We prepare the car for the job. Disconnect the negative terminal of the battery.
We remove the transmission
On a car with a manual transmission, remove the flywheel.
On vehicles with an automatic transmission, unscrew the bolts and remove the torque converter drive plate.
Remove the rear crankshaft oil seal
We hang the back of the engine
Remove the brackets of the rear engine mounts
We loosen, but do not unscrew the flywheel housing mounting bolts
Using a hammer with a rubber striker, tap the flywheel housing so as to break the seal between the housing and the rear cover of the timing gears.
While holding the flywheel housing, unscrew the bolts and remove the flywheel housing.
It is necessary to remember or mark the flywheel housing bolts. Some bolts vary in length. It is necessary to install the bolts during assembly into place.
Unscrew and remember the location of the flywheel crankcase plugs
We unscrew the bolts of the technological plug and remove it together with the gasket.
We remove the high pressure pump (injection pump)
Remove the compressor (if installed)
We remove the camshaft gear, for this:
We turn the crankshaft until the alignment marks are aligned.
The timing mark can be on the camshaft gear or on the bevel tooth.
- On engines with an air compressor, it may be necessary to synchronize the positions of the air compressor gears and the camshaft.
To ensure that the air compressor is correctly synchronized with the camshaft gear during installation, mark the gears before removing the camshaft gear.
Air Compressor Models: To remove the camshaft gear, loosen the air compressor mountings.
It is not necessary to completely remove the air compressor.
We unscrew the two bolts and remove the crankcase ventilation disc from the camshaft gear.
Unscrew the camshaft gear mounting bolts and remove the camshaft gear.
We remove the camshaft, for this:
- remove the cylinder head cover;
- remove the valve levers (rocker arms);
- remove the barbells;
- we raise the pushers;
- Unscrew the thrust plate mounting bolts and remove the thrust plate;
- we install a gear puller on the end of the camshaft. This will give the necessary leverage and make it easier to shoot the camshaft;
When removing the camshaft, you need to hold it so as not to damage its journal when exiting the last bushing.
- take out the camshaft.
We unscrew the four bolts securing the oil pan to the rear housing of the timing gears.
Using a dipstick, disconnect the oil pan from the rear housing of the timing gears.
We remove the rear housing of the timing gears by unscrewing the bolts.
The rear timing gear housing is secured with three bolts of different lengths and diameters. You need to remember or mark these bolts with tags.
Apply a bead of sealant Ø 1.5-2 mm to the gear housing from the side of the cylinder block, as shown in the figure.
Install the body and tighten the mounting bolts
We are convinced of the presence of a sealant bead at the intersection of the joints of the cylinder block, oil pan and gearbox housing.
Tighten the bolts in the order shown in the figure. Tightening torque: M12 bolts - 77 Nm; bolts М10 - 47 Nm; M8 - 24 Nm.
Tighten the four bolts securing the rear timing gear housing to the oil pan. Tightening torque 24 Nm.
We replace the rear camshaft oil seal, for this:
- remove and remember the location of the ventilation hose clamp. Disconnect the hose;
- Unscrew the bolts and remove the crankcase ventilation tube;
- we replace the rear oil seal;
- install the crankcase ventilation tube;
- we connect the hose and install the clamp.
We install the camshaft, for this:
- Apply assembly grease to the rear bore under the camshaft;
- we lubricate the cams, necks and thrust washer with assembly grease;
- we install a puller on the end of the camshaft;
- slightly pressing and turning the shaft, carefully insert it through the holes for the camshaft.
As each shaft journal passes through the holes, it will lower slightly and the cams will brush against the bushings.
Rotating the camshaft will move the cams out of contact with the bushing and allow the camshaft to continue fitting.
Install the thrust plate. The tightening torque of the thrust plate mounting bolts is 24 Nm.
After that, you need to make sure that the camshaft rotates freely.
We turn the camshaft until its pin aligns with the gear groove. Install the gear.
We combine the timing marks of the crankshaft and camshaft gears.
Tighten the camshaft mounting bolts.
If the engine has an air compressor, make sure the camshaft and compressor gear marks are aligned during installation.
Tighten the camshaft gear mounting bolts. The tightening torque is 36 Nm.
Install the crankcase ventilation disc, for this:
- you need to make sure that the oil seal is installed in the disk;
- install the crankcase ventilation disc on the camshaft gear and tighten the bolts of its fastening. Tightening torque 28 Nm.
We check the axial and radial play of the camshaft gear:
- axial play - 0.100 - 0.360 mm;
- radial play - 0.076 - 0.280.
Tighten the air compressor mount (if installed)
We lower the pushers
Installing the rods
Install the rocker arms
Installing the cylinder head cover
Installing the flywheel housing
Install the flywheel or the torque converter drive plate (depending on the gearbox)
Installing the transmission
We connect the battery and start the engine. We examine for leaks.