Camshafts and valve gear (Turbo)

Engine-out or head-off work. For the timing belt itself see Turbo cam belt change. The torque and clearance figures are on Torque values and Turbo engine data.

Camshafts

Turbo (Z20LET) only.

Remove

1. Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
2. Lower vehicle
3. Disconnect battery negative lead
   • Release windscreen wash reservoir, then move to one side
   • Release nut, bolt
4. Disconnect intercooler hose from connecting pipe for throttle body (Release clip; Pull off)
5. Raise vehicle to suitable working height
6. Remove rear road wheel from right side
   • Use special socket located under front bonnet
   • Remove 4x wheel bolt
7. Remove wheel arch liner, right rear (Remove 4x screw, 2x clip)
8. Remove intercooler hose from intercooler (Release clip; Remove, then discard 4x cable tie)
9. Remove upper front cover for timing belt (Remove 2x bolt; Pull off)
10. Remove ribbed V-belt
    • Using suitable spanner rotate tensioner clockwise, then (Using suitable spanner rotate tensioner clockwise, then Install suitable locking pin)
11. Remove crankshaft pulley
    • Apply match marks to crankshaft pulley and crankshaft
    • Counter-hold centre bolt on crankshaft sprocket
12. Remove ribbed V-belt tensioner (Remove 2x bolt)
13. Remove lower cover for timing belt (Remove 2x bolt)
14. Rotate crankshaft in normal direction of rotation to Top Dead Centre (TDC) on cylinder no. 1, until timing marks are aligned
15. Lock camshafts in position (Use Locking Tool KM-853)
16. Release tension from timing belt
    • Release bolt, then turn adjusting eccentric clockwise until
17. Remove timing belt from pulleys (Position timing belt to one side)
18. Lower vehicle
19. Remove air intake hose with engine breather hose
    • Release 2x clip
    • Remove, then discard cable tie (Release clip)
20. Remove heat shield from support bracket on cylinder head (Remove 4x bolt, 4x washer)
21. Remove support bracket for heat shield from cylinder head (Remove bolt, 2x washer; Remove bolt)
22. Disconnect harness connector from ignition module
23. Remove ignition module cover from cylinder head (Slide off)
24. Remove ignition module from cylinder head (Remove 2x bolt)
25. Disconnect harness connector from camshaft sensor
26. Release wiring harness from cylinder head cover (Release from 3x clip)
27. Disconnect 2x breather hose from cylinder head cover
28. Remove cylinder head cover (Remove 10x bolt; Remove, then discard 10x 'O' ring; Remove, then discard gasket)
29. Remove 2x camshaft pulley from camshaft Note: Note position of locating pin on exhaust pulley.
    • Discard 2x bolt (Counter-hold camshaft at hexagon with open end of spanner; Second technician required)
30. Remove intake camshaft (Remove 10x bolt; Remove, then discard front oil seal)
31. Remove exhaust camshaft (Remove 10x bolt; Remove, then discard front oil seal)

Install

32. Install new oil seal to new exhaust camshaft (Lubricate new oil seal)
33. Install new exhaust camshaft to cylinder head (Install 5x bearing cap; Install 10x bolt 8 Nm)
34. Install new oil seal to new intake camshaft (Lubricate new oil seal)
35. Install new intake camshaft to cylinder head (Install 5x bearing cap; Install 10x bolt 8 Nm)
36. Install 2x camshaft pulley to 2x camshaft Note: Note position of locating pin on exhaust pulley.
    • Second technician required (Counter-hold camshaft at hexagon with open end of spanner)
37. Install cylinder head cover to cylinder head (Install 10 x new 'O' ring, new gasket; Install 10x bolt 8 Nm)
38. Reconnect 2x breather hose to cylinder head cover
39. Secure wiring harness to cylinder head cover (Secure to 3x clip)
40. Reconnect harness connector to camshaft sensor
41. Install ignition module to cylinder head (Install 2x bolt 8 Nm)
42. Install ignition module cover to cylinder head (Slide on)
43. Reconnect harness connector to ignition module
44. Install support bracket for heat shield to cylinder head (Install bolt, 2x washer; Install bolt)
45. Install heat shield to support bracket on cylinder head (Install 4x bolt, 4x washer)
46. Install air intake hose with engine breather hose (Secure 2x clip; Install new cable tie (Secure clip))
47. Raise vehicle to suitable working height
48. Check timing marks are aligned
49. Lock camshafts in position (Use Locking Tool KM-853)
50. Install timing belt to pulleys
51. Pre-tension timing belt
    • Turn eccentric of tensioner in direction of arrow
    • Remove Locking Tool KM-853 from
    • Rotate crankshaft two complete turns in normal direction of
    • Install Locking Tool KM-853 to
52. Tension timing belt
    • Release tensioner bolt, then turn eccentric of tensioner in
53. Secure tensioner (Secure bolt 20 Nm; Remove Locking Tool KM-853)
54. Rotate crankshaft two complete turns in normal direction of rotation to (TDC) on cylinder no. 1, until timing marks are aligned. If pointer of tensioner does not align with corresponding notch mark, then repeat adjustment procedure
55. Install lower cover of camshaft timing belt (Install 2x bolt 6 Nm)
56. Install ribbed V-belt tensioner (Install 2x bolt 25 Nm)
57. Install crankshaft pulley
    • Align match marks
    • Counter-hold centre nut on crankshaft sprocket
58. Install ribbed V-belt
    • Use suitable spanner to rotate tensioner clockwise, then remove
59. Install upper cover of camshaft timing belt (Push on to secure; Install 2x bolt 6 Nm)
60. Install intercooler hose to intercooler (Secure clip; Install 4x new cable tie)
61. Install liner to wheel arch (Install 4x screw, 2x clip)
62. Install rear road wheel to right side (Install 4x bolt, security bolt; Do not tighten)
63. Lower vehicle
64. Secure rear road wheel right side (Tighten 4x bolt, security bolt 90)
65. Install intercooler hose to throttle body (Secure clip)
66. Reconnect battery negative lead (Secure nut and bolt)
67. Install windscreen wash reservoir (Push fit)
68. Program all volatile memories
69. Raise vehicle
70. Install engine undertray (Install 13x bolt, 13x washer)
71. Lower vehicle

Camshaft pulleys

Turbo (Z20LET) only.

Remove

1. Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
2. Lower vehicle
3. Disconnect battery negative lead
   • Release windscreen wash reservoir, then move to one side
   • Release nut, bolt
4. Disconnect intercooler hose from connecting pipe for throttle body (Release clip; Pull off)
5. Raise vehicle to suitable working height
6. Remove rear road wheel from right side
   • Use special socket located under front bonnet
   • Remove 4x wheel bolt
7. Remove wheel arch liner, right rear (Remove 4x screw, 2x clip)
8. Remove intercooler hose from intercooler (Release clip; Remove, then discard 4x cable tie)
9. Remove upper front cover for timing belt (Remove 2x bolt; Pull off)
10. Remove ribbed V-belt
    • Using suitable spanner rotate tensioner clockwise, then (Using suitable spanner rotate tensioner clockwise, then Install suitable locking pin)
11. Remove crankshaft pulley
    • Apply match marks to crankshaft pulley and crankshaft
    • Counter-hold centre bolt on crankshaft sprocket
12. Remove ribbed V-belt tensioner (Remove 2x bolt)
13. Remove lower cover for timing belt (Remove 2x bolt)
14. Rotate crankshaft in normal direction of rotation to Top Dead Centre (TDC) on cylinder no. 1, until timing marks are aligned
15. Lock camshafts in position (Use Locking Tool KM-853)
16. Release tension from timing belt
    • Release bolt, then turn adjusting eccentric clockwise until
17. Remove timing belt from pulleys (Position timing belt to one side)
18. Lower vehicle
19. Disconnect harness connector from ignition module
20. Remove ignition module cover from cylinder head (Slide off)
21. Remove ignition module from cylinder head (Remove 2x bolt)
22. Disconnect harness connector from camshaft sensor
23. Disconnect 3x breather hose from cylinder head cover
24. Remove cylinder head cover (Remove 10x bolt; Remove, then discard 10x 'O' ring; Remove, then discard gasket)
25. Remove 2x camshaft pulley from camshaft Note: Note position of locating pin on exhaust pulley.
    • Discard 2x bolt (Counter-hold camshaft at hexagon with open end of spanner; Second technician required)

Install

26. Install 2x new camshaft pulley to 2x camshaft Note: Note position of locating pin on exhaust pulley.
    • Second technician required (Counter-hold camshaft at hexagon with open end of spanner)
27. Install cylinder head cover to cylinder head (Install 10 x new 'O' ring, new gasket; Install 10x bolt 8 Nm)
28. Connect 3x breather hose to cylinder head cover
29. Connect harness connector to camshaft sensor
30. Install ignition module to cylinder head (Install 2x bolt 8 Nm)
31. Install ignition module cover to cylinder head (Slide on)
32. Connect harness connector to ignition module
33. Raise vehicle to suitable working height
34. Check timing marks are aligned
35. Lock camshafts in position (Use Locking Tool KM-853)
36. Install timing belt to pulleys
37. Pre-tension timing belt
    • Turn eccentric of tensioner in direction of arrow
    • Remove Locking Tool KM-853 from
    • Rotate crankshaft two complete turns in normal direction of
    • Install Locking Tool KM-853 to
38. Tension timing belt
    • Release tensioner bolt, then turn eccentric of tensioner in
39. Secure tensioner (Secure bolt 20 Nm; Remove Locking Tool KM-853)
40. Rotate crankshaft two complete turns in normal direction of rotation to (TDC) on cylinder no. 1, until timing marks are aligned. If pointer of tensioner does not align with corresponding notch mark, then repeat adjustment procedure
41. Install lower cover of camshaft timing belt (Install 2x bolt 6 Nm)
42. Install ribbed V-belt tensioner (Install 2x bolt 25 Nm)
43. Install crankshaft pulley
    • Align match marks
    • Counter-hold centre nut on crankshaft sprocket
44. Install ribbed V-belt
    • Use suitable spanner to rotate tensioner clockwise, then remove
45. Install upper cover of camshaft timing belt (Push on to secure; Install 2x bolt 6 Nm)
46. Install intercooler hose to intercooler (Secure clip; Install 4x new cable tie)
47. Install liner to wheel arch (Install 4x screw, 2x clip)
48. Install rear road wheel to right side (Install 4x bolt, security bolt; Do not tighten)
49. Lower vehicle
50. Secure rear road wheel right side (Tighten 4x bolt, security bolt 90)
51. Install intercooler hose to throttle body (Secure clip)
52. Connect battery negative lead (Secure nut and bolt)
53. Install windscreen wash reservoir (Push fit)
54. Program all volatile memories
55. Raise vehicle
56. Install engine undertray (Install 13x bolt, 13x washer)
57. Lower vehicle

Camshaft oil seal, timing side

Turbo (Z20LET) only.

Remove

1. Remove engine undertray (Raise vehicle; Remove 13x bolt, 13x washer)
2. Lower vehicle
3. Disconnect battery negative lead
   • Release windscreen wash reservoir, then move to one side
   • Remove nut, bolt
4. Disconnect intercooler hose from throttle body (Release clip)
5. Raise and support vehicle
6. Remove rear road wheel from right side
   • Use special socket located under front bonnet
   • Remove 4x wheel bolt
7. Remove liner from wheel arch (Remove 4x screw, 2x clip)
8. Remove intercooler hose from intercooler (Release clip; Remove 4x cable tie, then discard)
9. Remove upper front cover for timing belt (Remove 2x bolt; Pull off to release)
10. Remove ribbed V-belt
    • Rotate tensioner clockwise, then install suitable locking (Rotate tensioner clockwise, then install suitable locking pin)
11. Remove crankshaft pulley
    • Apply match marks to crankshaft pulley and crankshaft
    • Counter-hold centre nut on crankshaft sprocket
12. Remove ribbed V-belt tensioner (Remove 2x bolt)
13. Remove lower cover of camshaft timing belt (Remove 2x bolt)
14. Rotate crankshaft clockwise to top dead centre (TDC) on cylinder No. 1, until 2x timing mark are aligned
15. Lock camshafts in position (Use Locking Tool KM-853)
16. Release tension from camshaft timing belt
    • Release bolt, then turn adjusting eccentric in direction of
17. Remove camshaft timing belt from pulleys, move to one side
    • Do not remove camshaft timing belt from vehicle
18. Lower vehicle
19. Disconnect harness connector from ignition module
20. Remove ignition module cover from cylinder head (Slide off)
21. Remove ignition module from cylinder head (Remove 2x bolt)
22. Disconnect harness connector from camshaft sensor (Release integral clip; Release 3x integral clip)
23. Disconnect 3x breather hose from camshaft cover (Release 3x clip)
24. Remove camshaft cover from cylinder head (Remove 10x bolt; Remove 10x O ring, then discard; Remove gasket, then discard)
25. Remove camshaft sprocket (Remove bolt, then discard)
26. Remove camshaft oil seal (Prise out using suitable tool)

Install

27. Install new camshaft oil seal (Lightly lubricate new seal)
28. Install camshaft sprocket
    • Install, then secure new bolt, washer 50 Nm + 60° + 15°
29. Install camshaft cover (Install new gasket; Install 10x new O ring; Install 10x bolt 8 Nm)
30. Connect 3x breather hose to camshaft cover (Secure 3x clip)
31. Connect harness connector to camshaft sensor (Secure integral clip)
32. Secure harness to camshaft cover (Secure 3x integral clip)
33. Install ignition module to cylinder head (Install 2x bolt 8 Nm)
34. Install ignition module cover to cylinder head (Slide on)
35. Connect harness connector to ignition module
36. Raise vehicle to suitable working height
37. Rotate crankshaft clockwise to top dead centre (TDC) on cylinder No.1, until timing marks are aligned
38. Lock camshafts in position (Use Locking Tool KM-853)
39. Install camshaft timing belt to pulleys
40. Pre-tension camshaft timing belt
    • Turn eccentric of tensioner anti-clockwise until pointer is
    • Remove Locking Tool KM-853 from
    • Rotate crankshaft two complete turns (720°) clockwise to
    • Install Locking Tool KM-853 to
41. Tension camshaft timing belt
    • Release tensioner bolt, then turn eccentric of tensioner
42. Secure tensioner (Tighten bolt 20 Nm; Remove Locking Tool KM-853)
43. Rotate crankshaft two complete turns (720°) clockwise to top dead centre (TDC) on cylinder No.1, until timing marks are aligned. If pointer of tensioner does not align with corresponding notch mark, then repeat adjustment procedure
44. Install lower cover of camshaft timing belt (Install 2x bolt 6 Nm)
45. Install ribbed V-belt tensioner (Install 2x bolt 25 Nm)
46. Install crankshaft pulley
    • Align match marks
    • Using suitable tool, counter-hold centre nut on crankshaft (Using suitable tool, counter-hold centre nut on crankshaft sprocket)
47. Install ribbed V-belt
    • Using suitable tool, rotate tensioner clockwise, then remove
48. Install upper cover of camshaft timing belt (Install 2x bolt 6 Nm)
49. Install intercooler hose to intercooler (Secure clip; Install 4x new cable tie)
50. Install liner to wheel arch (Install 4x screw, 2x clip)
51. Install rear road wheel (Install 4x bolt, security bolt; Do not tighten)
52. Lower vehicle
53. Secure rear road wheel (Install 4x bolt, security bolt 90)
54. Connect intercooler hose to throttle body (Secure clip)
55. Connect battery negative lead (Install nut, bolt; Secure windscreen wash reservoir)
56. Program all volatile memories
57. Raise vehicle
58. Install engine undertray (Install 13x bolt, 13x washer)
59. Lower vehicle

Camshaft sensor

Turbo (Z20LET) only.

Remove

1. Disconnect harness connector from ignition module
2. Remove ignition module cover from cylinder head (Slide off)
3. Remove upper cover of camshaft timing belt - see “Camshaft Timing Belt, Upper Cover, Replace (Z 20 LET)”
4. Release camshaft sensor from cylinder head (Remove bolt)
5. Remove camshaft sensor, then disconnect harness connector

Install

6. Connect harness connector to camshaft sensor, then install to cylinder head
7. Secure camshaft sensor (Install bolt 6 Nm)
8. Install upper cover of camshaft timing belt - see “Camshaft Timing Belt, Upper Cover, Replace (Z 20 LET)”
9. Install ignition module to cylinder head (Install 2x bolt 6 Nm)
10. Install ignition module cover to cylinder head (Slide on)
11. Connect harness connector to ignition module

Valves: removal

Turbo (Z20LET) only.

Install

1. Special service tools required:
2. Assembly tool set KM-6215, installation/removal set MKM-6086
3. Note: All attaching parts such as camshaft(s) and hydraulic valve lifters are removed.
4. Attach side mounts KM-6215-5 for lever KM-6215-4 to assembly device KM-6215-1. Attach lever KM-6215-4.
5. See operation "Cylinder head, disassemble", "Cylinder head, assemble".

Valves: replacement

Turbo (Z20LET) only.

Remove

1. See operation - “Cylinder Head, Attaching Parts, Remove and Install (Z20LET)”

Install

2. See operation - “Cylinder Head, Attaching Parts, Remove and Install (Z20LET)”

Valve installation height check

Turbo (Z20LET) only.

Measure

1. Special service tools required:
2. Caliper Gauges, KM-419 (OHC I), KM-512 (OHC II), Measuring Bridge KM-301, Dial Gauge MKM-571-B
3. Preconditions:
4. Cylinder head sealing surface and valve heads are cleaned.
5. The installation height of the valves can be checked from both the underside and from the upper side of the cylinder head.
6. Valve indentation can be determined using Measuring Bridge KM-301 and Dial Gauge MKM-571-B.

Assemble

6. If the valve indentation cannot be determined, the extension provided should be inserted between dial gauge shaft and probe.
7. Measurement from Underside of Cylinder Head (Valve Indentation)
8. If the valve indentation cannot be determined, the extension provided should be inserted between dial gauge shaft and probe.

Clean

9. Position Measuring Bridge KM-301 on cleaned sealing surface, insert Dial Gauge MKM-571-B under pretension, fasten and adjust dial to Zero.

Inspect

11. Position Dial Gauge MKM-571-B with Measuring Bridge KM-301 at valve head and measure indentation of valve.
12. The specified valve indentation and the dimensions can be found in the "Technical Data".
13. The installation height of the valves should be measured from the upper side of the cylinder head using the depth gauge of a caliper gauge. The measurement is taken from the valve shaft end to the cylinder head.
14. The specified valve projection and the dimensions can be found in the "Technical Data".
15. Measurements are made using Distance Gauge KM-512.

Install

16. If dimension is exceeded, insert new valve and check valve stem projection again. If the valve stem projection is too great despite replacement of the valve, the cylinder head must be replaced.
17. The specified valve projection and the dimensions can be found in the "Technical Data".

Cylinder head: flatness check

Turbo (Z20LET) only.

Clean

1. Remove gasket residues and clean sealing surfaces.

Inspect

2. Cylinder head dismantled.

Measure

3. Check length and width of cylinder head sealing surfaces for deformation and diagonals for warpage - use straight edge.
4. Caution
5. Resurfacing of the cylinder head is not permitted.
6. Measure height of cylinder head (sealing surface to sealing surface): dimension - 134 mm.