Note: In this engine, the camshafts are located in the camshaft housing. Before removing the camshaft housing, the timing cover must be removed.
Note: The seating surface of the camshaft housing must not be machined.
Removing
First you need to check if the radio with encoding is installed in the car. If yes, then you should find out the security code.
Disconnect the ground wire from the battery with the ignition off.
Remove the timing cover.
Turn the crankshaft to TDC of the first cylinder, then turn the crankshaft back against the direction of engine rotation by about 45°and remove the camshaft sprockets with the timing chain.
Remove the EGR valve and unscrew the camshaft caps.
Disconnect the low pressure fuel pressure sensor connector.
Unscrew the ground cable from the camshaft housing.
Remove ignition coils. To do this, use a puller.
Remove the wiring box with wiring harness from the camshaft housing.
Pic. 2.39. Plug and fuel supply line
Disconnect the plug and the fuel supply line from the high pressure pump (pic. 2.39).
Remove the guide and remove the clamp from the high pressure line.
Note: When loosening the union nuts, hold the threaded connections on the high pressure pump and the bottom of the intake manifold with a wrench.
Unscrew union nuts 3 and 1 of the high pressure line.
Disconnect the plug from the Hall sensor.
Remove the oil dipstick.
Remove the lower part of the intake manifold.
Unscrew the left hanging eye.
Loosen and unscrew the camshaft housing mounting bolts from the edges to the center, alternating cross by cross.
Carefully lift the camshaft housing.
Installation
Remove any remaining sealant from the cylinder head and camshaft housing with a standard sealant remover.
Note: Pistons must not be at TDC.
Keep dirt and sealant residues out of the cylinder head.
Thoroughly clean the seating surfaces. They must be free of oil and grease.
Rotate the intake and exhaust camshafts until the camshaft retainer is fully seated in the holes in the camshafts.
To attach the retainer, screw in the M6 bolt by hand; without tightening.
Pic. 2.40. Application of sealant
Apply sealant to the clean seating surface of the camshaft housing with a thin, even bead, see the shaded area in Figure 2.40.
Note: The sealant bead must not be too thick, otherwise excess sealant may get into the oil passages, resulting in engine damage.
Pic. 2.41. Installing the valve stems in the appropriate support elements
Make sure that all roller levers are correctly attached to the ends of the valve stems 1 and clipped into the appropriate support element 2 (pic. 2.41).
Before installing the camshaft housing, screw in the two spacer bolts (M6x80) into the head of the block.
Carefully place the camshaft housing vertically on top of the spacer bolts and cylinder head dowel pins.
Note: Do not allow oil to come into contact with adjacent surfaces.
Tighten the new camshaft housing mounting bolts evenly in a criss-cross pattern, alternating from the center to the outside.
Make sure that the camshaft housing is not warped. Tightening torque 10 Nm + tighten 1/4 turn (90°)
Note: After installing the camshaft housing, the sealant should dry in about 30 minutes.
Adjust the valve timing.
Further installation is carried out in the reverse order.
Install the timing cover.
Connect fuel lines.
Install the EGR valve
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