Removal
Remove the engine cover.
Remove the air filter housing with the air flow meter and connecting tube.
Remove the poly V-belt.
Remove the EGR cooler and bypass cap (cooling system hoses may remain connected) and put them aside
Remove the EGR radiator mount.
Remove the timing belt from the camshaft gears.
Fig. 2.296. Fixing the hubs with pins
Remove the camshaft gear mounting bolts 1 and 2 (fig. 2.296).
Remove the camshaft gears from the hubs.
Fig. 2.314. Unscrewing the hub mounting bolt
Unscrew the hub mounting bolt 1 (fig. 2.314).
To do this, use a counter support.
Loosen the hub mounting bolt approximately 2 turns.
Fig. 2.315. Installing the puller on the hub
Install the puller, directing it towards the hub holes (fig. 2.315).
Tighten the mounting bolts 1.
Remove the hub by uniformly tightening puller 2, which will separate the hub from the camshaft cone.
Note: When doing this, secure the puller with a 30 mm wrench.
Remove the hub from the camshaft cone.
Remove the exhaust camshaft hub in a similar manner.
Remove the cylinder head cover.
Remove the tandem pump.
Fig. 2.316. Adjusting screw locknuts
Loosen the locknuts of the adjusting screws and unscrew the adjusting screws until the corresponding rocker rests on the spring of the pump-injector pusher (fig. 2.316).
Screw in bolts 5-1 evenly from outside to inside and remove the roller lever axle.
Remove the inner mounting bolts from the rear of the timing belt cover.
Fig. 2.317. Upper mounting bolt of the bypass cover holder
Remove the upper mounting bolt of the bypass cap holder and the EGR cooler (fig. 2.317).
Remove the cable connection of the pump injectors and glow plugs.
Screw the remaining 15 support module bolts evenly from the outside in.
Unscrew the release bolts 15 of the frame by hand counterclockwise until they stop.
Position the frame on the support module as shown and tighten the mounting bolts 10 to 10 Nm.
Installing the frame
Turn the release bolts clockwise by hand until they touch the cylinder head bolts.
Then evenly screw in the release bolts in the sequence indicated on the bolt heads until the support module is separated from the cylinder head.
Remove the support module.
Remove the camshafts.
Installation
Install the bearing module and roller lever axle.
Note: When installing the camshafts, the cams for the first cylinder must face up.
Note: Do not interchange previously used bearing shells (when removing, mark).
Note: When installing the camshafts, ensure that the locking noses of the bearings are correctly installed in the bearing caps and in the cylinder head.
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Note: Apply silicone adhesive sealant to the mating surfaces between the bearing module and the cylinder head.
Note: Lubricate the working surface of the bearings with engine oil.
Fig. 2.318. Tightening order of camshaft bearing mounting bolts
Tighten bolts 1–20 evenly, starting with the inner ones, as shown in Figure 2.318. Tightening torque 20 N·m.
Then turn the roller lever axle bolts 9 by 1/4 turn (90°) Fig. 2.316).
Install the camshaft seals.
Install the hubs onto the camshafts.
Tighten the hub mounting bolts 1 (fig. 2.314). Tightening torque 100 Nm.
To do this, use a counter support.
Install the camshaft gears onto the hubs.
Fig. 2.319. Position of the toothed sector
Note: The camshaft gear toothed sector must be at the top (fig. 2.319Note:).
Insert mounting bolts 1 and 2 into the camshaft gear by hand without any clearance (fig. 2.296).
Secure the hubs using the injection pump locking pin.
Install the timing belt and adjust the valve timing.
Install a tandem pump.
Install the cylinder head cover.
Install the poly V-belt.
Note: After installing new roller levers, the engine must not be started for approximately 30 minutes. The hydraulic lifters must be settled (otherwise the valves will touch the pistons).
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