"VCC-065609 EN 2012-05-19"

Camshafts and tappets, replacement

Special tools:9995021 , 9995199

Replacement of camshafts due to wear

It is imperative that engine be flushed clean before installing
new components.
In most cases, damage to tappets and camshafts is due to
engine oil contamination.
Flush engine
Change oil and filter.
Run engine for approx. 10 minutes.
Drain oil and remove filter.
Install camshafts.
Fit new filter and fill engine with fresh oil of correct grade.

Removal of camshafts
Note!Procedure describes removal of all tappets. To ensure
sealing function of liquid sealing compound between
camshaft carrier and cylinder head, tappets should be
exposed only on one side at a time.
Remove/disconnect:

- battery earth lead

- alternator drive belt
- radiator fan and pulley

Remove transmission covers (1) and (2)

Remove upper (1) and lower (2) transmission covers.

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 "VCC-065609 EN 2012-05-19"

Align camshaft/crankshaft markings

Turn engine to TDC position in No.1 cylinder.
Check that markings on camshaft pulleys are aligned with
those on transmission mounting plate.

Slacken tensioner locknut

Remove protective rubber cap over locknut.
Slacken locknut.
Compress tensioner spring.
Tighten locknut.

Remove timing belt from crankshaft pulleys

Caution!Crankshaft and camshafts must not be rotated

while timing belt is slack or has been removed.

Remove timing belt idlers

Check pulley surfaces and bearings.

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 "VCC-065609 EN 2012-05-19"

Remove camshaft drive pulleys

Use counterhold 9995199 .

Remove:

- upper section of transmission mounting plate

- ignition lead cover plate
- ignition leads at plugs and distributor cap
- ignition coil high-tension lead at distributor cap
Note!Always grip ignition leads by caps when removing to
avoid damage to leads.

Remove valve cover and gaskets

Remove gasket remains and clean joint faces.

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 "VCC-065609 EN 2012-05-19"

Detach distributor housing from camshaft carrier

Note!Remove ignition lead clip beside left-hand bolt.

Remove camshaft centre bearing caps

Plug openings in camshaft carrier (around spark plug
wells) with paper.
Remove camshaft centre bearing caps (No.3 on intake
side, No.8 on exhaust side). Mark caps as required.
Remove third nut in central bolted joint.

Remove exhaust side camshaft

Use press tool 9995021 . Place tool in No. 8 bearing cap
position.
Clamp press tool on camshaft.
Remove remaining bearing cap nuts and caps (6, 7, 9 and
10).
Inspect bearing surfaces for signs of wear.
Remove press tool 9995021 and lift out camshaft.

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 "VCC-065609 EN 2012-05-19"

Remove intake side camshaft

Use press tool 9995021 . Place tool in No. 3 bearing cap
position.
Clamp press tool on camshaft.
Remove remaining bearing cap nuts and caps (1, 2, 3 and
5).
Inspect bearing surfaces for signs of wear.
Remove press tool 9995021 and lift out camshaft together
with distributor.

Remove tappets from camshaft carrier

Magnet or suction cup may be used to facilitate tappet
removal.
Inspect tappets for signs of wear.
Note!Store tappets upside down to prevent drainage of oil.
Ensure tappets are placed in order they must not be
interchanged.

Clean/inspect camshaft carrier

Clean and inspect camshaft bearings and tappet bores for
signs of wear.

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 "VCC-065609 EN 2012-05-19"

Camshaft axial clearance

Check camshaft axial clearance
Place camshafts in position.
Install rear bearing caps and tighten nuts.

Axial clearance........ 0.05-0.40 mm (0.0020-0.0157 in)

Measure clearance with feeler gauges.
Install new rear bearing cap if clearance is excessive.
Remove bearing caps and camshafts.

Camshaft installation
Oil components
Oil bearings and sliding surfaces on camshaft carrier,
bearing caps, camshafts and tappets.

Insert tappets
Tappets must be replaced in original order.

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 "VCC-065609 EN 2012-05-19"

Install exhaust side camshaft

Place camshaft in camshaft carrier with pulley guide pin
facing upwards.
Press camshaft into place with press tool 9995021 (using
rear bearing cap as guide).
Install bearing caps in original order.
Apply liquid sealing compound to joint face between
camshaft carrier and front bearing cap (No. 6).
Install bearing cap nuts in stages.
Remove press tool 9995021 and install centre bearing (8).

Install intake side camshaft

Place camshaft in camshaft carrier with pulley guide pin
facing upwards.
Note!Turn distributor shaft to align driver with markings on
distributor housing.
Fit housing and rotor shaft with new O-rings.
Press camshaft into position with press tool 9995021
(using rear bearing cap as guide).
Install bearing caps in original order.
Apply liquid sealing compound to joint faces between
camshaft carrier and front and rear bearing caps (Nos. 1
and 5).
Install bearing cap nuts in stages.
Remove press tool 9995021 and install centre bearing cap
(8).
Install camshaft carrier centre nut.
Tighten bearing cap nuts and centre nut
Tighten to 20 Nm (15 ft.lb).

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 "VCC-065609 EN 2012-05-19"

Refit distributor
Reconnect high-tension lead between distributor cap and
ignition coil.
Remove paper in camshaft carrier openings.
Note!Replace ignition lead clip beside left-hand bolt.

Seal front and rear camshaft bearing caps

Use silicone sealer.
Apply bead of sealer to angle between cap and joint face.

Install new gaskets and replace valve cover

Inspect rubber seal behind camshaft on exhaust side.
Position spark plug well gasket with arrow pointing to No.1
cylinder and marking facing upwards.
Shape outer gasket to fit camshaft bearing caps.
Place gasket in position and replace valve cover.
Note!Remember to connect earth lead to distributor.

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 "VCC-065609 EN 2012-05-19"

Install:

- ignition leads (in correct firing order)

- ignition lead cover plate

Fit camshaft front oil seals

Fit seals as described in operations F12 Camshaft seals,
replacement -F24 .
Note!Install new oil filter and fill engine with fresh oil of
correct grade.
Caution!Some noise may be heard from tappets when
engine is first started. However, this will disappear as
tappets are filled with oil.
Engine must not be run at speed higher than 3000 r/min
while tappet noise is present.

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