Head-off work. For the timing chain see NA timing chain. The torque and clearance figures are on Torque values.
For what owners said about uprated cams, see Camshaft upgrades: what owners fitted on the NA and Turbo.
Other jobs from the same factory chapter: Cam followers, hydraulic tappets and connection flange (NA); Valves, installation height and cylinder head flatness (NA).
Camshafts
NA (Z22SE) only.
Remove
- Open the bonnet.
- Disconnect the battery.
- Open the engine cover.
- Detach the engine cover. (6 bolts)
- Release the fuel pressure.
- Disconnect the fuel lines. (2 union nuts; 2 bolts; Reposition the fuel lines to one side.)
- Detach the ignition module.
- Release and detach the wiring harness connector.
- 4 bolts
- Remove the cylinder head cover. (Detach the engine breather hose.; 2 bolts, 1 nut; 1 bolt; 12 bolts)
- Raise the lifting ramp.
- Remove the lower engine splash shield. (13 bolts)
- Align the crankshaft.
- Rotate the crankshaft in the normal direction of rotation to
- Lower the lifting ramp.
- Remove the guide rail. (2 bolts)
- Note: If there is no marking on the camshaft timing chain tensioner, then it should be replaced with a new camshaft timing chain tensioner (part number 24 448 509) including a new camshaft timing chain tensioner rail (part number 24 449 448).
- Remove the camshaft timing chain tensioner.
- Attach KM-6148. Note: In this position the cams of cylinder no. 4 point upwards.
- Attach KM-6148 with the enclosed
- Slide the positioning bolts into the designated bores
- Detach the exhaust camshaft sprocket. (Hold the exhaust camshaft by the hexagon.; Pull back the positioning bolt to release.)
- Detach the intake camshaft sprocket. (Hold the intake camshaft by the hexagon.)
- Detach the camshaft connecting flange cover. (2 bolts)
- Remove the intake camshaft.
- Take out the roller cam followers.
- Remove the exhaust camshaft.
- Visually inspect the camshaft and the camshaft bearings for (Working in a spiral pattern from the outside towards the middle, release the bolts on the camshaft bearing caps (I to V) 1/2 to 1 turn at a time. Note: The camshaft must be released evenly from the bearings.; Take out the camshaft.; Visually inspect the camshaft and the camshaft bearings for wear. Note: The cylinder head should be replaced if the camshaft bearings are defective.)
Install
- Install the exhaust camshaft. (Coat the sliding surfaces with engine oil.)
- Insert the roller cam followers. (Coat the sliding surfaces with engine oil.)
- Install the intake camshaft.
- Clean the sealing surfaces of camshaft bearing cap no.11.
- Coat the sliding surfaces with engine oil.
- Install the camshaft bearing caps.
- Coat the sealing surfaces of camshaft bearing cap no. 11 with
- Attach the camshaft connecting flange cover. (Use a new gasket.; Tightening torque 23 Nm)
- Attach the intake camshaft sprocket.
- Use a new bolt.
- Tightening torque 85 Nm + 30° + (Tightening torque 85 Nm + 30° + 15°)
- Attach the exhaust camshaft sprocket.
- Rotate the exhaust camshaft by the hexagon until the exhaust
- Use a new bolt.
- Tightening torque 85 Nm + 30° + (Pull back the positioning bolt to secure the camshaft sprocket.; Tightening torque 85 Nm + 30° + 15°)
- Install the camshaft timing chain tensioner.
- Insert the piston into the housing. (Clamp the piston at the square into a vice.; Turn clockwise to lock the internal piston in the last latch position.)
- Use new oil seals.
- Tightening torque 75 Nm
- Release the camshaft timing chain tensioner by pressing on the tensioner rail or the camshaft timing chain (using a blunt tool – e.g. a rounded assembly lever).
- Recut the thread. (2 off)
- Install the guide rail. (Tightening torque 8 Nm)
- Raise the lifting ramp.
- Rotate the crankshaft 720°.
- Rotate the crankshaft in the normal direction of rotation to
- Note: In this position the cams of cylinder no. 4 point upwards, and it must be possible to insert blocking tool KM-6148.
- Install the lower engine splash shield
- Lower the lifting ramp.
- Detach KM-6148.
- Attach the cylinder head cover
- Clean the sealing surfaces.
- Tightening torque 9 Nm
- Tightening torque 9 Nm
- 2 bolts, 1 nut
- Attach the engine breather hose.
- Tightening torque 8 Nm
- Attach the ignition module.
- Tightening torque 9 Nm
- Attach and secure the wiring harness connector.
- Attach the exhaust camshaft sprocket.
- Rotate the exhaust camshaft by the hexagon until the exhaust
- Use a new bolt.
- Tightening torque 85 Nm + 30° + (Tightening torque 85 Nm + 30° + 15°)
- Connect the fuel lines. (Tightening torque 10 Nm; Tightening torque 9 Nm)
- Install the rear engine cover. (Check the alignment.; 6 bolts, tightening torque 14 Nm)
- Close the rear engine cover.
- Connect the battery.
- Close the bonnet.
- Reprogram the volatile memories.
Camshaft sprockets
NA (Z22SE) only.
Remove
- Open the bonnet.
- Disconnect the battery.
- Open the engine cover.
- Detach the engine cover. (6 bolts)
- Release the fuel pressure. Note: Fuel may escape – observe the safety regulations and relevant national legislation.
- Collect any escaping fuel in a suitable container.
- Disconnect the fuel lines. (2 union nuts; 2 bolts; Reposition the fuel lines to one side.)
- Detach the ignition module.
- Release and detach the wiring harness connector.
- 4 bolts
- Remove the cylinder head cover. (Detach the engine breather hose.; 2 bolts, 1 nut; 1 bolt; 12 bolts)
- Raise the lifting ramp.
- Remove the lower engine splash shield. (13 bolts)
- Align the crankshaft.
- Rotate the crankshaft in the normal direction of rotation to
- Lower the lifting ramp.
- Remove the guide rail. (2 bolts)
- Note: If there is no marking on the camshaft timing chain tensioner, then it should be replaced with a new camshaft timing chain tensioner (part number 24 448 509) including a new camshaft timing chain tensioner rail (part number 24 449 448).
- Remove the camshaft timing chain tensioner.
- Remove the exhaust camshaft sprocket.
- Mark the chain link next to the EXH marking on the
- Hold the exhaust camshaft by the hexagon.
- Take out the exhaust camshaft sprocket.
- Remove the intake camshaft sprocket.
- Mark the chain link next to the INT marking on the
- Hold the intake camshaft by the hexagon.
- Pull back the positioning bolt.
- Take out the intake camshaft sprocket.
- Slide in the positioning bolt.
- Hang the camshaft timing chain over the positioning bolt.
Install
- Install the intake camshaft sprocket.
- Marked chain link to INT marking on the intake camshaft (Pull back the positioning bolt.; Marked chain link to INT marking on the intake camshaft sprocket)
- Slide the positioning bolts into the designated bores in the
- Tightening torque 85 Nm + 30° + (Hold the intake camshaft by the hexagon.; Tightening torque 85 Nm + 30° + 15°)
- Install the exhaust camshaft sprocket.
- Marked chain link to EXH marking on the exhaust (Pull back the positioning bolt.; Marked chain link to EXH marking on the exhaust camshaft sprocket)
- Slide the positioning bolt into the designated bore in the
- Tightening torque 85 Nm + 30° + (Hold the exhaust camshaft by the hexagon.; Tightening torque 85 Nm + 30° + 15°)
- Install the camshaft timing chain tensioner.
- Insert the piston into the housing. (Clamp the piston at the square into a vice.; Turn clockwise to lock the internal piston in the last latch position.)
- Use new oil seals.
- Tightening torque 75 Nm
- Release the camshaft timing chain tensioner by pressing on the tensioner rail or the camshaft timing chain (using a blunt tool – e.g. a rounded assembly lever).
- Recut the thread. (2 off)
- Install the guide rail. (Tightening torque 8 Nm)
- Raise the lifting ramp.
- Rotate the crankshaft 720°.
- Rotate the crankshaft in the normal direction of rotation to
- Attach the lower engine splash shield. (13 bolts)
- Note: In this position the cams of cylinder no. 4 point upwards, and it must be possible to insert blocking tool KM-6148.
- Lower the lifting ramp.
- Detach KM-6148.
- Attach the cylinder head cover
- Clean the sealing surfaces.
- Tightening torque 9 Nm
- Tightening torque 9 Nm
- 2 bolts, 1 nut
- Attach the engine breather hose.
- Tightening torque 8 Nm
- Attach the ignition module.
- Tightening torque 9 Nm
- Attach and secure the wiring harness connector.
- Connect the fuel lines. (Tightening torque 10 Nm; Tightening torque 9 Nm)
- Install the rear engine cover. (Check the alignment.; 6 bolts, tightening torque 14 Nm)
- Close the rear engine cover.
- Connect the battery.
- Close the bonnet.
- Reprogram the volatile memories.
