Removing ( Refitting )

1. Position the camshaft housing (1a) in a vice using the tool (1b).

 

Tool

 

Denomination

 

Function

 

Validity

 

1.860.470.000

 

Mount

 

Cylinder head overhaul

 

2.0 JTD 115 HP


1. Undo the bolt (1a) and remove the cam angle sensor (1b).

- Check that the camshaft end float is within the recommended values using a dial gauge.

 

Measurement

 

Value

 

Validity

 

Camshaft end float (mm)

 

0,100 ÷ 0,230

 

2.0 JTD 115 HP

- If the camshaft endfloat is not within the recommended values, replace the worn components when reassembling the cylinder head.


1. Remove the plugs (1a) and fit the camshaft timing tools (1b) on the camshaft housing.

Check that the tools are correctly fitted in the housings in the camshafts.

 

Tool

 

Denomination

 

Function

 

Validity

 

1.870.896.900

 

Template

 

Engine tuning

 

2.0 JTD 115 HP


1. Undo the bolts securing the camshaft gears.


1. Undo the bolt (1a) and remove the exhaust side camshaft toothed drive pulley (1b).


- Remove the camshaft timing tools from the camshaft housing.

 

Tool

 

Denomination

 

Function

 

Validity

 

1.870.896.900

 

Template

 

Engine tuning

 

2.0 JTD 115 HP

1. Withdraw the camshafts (1a) as far as necessary and remove the camshaft gears (1b).


1. Using a suitable drift, extract the inlet side camshaft (1a) and the plug (1b).

2. Using a suitable drift, extract the exhaust side camshaft (2a) and the oil seal (2b).


Refitting ( Removing )

- To determine whether the camshaft housing needs replacing or whether the camshafts are worn, carry out the dimension checks listed below.

- Check that the diameter of the camshaft journals corresponds to the recommended figures; if not, replace the worn camshaft.

 

Measurement

 

Value

 

Validity

 

Camshaft first journal diameter (mm)

 

43,600 ÷ 43,615

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft second journal diameter (mm)

 

43,400 ÷ 43,415

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft third journal diameter (mm)

 

43,200 ÷ 43,215

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft fourth journal diameter (mm)

 

43,000 ÷ 43,015

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft fifth journal diameter (mm)

 

30,000 ÷ 30,015

 

2.0 JTD 115 HP

- Check that the nominal camshaft cam lift corresponds to the recommended figures; if not, replace the worn camshaft.

 

Measurement

 

Value

 

Validity

 

Nominal intake cam lift (mm)

 

8.5

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Nominal exhaust cam lift (mm)

 

8.0

 

2.0 JTD 115 HP

1. Check that the diameter of the camshaft supports corresponds to the prescribed figures; if not, replace the upper camshaft housing.

 

Measurement

 

Value

 

Validity

 

Camshaft first support diameter (mm)

 

43,646 ÷ 43,671

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft second support diameter (mm)

 

43,446 ÷ 43,471

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft third support diameter (mm)

 

43,246 ÷ 43,271

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft fourth support diameter (mm)

 

43,046 ÷ 43,071

 

2.0 JTD 115 HP

 

Measurement

 

Value

 

Validity

 

Camshaft fifth support diameter (mm)

 

30,045 ÷ 30,070

 

2.0 JTD 115 HP


- Place the camshafts in their housings.

- Refit the camshaft gears in their housings and secure them without tightening the bolts.

1. Fit the camshaft timing tools.

Check that the tools are correctly fitted in the housings in the camshafts.

 

Tool

 

Denomination

 

Function

 

Validity

 

1.870.896.900

 

Template

 

Engine tuning

 

2.0 JTD 115 HP


1. Tighten the camshaft gear fixing screws to the prescribed torque using the angular tightening tool.

 

Component

 

Fastening

 

Ø

 

Value (daNm)

 

Validity

 

Camshaft gears

 

Screw

 

M12

 

2.9 - 3.2 + 48° - 52°

 

2.0 JTD 115 HP

 

Tool

 

Denomination

 

Function

 

Validity

 

1.895.897.001

 

Torque wrench

 

Angular torque tightening

 

2.0 JTD 115 HP


1. Fit the exhaust side camshaft front oil seal (1a) using the tool (1b).

 

Tool

 

Denomination

 

Function

 

Validity

 

1.870.896.800

 

Fitting tool

 

Fitting camshaft front oil seal on exhaust side

 

2.0 JTD 115 HP


- Fit the inlet side camshaft plug.

- Place the exhaust side camshaft toothed drive pulley in its housing and secure it without tightening the bolt.

1. Position the cam angle sensor (1a) in its housing and secure it by tightening the screw (1b) to the prescribed torque.

 

Component

 

Fastening

 

Ø

 

Value (daNm)

 

Validity

 

Cam angle sensor

 

Screw

 

M6

 

0.8 ÷ 1.0

 

2.0 JTD 115 HP

- Remove the support tool complete with camshaft housing from the vice and separate them.

 

Tool

 

Denomination

 

Function

 

Validity

 

1.860.470.000

 

Mount

 

Cylinder head overhaul

 

2.0 JTD 115 HP