Removing Top Section of Timing Case

REMOVING AND INSTALLING / SEALING OR REPLACING TOP SECTION OF TIMING CASE
- Remove both cylinder head covers, Removing Cylinder Head Covers.
- Remove fan.
- Remove non-return valve for cylinder bank 1 to 6.




- Unfasten hose clip. Remove vent line from water pump. Unscrew holder (1).
- Remove coolant expansion tank.
- Remove fan cowl.
- Remove both distributor rotors.




- Unfasten screws and remove sealing cover from oil filler neck.




- Remove guide rail from timing chain (belt).




- Unscrew bolts.

Installation Note: Fit bracket (1) for pipe in secondary air induction unit.




- Unscrew bolts. Remove top section of timing case.

Installation Note: Fit bracket (1) for pipe on secondary air induction unit.




- Rotate engine on central screw engine-wise.
- Remove dust cover from locating bore.
- Secure crankshaft in TDC position with special tool 11 2 300.

CAUTION: Remove special tool prior to operating engine.





NOTE: With first cylinder in TDC position, recess in flange on camshaft (1) is aligned with oil injector strip (2).




- Secure both camshafts in TDC position with special tool 11 3 190.




- Press retaining cap off chain tensioner with screwdriver.

Installation Note: Fit new retaining cap.




- Loosen lock nut (2) and unfasten adjusting screw (1) a few turns.

CAUTION: Screw plug (3) is spring-loaded - compression spring jumps out! Carefully unscrew and remove screw plug (3).

Tightening torque of screw plug, 40 Nm (29 ft. lbs.).




Arrangement of components
1. Adjusting screw
2. Lock nut
3. Screw plug
4. Replace sealing ring
5. Replace O-ring
6. Dowel sleeve
7. Compression spring (cylindrical section of compression spring must point towards piston)
8. Chain tensioning piston





Installation Note: Adjusting chain tensioner:
- Fit sprockets to camshaft and mount sprocket screws hand tight.
- Press tensioning rail once briefly towards the chain and measure dimension (A).
- Press tensioning rail against spring force up to stop and measure dimension (B).
- Subtract dimension (B) from dimension (A).
- Specified value: 6 ± 0.5 mm (0.24 ± 0.020 in).
- Adjust nominal value with the adjusting screw and tighten down lock nut.




- Unfasten screws on sprockets.

Installation Note:
1. Fit sprockets with chain and mount sprocket screws hand tight.
2. Install and adjust chain tensioner.
3. Tighten down sprocket screws, torque = 15 Nm (11 ft lb).





Installation Note:
- Before installing sprocket for cylinder bank 7 to 12, the sensor (1) for recognizing when camshaft is in TDC position must be fitted.
- The sensor (1) is secured with one lug in the camshaft




- Unfasten screw (1) on sliding rail. Pull sliding rail upwards to remove and withdraw lower retaining tab.





Installation Note: When timing case cover is fitted, retaining tab is not visible.




- Loosen screws (1).




- Loosen screws (1). Lift timing case upwards to remove.





Installation Note:
1. Fit timing case.
2. Install all screws hand tight.
3. Tighten screws connecting upper and lower timing case.
4. Tighten screws to cylinder head.
Torque bolts to: M6 10 Nm (7.5 ft lbs)
M8 22 Nm (16 ft lb)
M10 47 Nm (35 ft lb)








Installation Note: Coat sealing edges with Hylomar SQ 32 M.




- Unfasten screw. Remove impulse sensor.





Installation Note:
- Clean sealing faces on both cylinder heads.
- Replace left and right gaskets.
- Attach gaskets around chain below timing case.





Installation Note:
- Clean sealing faces on both cylinder heads.
- Check dowel sleeves for damage and correct installation.
- Replace seals (1 and 2).