CAMSHAFT IDLER GEARS - REPLACE

Operation 1036L20 · CAMSHAFT (2) IN TOP HEAD (1)

2.3 JTD 16V

Removing

1. Undo the bolts fixing the cold air intake to the upper crossmember.

2. Disconnect the intake hose from the air filter casing.

3. Remove the cold intake and intake hose assembly from the engine compartment.

1. Remove the air supply hose to the air/air heat exchanger (intercooler).

1. Undo the fixing bolts (1a) and remove the protective cover (1b) for the heater plugs control unit.

2. Disconnect the electrical connections for the heater plugs control unit (2a) and (2b) and the control unit positive electrical connection (2c).

3. Undo the fixing bolts (3a) and remove the mounting bracket (3b), complete with heater plugs control unit.

1. Undo the fixing bolt and nuts (1a) and remove the mounting bracket (1b).

1. Undo the studs on the camshaft housing and remove them.

- Rotate the crankshaft using small movements.

1. Fit the tools (1a) on the camshafts, inserting them until the cylindrical part (1b) of the tool is completely inserted in the opening (1c) in the camshafts. Secure the tool in place tightening the tool ring nuts (1d).

The tools fitted are used to produce a reaction whilst removing the idler gears.

1. Loosen the bolt fixing the collar joining the rigid section of the intake pipe to the turbocharger.

2. Undo the bolt fixing the engine oil vapour pipe connector.

3. Remove the rigid section of the air pipe from the turbocharger.

1. Undo the fixing bolts.

2. Remove the rear gears protective cover and oil seal.

1. Undo the bolt fixing the exhaust camshaft.

2. Undo the bolt fixing the inlet camshaft.

3. Undo the bolts (3a) fixing the idler gears to the camshaft housing, applying pressure at the point shown by the arrow (3b) and remove the idler gears (3c).

In order to be able to remove the assembly, the piston inside the idler gears has to be compressed. The outer profile of the idler gears is not symmetrical which prevents any incorrect fitting.

Refitting

- Fit the idler gears in the seat in the camshaft housing compressing the assembly piston.

- Tighten the bolts fixing the idler gear assembly to the camshaft housing.

- Tighten the bolts fixing the idler gears to the camshafts to torque.

- Fit the idler gears cover after having replaced the gasket.

- Fit the rigid section of the air pipe from the turbocharger.

- Tighten the bolt fixing the engine oil vapour pipe connector.

- Tighten the bolt for the collar fixing the pipe to the turbocharger.

- Remove the inlet and exhaust camshaft tightening tools.

- Fit the studs on the camshaft housing.

- Fit the mounting bracket between the air pipe and the camshaft housing.

- Tighten the bolt and the nuts fixing the mounting bracket.

- Fit the mounting bracket complete with heater plugs control unit.

- Tighten the nuts fixing the control unit to the bodyshell.

- Connect the electrical connections for the heater plugs control unit.

- Fit the protective cover for the heater plugs control unit and tighten the bolts fixing it to the mounting bracket underneath.

- Fit the air supply hose to the air/air heat exchanger (intercooler).

- Fit the cold intake and intake hose assembly in the engine compartment and tighten the bolts fixing the cold air intake to the upper headlamp holder crossmember.

- Connect the intake hose to the air filter casing.