Removing

Removing
– Remove engine cover.

– Remove upper toothed belt guard.

– Fit support bracket -10 - 222 A- as shown and take up

weight of engine in installation position.

– Unbolt cooling system expansion tank and lay to side.

– Unbolt power-assisted steering reservoir and place to

side.

– Take up weight of engine and remove right engine

bracket as shown.

– Unscrew securing bolts from assembly

mounting/engine bracket, assembly mounting/body
and assembly mounting/body bracket -arrows- and
remove assembly mounting complete.

– Remove upper securing bolt -1- from lower toothed

belt guard -2- under engine mounting -3-.

– Remove coolant hose from engine bracket -3-.

– Remove engine bracket -3-.

– Raise vehicle.

– Remove right wheel housing liner: →General body

repairs, exterior; Rep. gr.66

Page 1 of 3
Removing

– Turn crankshaft in engine direction of rotation until

both fixing holes of camshaft adjuster and exhaust
camshaft pulley align with fitting holes in camshaft
housing -arrows-.

– Lock camshaft adjuster and exhaust camshaft pulley

using locking pin -T10074- as follows:

– First fit retaining plate -T10073- on camshaft adjuster.

– Push locking pin -A- into fitting hole in camshaft

adjuster and camshaft housing onto stop.

– Then lock exhaust camshaft pulley by pushing a

locking pin -B- through second hole in retaining plate -
T10073- in fitting hole of camshaft housing to stop.

Note

The locking process is made easier by turning exhaust

camshaft pulley slightly on securing bolt with a ring
spanner until the fitting holes align.

– Unscrew camshaft adjuster plug.

– Collect leaking engine oil.

– Close opening in cover with clean cloths.

– Remove locking pins -T10074- and retaining plate -

T10073-.

WARNING

The cover of the camshaft adjuster is under tension

from a strong spring. It is essential to secure the
cover as follows to prevent accidents.

Page 2 of 3
Removing

– Remove two opposing securing bolts -3- for the cover.

– Screw the studs -2- into these holes until they are
flush with the rear of the camshaft pulley.

– Screw a nut onto each stud -2- until it just contacts the
cover.

– Remove the remaining securing bolts -3- for the cover.

– Then evenly unscrew the nuts on the studs -2-.

Note

Ensure the studs -2- do not unscrew from the camshaft

pulley.

– Collect leaking engine oil.

– Remove cover, spring and O-ring -arrow-.

– Do not remove the studs.

Page 3 of 3
Installing

Installing
– Moisten new O-ring -arrow- with clean engine oil.

– Check that the studs -2- are flush with the rear of the
camshaft pulley.

– Fit spring cover so that the fitting hole of the cover -1-
aligns with the fitting hole of the camshaft pulley.

– Screw a nut onto each stud -2- until it just contacts the
cover.

– Evenly tighten both nuts against the cover until the

cover securing bolts -3- can be screwed in.

Note

Ensure the studs -2- do not unscrew from the camshaft

pulley.

– Tighten securing bolts -3- hand-tight.

– Remove studs -2-. Install remaining securing bolts -3-

of the cover and tighten → Item.

– Check that both locating holes -1- of camshaft

adjuster and exhaust camshaft pulley align with fitting
holes in camshaft housing.

– Lock camshaft adjuster and exhaust camshaft pulley

using locking pin -T10074- as follows:

– First fit retaining plate -T10073- on camshaft adjuster.

Page 1 of 2
Installing

– Push locking pin -A- into fitting hole in camshaft

adjuster and camshaft housing onto stop.

– Then lock exhaust camshaft pulley by pushing a

locking pin -B- through second hole in retaining plate -
T10073- in fitting hole of camshaft housing to stop.

Note

The locking process is made easier by turning exhaust

camshaft pulley slightly on securing bolt with a ring
spanner until the fitting holes align.

– Install new plug with O-ring and tighten → Item.

– Remove locking pins -T10074- and retaining plate -

T10073-.

– Install engine bracket -3- and tighten → Item.

– Attach coolant hose to engine bracket.

– Install upper securing bolt -1- for lower toothed belt

guard -2- and tighten → Item.

– Raise vehicle.

– Install right wheel housing liner →General body

repairs, exterior; Rep. gr.66

– Install assembly mounting and align → Chapter.

– Tighten securing bolts -arrows- of assembly

mountings → Chapter.

– Remove support bracket -10 - 222 A-.

– Install power-assisted steering reservoir.

– Install cooling system expansion tank.

– Install lower part of toothed belt guard.

– Fit engine cover.

Page 2 of 2