Dismantling
1. Disconnect "negative" battery terminal.
2. Remove the accessory drive belt.
ENGINE START AND BATTERY CHARGING SYSTEM, REPAIR WORK, Attachment drive belt - Td4 engine.
3. Remove the right front wheel.
WARNING: Do not work under a vehicle that is only supported by a jack. Always install safety props.
4. Remove the valve cover with gasket.
ENGINE - Td4, Intake and exhaust camshafts, Valve cover gasket:.
5. Remove the hydraulic support.
ENGINE - Td4, Intake and exhaust camshafts, Right engine hydraulic mount.
6. Remove the chain tensioner plug from the front cover.
7. Turn out a cap of an aperture of a clamp TDC of a cranked shaft.
8. Using a socket head and a wrench, rotate the crankshaft until the piston of the 1st cylinder comes to the TDC position.
9. To fix the crankshaft in the TDC position of the first cylinder, install the tool LRT-12-108.
CAUTION: Do not rotate the engine against the normal direction of rotation.
10. Rotate the exhaust camshaft with the hex wrench to fully compress the chain tensioner.
11. Lock the cocked tensioner with LRT-12-172.
12. Turn out two bolts and remove an oil-supply directing level. Dispose of the gasket.
13. Holding the camshafts by the hexagons, unscrew the bolts securing both sprockets.
14. To avoid damaging the valves when rotating the camshafts, remove tool LRT-12-108 and turn the crankshaft approximately 45°in the opposite direction to normal rotation.
15. Turn out and utilize bolts of fastening of asterisks, remove asterisks from cam-shafts.
16. Pay attention to how the camshaft bearing caps are marked. The intake camshaft is marked with a letter "E", and covers are marked from "E1" before "E5", starting from the sprocket, when looking at the engine from the exhaust side. Exhaust camshaft marked with letter "A" and the lids are marked from "A1" before "A5", starting from the sprocket, when looking at the engine from the exhaust side.
17. Consistently and evenly loosen and turn away 10 bolts of fastening of covers of bearings of a cam-shaft.
18. Remove the camshaft covers.
19. Remove the camshaft.
20. Exhaust camshaft: Disengage the camshaft from the vacuum pump drive.
Installation
1. Wipe the camshaft, bed journals and bearing caps.
2. Lubricate the camshaft, its beds and covers.
3. Lay the camshaft in the cylinder head in a position approximately corresponding to the TDC of the start of the stroke of the first cylinder.
4. Exhaust camshaft: Insert the camshaft into engagement with the vacuum pump drive.
5. Reinstall the bearing caps, screw in the mounting bolts and tighten them evenly and consistently to a torque of 10 Nm.
6. Install the sprockets on the camshafts and tighten them with new bolts so that the sprockets can rotate freely without end runout.
7. Wipe the oil guide bar and counter mating surface.
8. Install a new gasket on the oil guide bar.
9. Install the bar in place and tighten it with bolts. Tightening torque 10 Nm.
10. Rotating (wrench, behind the head of the pulley mounting bolt) crankshaft in the direction of normal rotation, lock the crankshaft in the TDC position of the start of the stroke LRT-12-108.
CAUTION: Do not rotate the engine against the normal direction of rotation.
11. While holding the exhaust camshaft by the hex wrench, tighten the sprocket mounting bolt and turn the exhaust camshaft in the direction of normal rotation to fully compress the chain tensioner.
12. Remove tool LRT-12-172 from the tensioner.
13. Loosen the bolt of the exhaust camshaft sprocket so that it can rotate freely without end runout.
14. Wipe the tensioner window plug and plug seat.
15. Replace the plug and tighten it. Tightening torque 30 Nm.
16. Install tool LRT-12-174 on the cylinder head.
17. Using tool LRT-12-173, set the intake camshaft to the correct position and tighten the LRT-12-174 mounting bolt.
18. Holding the intake camshaft with a hexagon wrench and using a torque sector, tighten the intake camshaft sprocket bolt to 20 Nm and tighten it another 35°.
19. Loosen the LRT-12-174 mounting bolt and remove the LRT-12-173 from the intake camshaft.
20. Using LRT-12-173, position the exhaust camshaft in the correct position and tighten the LRT-12-174 mounting bolt.
21. Holding the exhaust camshaft with a hexagon wrench and using a torque wrench, tighten the exhaust camshaft sprocket bolt to 20 Nm and tighten it another 35°.
22. Remove tools LRT-12-174 and LRT-12-173.
23. Remove tool LRT-12-108 to free crankshaft.
24. Turn the crankshaft two turns using a socket head and a wrench until the piston of the 1st cylinder reaches the TDC position for the start of the stroke.
25. To fix the crankshaft in the TDC position of the first cylinder, install the tool LRT-12-108. CAUTION: Do not rotate the engine against the normal direction of rotation.
26. Install tool LRT-12-173 on intake camshaft.
27. If the intake camshaft is in the correct position, then the bearing surfaces of the tool LRT-12-173 will touch the plane of the valve cover connector on both sides.
28. Remove tool LRT-12-173 from the intake camshaft and install it on the exhaust camshaft.
29. If the exhaust camshaft is in the correct position, then the bearing surfaces of the tool LRT-12-173 will touch the plane of the valve cover connector on both sides.
30. If necessary, the valve timing adjustment should be repeated.
31. Remove tools LRT-12-173 and LRT-12-108.
32. Wrap the plug hole of the crankshaft TDC retainer.
33. Install the hydraulic support.
ENGINE - Td4, Intake and exhaust camshafts, Right engine hydraulic mount.
34. Install the valve cover with gasket.
ENGINE - Td4, Intake and exhaust camshafts, Valve cover gasket.
35. Install the accessory drive belt.
ENGINE START AND BATTERY CHARGING SYSTEM, REPAIR WORK, Attachment drive belt - Td4 engine.
36. Install the wheel.
37. Attach "negative" battery terminal.
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