Contents: Removal ↓ Installation ↓
Removal
1. Remove the timing belt from the camshaft timing pulley.
2. Remove the retainer.
3. Unscrew the mounting screws (1) securing the camshaft pulley.
4. Remove the toothed pulley from the hub.
5. Loosen the screw (1) securing the camshaft hub.
6. To do this, use a device to hold the camshaft.
7. Loosen the hub mounting screw by approximately 2 turns.
8. Remove the hub from the camshaft taper shank using a puller.
9. Remove the cylinder head cover.
10. Mark the rocker arm axles with a waterproof marker to avoid confusion later. Otherwise, it may be necessary to adjust the position of the pump injectors (arrows).
11. Loosen the locknuts of the adjusting screws (1) and unscrew the adjusting screws.
12. Unscrew the mounting screws (2) of the rocker arm shaft sequentially from the outer to the inner and remove the rocker arm shaft of the pump-injector drive.
13. Remove the dual pump.
14. First remove covers (5), (1) and (3). Loosen the support covers (2) and (4) one by one, crosswise.
15. Remove the camshaft.
Installation
Caution: Before you begin installing the camshaft, the following conditions must be met:
- When installing the camshaft, the cams for the first cylinder (arrows) must point upwards.
- Do not interchange previously used bearing shells (mark when removing).
- When installing the camshaft, pay attention to the fact that the retaining protrusions of the liners installed in the cylinder block cover must be located opposite each other.
- Before installing the covers, make sure that the washers for the cylinder head mounting screws are installed in the cylinder head.
- Lubricate the working surfaces of the liners.
1. Install the support covers (2) and (4), securing them with new screws (see figure VC 2.045).
2. Tighten the cover screws (2) and (4) alternately crosswise to a torque of 8 Nm, and then turn them an additional 1/4 turn (90°).
3. Install the support covers (5), (1) and (3), securing them with new screws.
4. Apply sealant to the seating surfaces of the bearing caps (1) and (5).
5. The support cover (5) must not form a ledge with the edge of the cylinder head, otherwise leaks in the twin pump may occur.
6. Tighten the cover screws (5), (1) and (3) to a torque of 8 Nm, and then turn them an additional 1/4 turn (90°).
7. Install the camshaft oil seal.
8. Tighten the camshaft hub mounting screw (1) to a torque of 100 Nm (see figure VC3.040).
Caution! The toothed segment (arrow) of the camshaft pulley must be located at the top.
9. Install the hub on the camshaft.
10. Tighten the hub mounting screw (1) to a torque of 100 Nm.
11. Install the camshaft timing pulley onto the hub.
12. Install the pulley so that the mounting screws are in the middle of the concentric grooves.
13. Screw in the fastening screws (1) by hand until they stop 8 camshaft pulley.
14. Fix the hub. Install the timing belt and adjust the valve timing.
Caution! After each removal of the rocker arm shaft and during each work requiring adjustment of the unit injectors, it is necessary to replace the adjusting screws and ball pins of the unit injectors.
15. Install the rocker arm shafts with new adjusting screws and tighten the new mounting screws as follows:
- tighten the inner and then the outer mounting screws evenly in a crosswise pattern. Tightening torque; 20 Nm + tighten by 1/4 turn (90°).
16. Install the dial indicator as shown in the figure on the adjusting screw of the pump injector.
17. Turn the crankshaft in the direction of engine rotation until the rocker arm roller is on top of the drive cam. The roller (arrow A) is at the highest point, the indicator (arrow B) is at the lowest point.
18. Remove the dial indicator.
19. Screw the adjusting screw into the rocker arm until you feel a clear resistance (the tappet clearance is selected).
20. Turn the adjusting screw back 180°.
21. Holding the adjusting screw in this position, tighten the lock nut to a torque of 30 Nm.
22. Install the cylinder head cover.
23. Install the double pump.
Caution! After installing new hydraulic lifters, do not start the engine for approximately 30 minutes. This will allow the hydraulic lifters to compress (otherwise, the slightly open valves will collide with the pistons).
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