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Camshaft Seal > < Valve Seals

Galaxy 2000.75 (04.2000-02.2006)

Engine - 1.9L Diesel - Camshaft Galaxy 2000.75 (04/2000-02/2006)
In-vehicle Repair

Special Tool(s)

Installer, Wheel Hub

204-148 (14-037)

Flange Holding Wrench, Universal

205-072 (15-030A)

Locking Tool, Crankshaft

310-085 (23-059)

Remove, Crankshaft Vibration Damper

303-338 (21-153B)
Materials
Name
Specification
Engine oil
WSS-M2C917-A 
Sealer
 

Removal

  1. Remove the timing belt.
    For additional information, refer to Timing Belt - in this section.

  1. Remove the valve cover (13 bolts).

  1. Remove the camshaft pulley.
    1. Loosen the camshaft pulley center bolt by two turns.
    1. Remove the camshaft pulley.

  1. Using the special tool and three M8 x 70 mm bolts, remove the camshaft pulley hub.

  1. Detach the vacuum and fuel pump from the cylinder head.
    • Discard the gaskets.

  1. Release the rocker arms.
    1. Loosen the lock nut.
    1. Unscrew the adjusting screw until the rocker arm rests on the unit injector tappet spring.

  1. NOTE:
    NOTE:Keep the rocker shafts in order for installation.
    NOTE:
    NOTE:Loosen the rocker shaft retaining bolts starting from the outer bolts, working to the inner bolts.
    Remove the rocker shafts.
    • Discard the bolts.

  1. NOTE:
    NOTE:Keep the camshaft bearing caps in order for installation.
    NOTE:
    NOTE:Loosen the bolts of the camshaft bearing caps No. 5, No. 1 and No. 3 in pairs.
    Remove the camshaft bearing caps.
    • Discard the bolts.

  1. NOTE:
    NOTE:Keep the camshaft bearing caps in order for installation.
    Loosen the bolts of the camshaft bearing caps No. 2 and No. 4 alternately, working diagonally opposite.
    • Discard the bolts and the camshaft oil seal.

Installation
  1. Remove the special tool and rotate the engine against its normal direction 90 degrees.
  1. Lubricate the running surfaces of the cylinder head and the camshaft with engine oil.
  1. NOTE:
    NOTE:Install the camshaft with the intake and exhaust cam of piston No. 1 pointing upwards.
    Install the camshaft.

  1. CAUTION:
    CAUTION:The crankshaft and the camshaft must not be turned for at least 30 minutes after tightening the camshaft bearing caps.
    NOTE:
    NOTE:Lubricate the running surfaces of the bearing caps with engine oil.
    NOTE:
    NOTE:Install new bolts.
    Install the bearing caps No. 3 and No. 4 in the location from which they were removed.
    • Tighten the camshaft bearing caps bolts finger tight gradually and alternately, working diagonally opposite, until the bearing caps lie flat on the cylinder head.
    • Tighten the camshaft bearing caps bolts, working diagonally opposite.
    • Tighten the bolts in two stages.
    • Stage 1: 8 Nm.
    • Stage 2: 90 degrees.

  1. Coat the bearing caps No. 1 and No. 5 with sealer at the shown mating face.

  1. NOTE:
    NOTE:Lubricate the running surfaces of the bearing caps with engine oil.
    NOTE:
    NOTE:Install new bolts.
    Install the bearing caps No. 5, No. 1 and No. 3 in the location from which they were removed.
    • Tighten the camshaft bearing caps bolts in pairs.
    • Tighten the bolts in two stages.
    • Stage 1: 8 Nm.
    • Stage 2: 90 degrees.

  1. NOTE:
    NOTE:Install new bolts.
    NOTE:
    NOTE:First tighten both of the inner retaining bolts and then the outer retaining bolts finger tight.
    Install the rocker shafts.
    • Tighten the bolts in two stages.
    • Stage 1: 20 Nm.
    • Stage 2: 90 degrees

  1. NOTE:
    NOTE:Install new gaskets.
    Install the vacuum and fuel pump.

  1. NOTE:
    NOTE:Install a new camshaft oil seal.
    NOTE:
    NOTE:Do not coat the sealing lip with engine oil or grease.
    Using the special tool and a M12 x 100 mm bolt, install the camshaft oil seal.

  1. NOTE:
    NOTE:Do not tighten the camshaft pulley retaining bolts at this stage.
    Using the special tool, install the camshaft pulley hub together with the camshaft pulley and tighten the camshaft pulley hub.

  1. Carry out the unit injector basic adjustment.
    1. Rotate the camshaft until the cam of piston No. 1 points to the rocker arm roller.
    1. Screw the adjusting screw into the rocker arm, until a resistance is felt. Unscrew the adjusting screw 225 degrees.
    • Tighten the lock nut to 30 Nm.

  1. Rotate the crankshaft in its normal direction 90 degrees and install the special tool.

  1. NOTE:
    NOTE:Install the valve cover within five minutes of applying the sealer.
    Apply a 5 mm diameter point of sealer to the front and rear camshaft bearing caps.

  1. NOTE:
    NOTE:Inspect the valve cover gasket for damage. Install a new valve cover gasket if damaged.
    Install the valve cover and tighten the bolts in the sequence shown.
  1. Install the timing belt.
    For additional information, refer to Timing Belt - in this section.

Camshaft Seal > < Valve Seals