Attention! Replacing camshafts without the use of special tools is strictly prohibited, due to their possible breakage.
Camshafts can be replaced without removing the engine from the vehicle. The sequence in which the camshafts are removed does not matter. Replacing the camshafts should be preceded by measuring the values of axial and radial clearances, which should not go beyond 0.15-0.33 mm and 0.02-0.054 mm, respectively.
The replacement of the camshaft must be carried out in the following order. Prepare fixtures «00.9.250», «11.2.300», «11.3.240», «11.3.244», «11.3.250», «11.3.260», «11.3.292», «11.4.220», «11.6.150» And «11.6.180». Remove the cylinder head cover. Remove spark plugs. Set the crankshaft to the TDC position of the compression stroke of the first cylinder (see fig. 3.106)...
... and block the flywheel using the tool «11.2.300» (see fig. 3.122).
Remove the D-VANOS adjustment unit.
Loosen the nut (7, see fig. 3.12) and remove the timing chain tensioner piston cylinder.
1, 2 - compression ring; 3 - oil scraper ring; 4 - piston; 5 - piston pin; in - retaining ring (∅22x1,5); 7 - bushing of the upper head; 8 - connecting rod; 9 - centering sleeve; 10 - insert (blue); 11 - insert (red); 12 - connecting rod cover; 13 - connecting rod bolt (47 mm)
Note that the piston cylinder is under significant spring pressure. Release the top tensioner (14, see fig. 3.13) secondary chain down and block it with the tool «11.3.292» (kernel).
1 - crankshaft; 2,8,14,15 - asterisk; 3 - tensioner bar; 4 - piston; 5 - spring; 6 - sealing ring; 7 - cover bolt; 9.16 - chain; 10.12 - strap bolt; 13 - key; 17 - exhaust camshaft; 18 - intake camshaft; 19 - hydraulic pusher; 20 - valve cotters; 21 - top plate; 22 - spring; 23 - bottom plate; 24 - oil scraper cap; 25 - inlet valve; 26 - exhaust valve
Loosen the nuts (1) and remove the wheel (2) camshaft position sensor. Remove belleville spring (3). Loosen the nuts (16) on the intake shaft side and remove the washer (17).
Remove bolts (8) on the side of the exhaust shaft and remove the sprockets (7 and 20) chain drive of the intake and exhaust camshafts together with the chain (24) drive, thrust disc (4) and splined shaft (18).
Note. Splined shafts (5 and 18) for the exhaust side and the intake side are the same. Used splined shafts should be installed strictly in their places.
Remove spline shaft (5) with toothed sleeve (11). Remove bolts (9,10,15) and remove tensioner (14) secondary circuit. Unscrew the studs (12) and disconnect the sprocket (13) away from the timing chain by pulling it up.
Moving forward, remove the asterisk (13) timing drive. The drive target remains above the exhaust camshaft. Unscrew the studs (21) on the intake shaft side and remove the thrust plate (22). Remove wheel (23) sensor and the intake camshaft position sensor itself.
Attention! bolts (pic. 3.102) do not unscrew at the ends of the camshafts.
If the camshafts are removed from the cylinder head mounted on the engine, then all pistons must be set to the middle position. This will eliminate the contact of valves and pistons, because. None of the pistons will be in the TDC position.
Unscrew the mounting pins (arrows, fig. 3.103).
Pull back fixture «11.2.300» (see fig. 3.122) back enough to unlock the flywheel.
Lift the timing chain up and, holding it taut, secure it with a wire shackle to prevent it from slipping. Turn the crankshaft by the central bolt 30-40°against the direction of rotation of the shaft, from the point where the piston of the first cylinder is at the TDC of the end of the compression stroke.
Attention! The bearing cap of the intake camshaft of the first cylinder is centered using plug-in bushings. To avoid tilting the intake camshaft in the bearing plate, loosen the nuts and remove the first bearing cap.
Install fixture «11.3.260» on the cylinder head and secure it with bots (arrows, fig. 3.104) installed in the holes of the spark plugs of the 1st and 4th cylinders, the tightening torque of the bolts is 25 Nm (2.5 kgf·m).
Fasten the camshaft bearing caps by turning the eccentric shaft clockwise (2) fixtures «11.3.260». Loosen all bolts securing the camshaft bearing caps. Release the clamping force from the bearing caps by turning the eccentric shaft (2) fixtures «11.3.260» and remove the tool from the cylinder head.
Remove all bearing caps, first make sure they are marked. When assembling, they must be installed in their original places. The bearing caps for the exhaust camshafts are marked with «A1» By «A7», inlet valves with «E1» By «E7».
Before removing the cylinder head and valves, you must first remove the bar assembly with the camshaft bearing caps and hydraulic tappets. To prevent the hydraulic pushers from falling out, install devices «11.3.250», on top of the pushers. Hydraulic pushers should be installed strictly in their places, therefore, when removing them, mark them with a marker.
Remove the support bar assembly together with the cylindrical hydraulic pushers. Check for wear at the installation site of the cylindrical pushers. Support bars are marked «A» (pic. 3.105) for exhaust valves and marking «E» for intake valves.
When installing support bars (19, see fig. 3.4) follow the centering bushings on the bearing studs 2 and 7.
1 - cylinder head; 2.7 - centering sleeve; 3.8 - screw plug (M8x1); 4 - cover (∅28); 5 - hairpin (M6x30); 6 - hairpin (M6x60); 9 - hairpin (M6x28); 10 - bolt (M8x28); 11 - harness holder; 12 - spacer; 13 - sealant; 14.30 - cover; 15 - self-blocking nut; 16 - nut (M7); 17 - hairpin (М7x95); 18, 20 - center, sleeve (∅9,5); 19 - support bar; 21 - bolt T (M6x50); 22 - bolt T (M6x70); 23 - bolt 7 (M6x100); 24 - screw plug with sealing ring (М12x1.5x26); 25 - bolt; 26.35 - sealing ring; 27 - hairpin (М7x39); 28 - hairpin (M7/6x29.5); 29 - screw plug (M18x1.5); 31 - guide sleeve; 32 - head bolt (M10x110); 33 - gasket washer; 34 - cover (∅22); 36 - screw plug (M10x1.0); 37 - cover (∅18); 38 - hairpin (M7x55); 39 - sensor; 40 - saddle issue. valve; 41 - saddle vp. valve; 42 - hairpin (M6x25); 43 - sealing gasket; 44 - check valve
Attention! Lubricate camshafts, bearings and bearing caps, thrust discs, gear rims of splined shafts and gear bushings before installation with engine oil.
After installing the camshafts and before turning the crankshaft against the direction of its rotation, in order to set the pistons to TDC, it is necessary to maintain a time interval of 5 minutes (at Т = 20°С) up to 30 min (at Т = 10°С).
Installation of a camshaft should be carried out in the following order. Pull the timing chain up and install the exhaust camshaft. Lay the timing chain on the exhaust camshaft, observe the above time intervals.
Install the bearing caps according to their markings (pic. 3.107), on their former bridges.
Bearing caps are marked on the exhaust side:
- A1 A7 - for the exhaust camshaft;
- E1 E7 - for the intake camshaft.
Install the shafts so that the tops of the intake and exhaust cams (pic. 3.106) first cylinder pointed at each other (dotted line), symmetrical in its corners.
Install fixture «11.3.260» (see fig. 3.104) on the block head as described above.
Rotate the eccentric shaft and press on the camshaft bearing caps. Tighten the bolts (M7) cap fastening torque 14 Nm (1.4 kgf·m) and remove fixture «11.3.260».
Set the camshafts with a modified wrench, cut off the jaws (pic. 3.108).
Set the key on the hexagon (arrow).
Install fixture «11.3.240» (pic. 3.109) on the camshafts in the region of the sixth cylinder.
Adjust the position of the camshafts so that the tool fits snugly on the cylinder head, without play. Install fixture «11.3.244» on adaptation «11.3.240» and fix it with a bolt screwed into the spark plug hole.
Pull timing chain up and hold tight. Return the piston of the first cylinder to the TDC position of the end of the compression stroke by rotating the crankshaft clockwise. Block the crankshaft to the TDC position of the end of the compression stroke using the tool «11.2.300».
Attention! Before starting the engine, check the removal of the tool «11.2.300».
Set wheel (23, see fig. 3.13) intake camshaft position sensor.
Install thrust disc (22) on the intake camshaft and tighten the stud bolts (21, 3 pcs.) torque 20 Nm (2.0 kgf·m).
Install timing chain to sprocket (13) so that the label (light triangle) on an asterisk (arrows, fig. 3.110) was facing the upper plane of the engine cylinder head.
Install fixture «11.4.220» (pic. 3.111) into the hole in the cylinder head and screw the adjusting bolt until it touches the chain, without tensioning the drive chain itself.
Check label position (light triangle, see fig. 3.110) on the sprocket relative to the upper plane of the cylinder head, if necessary, remove and reinstall the sprocket.
Screw the studs into the thrust disk of the exhaust camshaft (12, 3 pieces, see fig. 3.13) and tighten them to 20 Nm (2.0 kgf·m). Install tensioner (14) secondary chain and tighten the bolts (9,10,15) its fasteners.
Install toothed bushing (11) and align it on the camshaft so that the gap between the teeth is located one above the other. Install splined shaft (5) and align its pin in such a way that it copes with the gap between the teeth of the camshaft and the toothed sleeve (11). Install splined shaft (5) so that the longitudinal holes of the toothed sleeve (11) were symmetrical to the threaded holes.
Insert sprockets with drive chain into tool «11.6.180» (pic. 3.112), set the gap between the teeth on the intake camshaft chain sprocket, as shown in the fragment of the figure.
Attention! It is forbidden to change the position of the sprockets relative to the chain when removing them from the fixture «11.6.180».
Without changing the position, remove the chain with sprockets from the tool «11.6.180» and install them so that the gaps between the teeth on the intake side are opposite each other (arrows, fig. 3.113).
Adjust the position of the sprocket chain so that the gaps between the teeth on the intake side are exactly one above the other (arrows, fig. 3.114).
Install splined shaft (1, fig. 3.114) so that the pins of the splined shaft are mated (1) with a gap between the teeth of the camshaft and sprocket.
Insert splined shaft (1) so that approximately 1 mm of the ring gear remains on the outside. Install washer (17, see fig. 3.13) so that the inscription is visible «FRONT», put nuts (16, 3 pcs.) and wrap them by hand. Insert bolts (8, 3 pcs.) on the outlet side, screw them in until tight, to a torque of approx. 5.0 Nm (0.5 kgf·m) and loosen half a turn. Install thrust disc (4) and belleville spring (3) so that the index «F» was visible.
Note. If index «F» worn out during operation, then the Belleville spring (3) install so that it faces the larger diameter towards the drive sprocket, and the smaller diameters towards the camshaft position sensor wheel.
Set wheel (1, see fig. 3.116) camshaft position sensor so that the light triangle on the wheel is facing the upper plane of the cylinder head.
Screw nuts (3 pcs., circular arrows) and wrap them by hand without completely tightening them. Pull out the splined shaft (5, see fig. 3.15) forward all the way.
1, 16 - nut (M6); 2.23 - pulse sensor wheel; 3 - disc spring; 4 - thrust disk; 5.18 splined shaft; 6 - bolt T (M6x20); 7.13, 20 - asterisk; 8 - bolt T (М7х18); 9 - bolt (M6x40); 10 - bolt (M6x16); 11 - toothed sleeve; 12, 21 - pin; 14 - tensioner; 15 - bolt (М6х55); 17 - washer; 19 - guide; 22 - thrust disc
Slightly press the upper secondary chain tensioner down and remove the tool «11.3.292» (blocker). Using fixture «11.4.220» (pic. 3.117), pre-tighten the tensioner bar by screwing in the adjusting bolt «00.9.250» or a conventional torque wrench with a torque of 0.7 Nm (0.07 kgf·m).
press the wheel (2, see fig. 3.15) exhaust camshaft position sensor by applying slight tension to the belleville spring (3) and tighten nuts (8. 3 pcs.) only by hand. Check centering sleeves (2.7 see fig. 3.4) for damage and correct installation.
Remove seal residues, clean and degrease the sealing surface of the head end.
Install fixture «11.6.150» (pic. 3.118) only on a clean surface and tighten the nuts (5 pcs., arrows) by hand.
Tighten the tool fastening nuts evenly so that it fits snugly over the entire surface of the cylinder head.
Screw in the bolts (8, 3 pieces, see fig. 3.15) on the outlet side and tighten them to 5.0 Nm (0.5 kgf·m) to a tight fit.
Tighten the nuts (1, Zsht.) on the outlet side and nuts (16) on the intake side and tighten them to 5.0 Nm (0.5 kgf·m) to a tight fit.
Tighten the bolts (8, 3 pieces, M7) on the exhaust side, initially with a torque of 5.0 Nm (0.05 kgf·m), and then tighten with a torque of 20 Nm (2.0 kgf·m). Tighten nuts M6 (1, 3 pcs.) on the outlet side and nuts M6 (16, 3 pcs.) on the intake side torque 10.0 Nm (1.0 kgf·m). The hairpin itself (21, M7) must be tightened to 20 Nm (2.0 kgf·m).
Attention! Do not turn the engine in the opposite direction.
Pull back fixture «11.2.300» back far enough to unlock the flywheel. Remove fixtures «11.3.244» And «11.3.240» (see fig. 3.109).
Rotate the crankshaft two full turns clockwise (720°) and check the position of the tops of the camshafts of the first cylinder (see fig. 3.106), which should face each other (dotted lines).
Install fixture «11.2.300», to lock the flywheel to the TDC position of the first cylinder at the end of the compression stroke. Remove the tool before starting the engine «11.2.300».
Install fixture «11.3.240» on camshafts (see fig. 3.109).
Despite the correct adjustment of the camshafts, the tool «11.3.240» can protrude up to 1 mm (arrows, fig. 3.119) in relation to the intake side due to manufacturing tolerances of the components of the D-VANOS system.
fixture «11.3.240» must not protrude from the exhaust side, while the valve timing must be readjusted.
Loosen the fastener and remove the tool «11.6.150» (see fig. 3.118).
Install the D-VANOS adjustment unit. Assemble the engine. Install previously removed elements in the engine compartment. Restore the coolant and oil level Start the engine and check the tightness of the connections, oil and coolant level, make a test drive.