1. Camshaft angle sensor (PHASE); 2. O-ring; 3. Camshaft angle sensor bracket; 4. Sealing washer; 5. Bracket (№1) camshafts; 6. Camshaft sprocket (inlet); 7. Camshaft sprocket (release); 8. Valve pusher; 9. Camshaft (release); 10. Signal disk; 11. Camshaft (inlet); 12. Brackets (N°N°2-5) camshafts; A. See below.
Removal and installation
Removal
Note. This section describes the procedure for removing and installing the camshaft without removing the front cover. If the front cover is crushed or installed, the bracket (№1) It is better to remove the camshafts before step 9, and install them after step 4. For operations on removing and installing the front cover, see below in point. «Timing chain».
1. Relieve fuel pressure. See chapter "Engine management system".
2. Remove the following components:
3. Remove the camshaft angle sensor (PHASE).
Attention:
- Handle the sensor carefully and do not drop or hit it.
- Do not disassemble the sensor.
- Do not allow metal powder to come into contact with the magnetic part of the sensor tip.
- Do not leave the sensor in places where it may be exposed to magnetism.
4. Remove the camshaft angle sensor bracket.
- Loosen the mounting bolts in the reverse order of the illustration.
5. Remove the cover from the intake valve timing control mechanism next. way:
A. Disconnect the connector from the intake valve timing control solenoid valve.
b. If necessary, remove the intake valve timing control solenoid valve.
With. Loosen the bolts in the reverse order shown in the illustration.
d. Cut off the sealant using a cutter (special tool: KV10111100) or equivalent tool and remove the cover.
6. Remove the timing chain guide between the camshaft sprockets through the front cover.
7. Set the piston of cylinder No. 1 to TDC on the next compression stroke. way:
A. Remove the mudguard on the right side.
b. Rotate the crankshaft pulley clockwise and align the TDC mark with the timing indicator on the front cover.
With. At the same time, make sure that the alignment marks on the camshaft sprockets are aligned as shown in the figure.
- Otherwise, turn the crankshaft pulley one more turn and align the marks as shown in the figure.
8. Remove the camshaft sprockets as follows:
A. Using indelible paint, apply alignment marks on the timing chain link linings opposite the marks on the camshaft sprockets.
b. Press in the chain tensioner plunger. Insert the locking pin into the hole in the tensioner housing, lock the plunger, and remove the chain tensioner.
Note. A metal rod with a diameter of approx. 0.5 mm.
With. Secure the camshaft by the hexagonal part with a wrench. Loosen the camshaft sprocket mounting bolts and remove the sprockets.
Attention. After removing the timing chain, do not rotate the crankshaft or camshafts individually, otherwise the valves will hit the piston crowns.
Note. There is no need to maintain chain tension. The crankshaft sprocket and timing chain are not structurally disconnected when installing the front cover.
9. Loosen the mounting bolts and nuts in the reverse order shown in the illustration and remove the camshaft brackets and camshafts.
- Remove the bracket (№1) camshafts by lightly tapping it with a plastic hammer.
10. Remove the valve tappets.
- Mark the locations and place the components in order without mixing them.
Installation
1. Install the valve lifters.
- Install them in the same places they were in before removal.
2. Install the camshafts.
- The intake and exhaust camshafts can be distinguished by the shape of their rear ends.
1. Camshaft (release).
2. Camshaft (inlet).
- Install the camshafts so that the guide lugs on the front ends align as shown in the figure.
3. Install the camshaft brackets as follows:
A. Completely remove any foreign matter from the back of the camshaft bracket and from the mounting surface in the cylinder head.
b. Install brackets (№№2-5) camshafts according to the identification markings stamped on the top surface as shown in the figure.
Note. Install so that the identification marking can be correctly read when viewed from the outlet side.
With. Install the bracket (№1) camshafts as follows:
I. Apply sealant to the bracket (№1) camshafts as shown in the figure. Use branded sealant or equivalent.
Attention. After installation, remove any exposed sealant in the area «A».
II. Apply sealant to the contact surface under the bracket (№1) camshafts on the back of the front cover.
1. Front cover
A. 3.4-4.4 mm
Use branded sealant or equivalent.
- Apply sealant to the outside of the front cover bolt holes.
III. Install the bracket (№1) camshafts so that the sealant applied to the surfaces does not move.
4. Tighten the camshaft bracket mounting bolts in several passes in the order indicated by the numbers in the figure:
A. Tighten in order from #9 to #11.
: 2.0 Nm (0.2 kg-m)
b. Tighten in order from #1 to #8.
: 2.0 Nm (0.2 kg-m).
With. Tighten all bolts in the order indicated by the numbers in the figure.
: 5.9 Nm (0.6 kg-m)
d. Tighten all bolts in the order indicated by the numbers in the figure.
: 10.4 Nm (1.1 kg-m).
Attention:
- After tightening the camshaft bracket mounting bolts, remove excess sealant from the following components:
- contact surface of the valve cover;
- contact surface of the front cover (when installed without front cover).
5. Install the sprockets on the camshafts.
- Install them by aligning the marks on the camshaft sprockets with the marks applied with paint on the timing chain link linings when removed.
Attention:
- Once aligned, the marks may move. Therefore, after combining them, hold the timing chain with your hand.
- Before and after installing the chain tensioner, double check that the alignment marks have not moved.
Note. Before installing the chain tensioner, it is possible to once again align the marks on the timing chain with the marks on the sprockets.
6. Install the chain tensioner
Attention. After installation, completely remove the locking pin and release the chain tensioner plunger.
7. Install the chain guide.
8. Install the cover of the intake valve timing control mechanism next. way:
A. If removed, install the inlet valve timing control solenoid valve into the cover.
b. Insert the oil scraper rings into the appropriate locations on the intake camshaft sprocket on the back of the intake valve timing control cover.
With. Insert the O-ring into the front cover.
d. Apply sealant using a syringe (suitable special tools) onto the intake valve timing control mechanism cover as shown in the figure.
Use branded sealant or equivalent.
Attention. Installation should be performed within 5 minutes after applying the sealant.
e. Tighten the mounting bolts in the order indicated by the numbers in the figure.
9. Install the camshaft angle sensor bracket.
A. Apply sealant using a syringe (suitable special tools) onto the camshaft angle sensor bracket as shown in the figure.
A. 2.0-3 0 mm
b. 10.5 mm
Use branded sealant or equivalent
Attention:
- After installation, remove any exposed sealant in the area «b»
- Installation should be performed within 5 minutes after applying the sealant.
b. Tighten the mounting bolts in the order indicated by the numbers in the figure.
10. Install the camshaft angle sensor (PHASE).
11. Check and adjust valve clearances. See above.
12. After this operation, installation is performed in the reverse order of removal.
Check after removal
Camshaft runout
1. Install the camshaft on two prisms with journals No. 2 and No. 5.
Attention. Do not install the camshaft on the strokes with journal No. 1 (from the camshaft sprocket side), because its diameter is different from the other four.
2. Attach the sensitive indicator head (A) vertically on gang No. 3.
3. Rotate the camshaft manually in one direction and measure the runout with an indicator (maximum indicator reading).
Standard: See below distributed «Technical data and specifications».
4. If the runout is different from the norm, replace the camshaft.
Camshaft lobe height
- Measure the camshaft lobe height with a micrometer (A)
Standard and Limit: See section below «Technical data and specifications»
- If wear exceeds the limit, replace the camshaft.
Oil gap in camshaft journals
Camshaft journal outer diameter
- Measure the outer diameter of the camshaft journal with a micrometer (A)
Standard. See section below «Technical data and specifications».
Camshaft bracket inner diameter
- Tighten the camshaft bracket bolts to the required torque. See above.
- Measure the inner diameter of the camshaft bracket with a bore gauge (A).
Standard: See section below «Technical data and specifications».
Oil gap in camshaft journals
(Oil gap in journals) = (camshaft bracket inner diameter) - (camshaft journal outer diameter)
Standard: See section below «Technical data and specifications».
- If the clearance is abnormal, replace either the camshaft or cylinder head, or both.
Note. The camshaft bracket is manufactured in one piece with the cylinder head. Replace the cylinder head assembly.
Camshaft end play
1. Install the camshaft into the cylinder head. See above.
2. Set the indicator (A) in the axial direction with the sensitive head to the front end of the camshaft. Measure the end play by moving the camshaft forward/backward (in axial direction).
Standard: See section below «Technical data and specifications».
- If the end play is abnormal, measure the dimensions of the following components:
- Size «A» camshaft journals No. 1.
Standard: 25.600-25.646 mm
- Size «IN» support bearing No. 1 of the cylinder head.
Standard: 25.660-25.665 mm.
- Compare the measurement results with the standard values mentioned above, and replace the camshaft and/or cylinder head.
Camshaft sprocket runout
1. Install the camshaft on two prisms with journals No. 2 and No. 5.
Attention. Do not install the camshaft on the prisms with journal No. 1 (from the camshaft sprocket side), because its diameter is different from the other four.
2. Measure the runout of the camshaft sprocket with an indicator (maximum indicator reading).
Limit: See section below «Technical data and specifications».
- If the runout exceeds the limit value, replace the camshaft sprocket.
Valve pusher
- Check the valve tappet surface for wear or chips.
- If any defects are found, replace the valve tappet. See section below «Technical data and specifications».
Valve tappet clearance
Valve tappet outer diameter
- Measure the outer diameter of the valve tappet with a micrometer (A)
Standard: See section below «Technical data and specifications».
Valve tappet hole diameter
- Measure the diameter of the valve tappet hole in the cylinder head using a bore gauge (A).
Standard. See section below «Technical data and specifications».
Valve tappet clearance
(Valve tappet clearance) = (valve tappet hole diameter) - (valve tappet outer diameter).
Standard: See section below «Technical data and specifications».
- If the value obtained is not normal for the inner and outer diameters, replace either the valve lifter or cylinder head, or both.