve timing (VVT) unit to the camshaft. Do not tighten yet!
Install the upper camshaft belt cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.
Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw in the variable valve timing (VVT) unit to 120 Nm (88 lb.ft).
Check that the variable valve timing (VVT) unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm (26 lb.ft)
Install the timing gear pulley on the intake camshaft:
Install the timing gear pulley on the intake camshaft with two screws, but do not tighten.
Check that the markings on the timing gear pulley and the upper timing cover correspond.
Installing the timing belt
Install the timing belt:
Tighten the center screw on the camshaft belt tensioner to 5 Nm (4 lb.ft) .
Turn the variable valve timing (VVT) unit clockwise until stop.
Hold the variable valve timing (VVT) unit secure at the clockwise limit position when the belt is being installed.
Install the belt in the following order:
Install the camshaft belt over the pulley on the crankshaft.
Then install the belt as follows
Idler pulley.
Intake cam pulley.
Exhaust cam pulley.
Water pump.
Belt tensioner.Note! Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.
Tighten the timing belt
Adjust the belt tensioner:
Note! This adjustment is to be made with a cold engine.
A suitable temperature is 20°C/68°F.
At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.
The illustration shows the needle position when adjusting the camshaft belt tensioner at different engine temperatures.
Tighten the timing belt as follows:
Hold the belt tensioner center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
Tighten the screws on the exhaust camshaft timing gear pulley to 10 Nm (7.4 lb.ft)
Install the screw missing on the intake camshaft belt pulley.
Tighten the screws on the intake camshaft timing gear pulley to 20 Nm (15 lb.ft) .
Note! The variable valve timing (VVT) unit must not be released from the limit position until after the timing gear pulleys have been tightened
Then turn the eccentric back so that the needle reaches the marked position corresponding to the relevant temperature.
Remember to hold the center screw secure at the same time.
At 20°C the needle must be centered in the window. See the illustration above.
Hold the eccentric secure and tighten the center screw to 20 Nm (15 lb.ft) .
Check that the indicator is in the correct position. As illustrated.
If the indicator is not in the correct position, a new alignment must be carried out.
Remove:
the camshaft adjustment tools.
the crankshaft stopper.
Install the plug with a new sealing washer. Tighten to 40 Nm (29 lb.ft)
Checking the markings and belt tension
Check:Press the belt to check that the indicator on the tensioner moves easily.
Install the upper timing belt cover.
Turn the crankshaft two turns and check that the markings on the crankshaft and camshaft pulley correspond.
Check that the indicator on the belt tensioner is within the marked area.
Reinstall
Install:
the front camshaft belt cover. Tighten to 12 Nm (8.8 ft.lb) .
the upper camshaft belt cover. Tighten to 8 Nm (6 lb.ft) .
the auxiliaries belt.
the cable duct. 3 nuts.
the expansion tank.
the servo reservoir.
Wipe clean. Check the level and top up as necessary.
Note! Check that the hoses are correctly positioned.
the starter motor.
Tighten the screws at the transmission to 40 Nm (29 lb.ft) .
Tighten the support bracket screw to 25 Nm (18 Ib.ft)
the engine cooling fan (FC).
the hose between the charge air cooler and the intake.
Remove the seals.
Tighten the clamp on the charge air pipe at the throttle body (TB).
screw the relay bracket and the fan shroud into place.
the canister purge (CP) valve, relays and connectors.
the air ducts.
the brake vacuum hose.
the trigger wheel.
Tighten to 17 Nm (12 lb.ft) .
the camshaft position (CM P) sensor housing and a new cover.
Tighten the screws.
the torque rod bracket.
Tighten to 50 Nm (37 lb.ft) .
the upper torque rod.
Tighten to 35 Nm (26 lb.ft) . Angle-tighten 90 degrees.
the cover over the ignition coils.
Tighten to 8 Nm (6 lb.ft) .
the charge air pipe over the engine.
Remove the seals.
the air cleaner (ACL) cover and the intake air hose.
the solenoid valves on the air cleaner (ACL) cover.
the cable to the battery negative terminal.
The cover in the fender liner.
Replacing the rear seal
The following components must be removed when replacing the rear seal:
the solenoid valves.
Lift out from the air cleaner (ACL) cover.
the air hose from the air cleaner (ACL) to the turbocharger (TC). Place to one side.
Seal the hose.
place the air cleaner (ACL) cover to one side.
the charge air pipe over the engine.
Seal the openings.
the cover over the ignition coils.
the upper torque rod bracket.
the camshaft position (CMP) sensor housing.
the trigger wheel.
Replacing the rear camshaft seal
Remove and replace the seal:
Carefully pull out the old seal.
Use extractor 999 5919.
Replacing the rear camshaft seal
Install new seals:
Grease and install the new seal.
Use drift 999 5450.
Note! The seal is normally pressed in so that it is level with the internal beveled edge.
If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm (0.079 in) deeper by turning the drift socket.
The abbreviation VVT stands for: Variable Valve Timing.
Note! Crankshaft or camshafts must not, under any circumstances, be rotated more than is listed below. Failure to follow these instructions may cause damage to the valves.
Remove:
the cable from the battery negative terminal.
the charge air pipe over the engine.
Seal the openings.
the upper camshaft belt cover.
the cover over the ignition coils.
lift the solenoid valves away from the air cleaner (ACL) cover.
the air intake hose for the turbocharger (TC) from the air cleaner (ACL) cover.
Put to one side.
the upper torque rod bracket.
the camshaft position (CMP) sensor housing.
the trigger wheel.
the rear cover for the intake camshaft.
the servo reservoir and the expansion tank.
Lift up and place on top of the engine.
Note! Take care not to spill servo oil from the bleed hole in the cap.
Place paper wipe around the reservoir and then cover with a plastic bag as protection.
Spilled servo oil is highly inflammable.
3 nuts for the cable duct at the right suspension turret.
Lift the duct away from the screws.the auxiliaries belt.the front camshaft belt cover.
Position the engine according to the marking
Raise the car.Remove:
the right front wheel.
the nuts for the cover in the fender liner.
Install the upper camshaft belt cover.
Turn the crankshaft clockwise until the markings on the crankshaft and camshaft pulley correspond.Turn the crankshaft a further 1/4 of a turn clockwise, then back counter-clockwise until the markings correspond.The markings are illustrated.
Remove the upper camshaft belt cover.Removing the camshaft belt
Slacken off the belt tensioner.Slacken off the belt tensioner center screw slightly.
Hold the center screw still and turn the tensioner eccentric clockwise with a 6 mm (15/64") Allen key to "10 o'clock".Remove the camshaft belt from the belt tensioner, camshaft pulley and idler pulley.Removing the timing gear pulley with the variable valve timing (WT) unit Use camshaft adjustment tool:
Install camshaft adjustment tool 999 5452 at the rear edge of the camshafts.
First screw in the part of the tool intended for the exhaust camshaft.
Install the adjustment tools
Screw the camshaft adjustment tools together
Carefully turn the exhaust camshaft clockwise with the camshaft adjustment tool until the intake camshaft tool can be applied.
Screw the camshaft adjustment tools together.
Remove the timing gear pulley
Remove
Exhaust camshaft pulley:
The plug at the front edge of the variable valve timing (WT) unit (TORX 55).
The center screw from the variable valve timing (WT) unit (TORX 55).
Carefully pull out the timing gear pulley with the variable valve timing (WT) unit.
Intake camshaft pulley:
Remove the screws and remove the timing gear pulley.
Replace the camshaft seal
Replacing the camshaft seal:
Carefully press in tool 999 5651 between the sealing ring and the camshaft.
Carefully pry out the seals.
Install a new seal:
Grease the new seal.
Install the new seal for the intake camshaft using drift 999 5719.
Install the new seal for the exhaust camshaft using drift 999 5718.
Secure the crankshaft position
Install the adjustment tool.
Pull the charge air pipe forward
Remove the 3 starter motor screws for the starter motor mounting.
Place the starter motor to one side.
Remove the blind cover plug and the sealing washer.
Turn the crankshaft clockwise slightly to avoid the camshaft adjustment tool being in the wrong position.
Install camshaft adjustment tool: 999 5451.
Ensure that the camshaft adjustment tool reaches down to the cylinder block.
Turn the crankshaft back counter~ockwise until it stops against the drift.
Check that the marking on the crankshaft timing gear pulley corresponds with the marking on the oil pump.
Reinstall
Install the variable valve timing (VVT) unit with the toothed belt pulley:
Slacken off, but do not remove, the screws which secure the timing gear pulley to the variable valve timing (VVT) unit.
Press the timing gear pulley and variable valve timing (VVT) unit on to the camshaft.
Install the center screw which secures the variable valve timing (VVT) unit to the camshaft. Do not tighten yet!
Install the upper camshaft belt cover.
Turn the timing gear pulley clockwise until the screws at the oval holes are in the limit position.
Continue turning clockwise until the timing gear pulley marking is 1 cog before the marking on the upper timing cover.
Check that the timing gear pulley is still in the limit position in the oval holes.
Tighten the center screw in the variable valve timing (VVT) unit to 120 Nm (88 lb.ft).
Check that the variable valve timing (VVT) unit does not rotate when tightening.
Install the center plug. Tighten to 35 Nm (26 lb.ft)
Install the timing gear pulley on the intake camshaft:
Install the timing gear pulley on the intake camshaft with two screws, but do not tighten.
Check that the markings on the timing gear pulley and the upper timing cover correspond.
Installing the timing belt
Install the timing belt:
Tighten the center screw on the camshaft belt tensioner to 5 Nm (4 lb.ft) .
Turn the variable valve timing (VVT) unit clockwise until stop.
Hold the variable valve timing (VVT) unit secure at the clockwise limit position when the belt is being installed.
Install the belt in the following order:
Install the camshaft belt over the pulley on the crankshaft.
Then install the belt as follows
Idler pulley.
Intake cam pulley.
Exhaust cam pulley.
Water pump.
Belt tensioner.Note! Adjust the timing gear pulleys so that the screws are not at a limit position in the oval holes.
Tighten the timing belt
Adjust the belt tensioner:
Note! This adjustment is to be made with a cold engine.
A suitable temperature is 20°C/68°F.
At a higher temperature, for example with a warm engine or a higher ambient temperature, the needle is further to the right.
The illustration shows the needle position when adjusting the camshaft belt tensioner at different engine temperatures.
Tighten the timing belt as follows:
Hold the belt tensioner center screw secure and turn the belt tensioner eccentric counter-clockwise until the tensioner indicator passes the marked position.
Tighten the screws on the exhaust camshaft timing gear pulley to 10 Nm (7.4 lb.ft)
Install the screw missing on the intake camshaft belt pulley.
Tighten the screws on the intake camshaft timing gear pulley to 20 Nm (15 lb.ft) .
Note! The variable valve timing (VVT) unit must not be released from the limit position until after the timing gear pulleys have been tightened
Then turn the eccentric back so that the needle reaches the marked position corresponding to the relevant temperature.
Remember to hold the center screw secure at the same time.
At 20°C the needle must be centered in the window. See the illustration above.
Hold the eccentric secure and tighten the center screw to 20 Nm (15 lb.ft) .
Check that the indicator is in the correct position. As illustrated.
If the indicator is not in the correct position, a new alignment must be carried out.
Remove:
the camshaft adjustment tools.
the crankshaft stopper.
Install the plug with a new sealing washer. Tighten to 40 Nm (29 lb.ft)
Checking the markings and belt tension
Check:Press the belt to check that the indicator on the tensioner moves easily.
Install the upper timing belt cover.
Turn the crankshaft two turns and check that the markings on the crankshaft and camshaft pulley correspond.
Check that the indicator on the belt tensioner is within the marked area.
Reinstall
Install:
the front camshaft belt cover. Tighten to 12 Nm (8.8 ft.lb) .
the upper camshaft belt cover. Tighten to 8 Nm (6 lb.ft) .
the auxiliaries belt.
the cable duct. 3 nuts.
the expansion tank.
the servo reservoir.
Wipe clean. Check the level and top up as necessary.
Note! Check that the hoses are correctly positioned.
the starter motor.
Tighten the screws at the transmission to 40 Nm (29 lb.ft) .
Tighten the support bracket screw to 25 Nm (18 Ib.ft)
the engine cooling fan (FC).
the hose between the charge air cooler and the intake.
Remove the seals.
Tighten the clamp on the charge air pipe at the throttle body (TB).
screw the relay bracket and the fan shroud into place.
the canister purge (CP) valve, relays and connectors.
the air ducts.
the brake vacuum hose.
the trigger wheel.
Tighten to 17 Nm (12 lb.ft) .
the camshaft position (CM P) sensor housing and a new cover.
Tighten the screws.
the torque rod bracket.
Tighten to 50 Nm (37 lb.ft) .
the upper torque rod.
Tighten to 35 Nm (26 lb.ft) . Angle-tighten 90 degrees.
the cover over the ignition coils.
Tighten to 8 Nm (6 lb.ft) .
the charge air pipe over the engine.
Remove the seals.
the air cleaner (ACL) cover and the intake air hose.
the solenoid valves on the air cleaner (ACL) cover.
the cable to the battery negative terminal.
The cover in the fender liner.
Replacing the rear seal
The following components must be removed when replacing the rear seal:
the solenoid valves.
Lift out from the air cleaner (ACL) cover.
the air hose from the air cleaner (ACL) to the turbocharger (TC). Place to one side.
Seal the hose.
place the air cleaner (ACL) cover to one side.
the charge air pipe over the engine.
Seal the openings.
the cover over the ignition coils.
the upper torque rod bracket.
the camshaft position (CMP) sensor housing.
the trigger wheel.
Replacing the rear camshaft seal
Remove and replace the seal:
Carefully pull out the old seal.
Use extractor 999 5919.
Replacing the rear camshaft seal
Install new seals:
Grease and install the new seal.
Use drift 999 5450.
Note! The seal is normally pressed in so that it is level with the internal beveled edge.
If the shaft journal is showing signs of wear, the seal can be pressed in 2 mm (0.079 in) deeper by turning the drift socket.
