| In-vehicle Repair Special Tool(s) | | Guide Studs, Cylinder Head 303-034 | | | Remover/Installer, Hose Clamp 303-397 | Materials Name Specification Engine Oil - 5W-30 WSS-M2C913-B Silicone Sealant WSE-M4G323-A4 | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
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Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03E Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
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Remove the fuel filter and bracket.
For additional information, refer to: Fuel Filter - 1.6L Duratorq-TDCi (DV) Diesel (310-01 Fuel Tank and Lines, Removal and Installation).
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Remove the fuel injectors.
For additional information, refer to: Brake Vacuum Pump - 1.6L Duratorq-TDCi (DV) Diesel (206-07 Power Brake Actuation, Removal and Installation) /
Fuel Injectors - VIN Plate Emission Level Code: K (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
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Remove the intake manifold.
For additional information, refer to: Intake Manifold - VIN Plate Emission Level Code: S (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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Remove the timing belt.
For additional information, refer to: Timing Belt (303-01E Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
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Remove the brake vacuum pump.
For additional information, refer to: Brake Vacuum Pump - 1.6L Duratorq-TDCi (DV) Diesel (206-07 Power Brake Actuation, Removal and Installation).
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Using the special tool, disconnect the coolant hose and detach the coolant expansion tank. | 9. Remove the components in the order indicated in the following illustration(s) and table(s). 3 - Camshaft bearing cap retaining bolts 5 - Camshaft chain tensioner All vehicles | | -
To install, reverse the removal procedure. | Vehicles with front and rear power windows | | -
Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| Removal Details Item 1 : Camshaft housing retaining studs and bolts | | -
Remove the camshaft housing retaining bolts and studs in the sequence shown. | Item 4 : Camshaft bearing caps CAUTION:Keep the camshaft bearing caps and the camshafts in order for installation. | | -
NOTE:Make a note of the position of the camshaft bearing cap shells to make sure they are installed in the same position. Remove the camshaft bearing cap shells. | Installation Details Item 6 : Exhaust camshaft | | -
CAUTION:The copper links of the timing chain must align with the timing marks on the camshaft sprockets. Align the camshafts. | Item 4 : Camshaft bearing caps | | -
Install the camshaft bearing cap shells. - Coat the camshaft bearing cap shells with clean engine oil.
| Item 2 : Camshaft housing | | -
Clean the mating faces of the cylinder head and the camshaft housing. | | | -
CAUTION:Install the camshaft housing within five minutes of applying the sealant. Apply a 2.5 mm diameter bead of sealant to the mating face of the cylinder head. | | | -
Using the special tool, align the camshaft housing to the cylinder head. | Item 1 : Camshaft housing retaining studs and bolts | | -
Install the camshaft housing retaining bolts and studs. - Tighten the bolts and studs in two stages in the sequence shown.
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