Camshafts and camshaft seals

Pic. 2.16. Camshafts and camshaft oil seals since 1999: 1 - support bracket for fuel injector wiring harness; 2 - crankcase ventilation hose; 3-PCV hose; 4 - cylinder head cover; 5- cylinder head roof gasket; 6 - base of the camshaft position sensor; 7 - cylindrical rotor of the camshaft position sensor; 8 - camshaft pulley; 9 - camshaft seal; 10 - idle pulley; 11- rear casing of the toothed belt; 12—camshaft cover; 13 - camshaft cover gasket; 14 - exhaust camshaft; 15 - intake camshaft

Pic. 2.17. Camshafts and camshaft seals of the engine since 2000 of release: 1-engine cover; 2 - crankshaft angle sensor connector: 3 - fuel pressure sensor connector; 4 - connector of the front oxygen concentration sensor; 5 - connector of the wiring harness for control and EGR; 6- connector of the solenoid valve for cleaning the adsorber; 7 - throttle position sensor connector; 8 - throttle control servo connector; 9 - connector of the wiring harness for control and injectors; 10 - connectors for ignition coils; 11 - connector for the sensor for detecting misfires; 12 - camshaft position sensor connector; 13 - coolant temperature sensor connector; 14 - connector for the sensor of the coolant temperature indicator; 15 - control wiring harness; 16—PCV hose; 17 - crankcase ventilation hose; 18 - connector bracket (injector wiring harness); 19 - cylinder head cover (inlet side); 20 - cylinder head cover gasket; 21 - cylinder head cover (release side); 22 - cylinder head cover gasket

Pic. 2.18. Camshafts and camshaft seals of the engine since 2000 of release: 1 - camshaft pulley; 2 - idle pulley; 3 - upper rear casing of the toothed belt; 4 - camshaft seal; 5 - base of the camshaft position sensor; 6 - round plug; 7 - camshaft cover; 8 - camshaft cover gasket; 9 - intake camshaft; 10 - exhaust camshaft; 11 - cylindrical rotor of the camshaft position sensor

Removing

• Disconnect the wire from the negative battery terminal.
• Loosen the clamps and remove the air intake pipe.

Engine from 2000

• Remove the air filter.
• Drain the coolant from the cooling system.
• Loosen the screws and remove the engine cover.

All engines

• Remove the timing belt drive timing.
• Remove the intake manifold.
• Remove the camshaft high pressure pump housing (see the relevant chapter under "Direct fuel injection system (GDI)").

Engine from 2000

• Disconnect the connectors from the crank angle sensor (2) , pic. 2.17, fuel pressure sensor (3), front oxygen sensor (4), control harness and EGR (5), canister cleaning solenoid valve (6),throttle position sensor (7),throttle control servo (8), control harness and injectors (9), ignition coils (10), misfire detection sensor (11), camshaft position sensor (12), coolant temperature sensor (13), coolant temperature gauge sensor (14) and control wiring harness (15).
• Disconnect the connectors, remove the bolts and remove the ignition coils.
• Remove the intake manifold.
• Remove the timing belt drive timing.
• Loosen the bolt and remove the injector harness connector bracket.
• Turn out bolts and remove covers of a head of cylinders.
• Remove the cylinder head gaskets.
• Turn out bolts and remove the fuel pump of a high pressure.

All engines

• Loosen the bolt and remove the fuel injector harness support bracket.
• Disconnect the crankcase ventilation hose from the fitting on the cylinder head cover.
• Disconnect the PCV hose from the fitting on the cylinder head cover.
• Turn out bolts and remove a cover of a head of cylinders.
• Remove the cylinder head cover gasket.
• Disconnect the electrical connector, remove the bolts, remove the camshaft position sensor base.
• Turn out a bolt and remove a cylindrical rotor of the gauge of position of a camshaft.
• Using special tools MD998719 and MB990767, block the camshaft pulley from turning and remove the pulley mounting bolt (pic. 2.19). Remove pulleys from camshafts.
• Punch a groove near the sealing lip with a knife or flathead screwdriver.

Fig.2.19. Using special tools to block the camshaft pulley from turning

Warning. Be careful not to damage the camshaft and cylinder head.

• Insert a flat screwdriver blade wrapped in cloth into the punched groove, and, using a screwdriver as a lever, remove the oil seal
• Turn out a bolt and remove an idle pulley of a gear belt of a drive of the gas-distributing mechanism.
• Turn out bolts and remove back casings of a gear belt.
• Gradually, in several passes, unscrew the bolts and remove the camshaft cover from the cylinder head.
• Remove the camshaft cover gasket.
• Remove the camshafts from the cylinder head.

Installation

• Installation is carried out in the reverse order of removal, taking into account the following.
• Lubricate the necks and cams of the camshafts with engine oil.
• Install the camshafts into the cylinder head.

Warning. Do not interchange the intake and exhaust camshafts. The exhaust camshaft has a hole on the rear end for the bolt of the cylindrical rotor of the camshaft position sensor (fig 2.20).

Pic. 2.20. Hole location on the rear end of the exhaust camshaft

• Position the camshaft locating pins as shown in Figure 2.21.
• Apply a layer of sealant to the camshaft cover and cylinder head in the places shown in Figure 2.22.
• Install the gasket and camshaft cover.
• Gradually, over several passes, in the sequence shown in Figure 2.23. screw in the camshaft cover bolts and tighten them to the required torque.

Pic. 2.21. The location of the dowel pins when installing the camshafts

Pic. 2.22. Places for applying sealant and lubrication of the camshaft oil seal

Pic. 2.23. The sequence of tightening the cylinder head cover bolts

• Lubricate the lip of the camshaft oil seal with engine oil.
• Using a special tool, press in the camshaft seals (fig 2.24).
• Install the camshaft pulleys and secure with bolts. Using special tools MD998719 and MB990767, block the camshaft pulley from turning and tighten the pulley mounting bolt to 88 Nm (see fig. 2.19).
• Install and bolt the cylindrical rotor of the camshaft position sensor.
• Install and bolt the camshaft position sensor base. Connect the electrical connector to the camshaft position sensor.

Fig. 2.24 Using a special tool to press in the camshaft oil seal

Engine from 2000

• Using a special tool, press in a steep plug as shown in Figure 2.25.

Pic. 2.25. Using a hammer and a special tool to press in a round plug

All engines

• Install the cylinder head cover gasket.
• Install and bolt the cylinder head cover
• Connect the PCV hose to the fitting on the cylinder head cover.
• Connect the crankcase ventilation hose to the fitting on the cylinder head cover
• Install the fuel injector drive harness support bracket.
• Install the camshaft high pressure pump housing.
• Install the intake manifold.
• Install the timing belt drive of the gas distribution mechanism.
• Install the air intake pipe.

Engine from 2000

• Install the engine cover and hand-tighten the mounting bolts so that the cover can be moved. In the sequence shown in Figure 2.26, tighten the engine cover bolts to 3.0 Nm.

Pic. 2.26. Engine cover bolt tightening sequence

All engines

• Connect the wire to the negative battery terminal.