Special tools
- Camshaft alignment tool – No.T40094.
- Camshaft holding tool – No.T40095.
- Camshaft sprocket hub holding tool – No.T10051.
- Camshaft sprocket hub puller – No.T10052.
- Camshaft/high-pressure fuel pump locking tool – No.3359.
- Crankshaft sprocket locking tool – No.T10050.
- Two-piece exhaust camshaft gear alignment tool – No.T40096/1.
General precautions
- Disconnect battery earth lead.
- Remove glow plugs to ease turning engine.
- Turn engine in normal direction of rotation (unless otherwise stated).
- Observe tightening torques.
- If fitted: Mark position of crankshaft position (CKP) sensor before removal.
- Do NOT turn crankshaft via camshaft or other gears.
- Do NOT turn crankshaft or camshaft with timing gear(s) removed.
Valve timing procedures
- Removal/installation of timing gears requires:
- Timing belt removal.
- Removal of camshafts.
- Engine at TDC on No.1 cylinder.
- Fit crankshaft sprocket locking tool [1] .
- Ensure timing marks aligned [2] .
- Install camshaft sprocket locking tool [3] .
- Fit inlet camshaft on camshaft alignment tool [4] .
- Ensure camshaft alignment tool engages in end of camshaft [5] .
- Insert 0,5 mm feeler gauge between camshaft alignment tool and inner edge of camshaft slot [6] .
- Fit exhaust camshaft on camshaft alignment tool [7] .
- Ensure camshaft alignment tool engages in end of camshaft [8] .
- Ensure indents on camshafts are facing outwards [9] .
- If fitted: Align gear teeth of two-piece exhaust camshaft gear with camshaft gear alignment tool [10] .
- Move inlet camshaft in direction of arrow to engage teeth of camshaft gears [11] .
- Fit camshaft housing on camshafts [12] .
- Retain camshafts in position with camshaft holding tool [13] .
- Disengage camshaft alignment tool from end of camshafts [5] & [8] .
- Remove camshaft housing and camshafts held in position with special tools from camshaft alignment tool.
- Place camshaft housing with camshafts and special tools on cylinder head [12] .
- Ensure crankshaft sprocket locking tool located correctly [1] .
- Ensure timing marks aligned [2] .
- Refit camshaft housing [12] .
- Remove special tools [10] & [13] .
WARNING: Allow 30 minutes after installing camshafts before starting engine to prevent engine damage.
