Cylinder Head Removed
LEGEND
1 Camshaft Sprocket For Double Chain
2 Sensor Wheel
3 Camshaft Sprocket Bolt
4 Pivot Pin
5 Seal
6 Chain Tensioner For Double Chain
7 Tensioning Plate For Double Chain
8 Sprocket For Single Chain
9 Double Chain
10 Intermediate Shaft Sprocket Bolt
11 Sprocket For Double Chain
12 Tensioner Rail Bolt
13 Chain Tensioner Rail With Tensioning Plate For Single Chain
14 Crankshaft Sprocket
15 Single Chain
16 Guide Rail For Single Chain
17 Locating Pin Without Collar
18 Locating Pin Without Collar
19 Guide Rail Bolt
20 Guide Rail Bolt
21 Guide Rail For Double Chain
22 Bolt
23 Thrust Washer
24 Intermediate Shaft
NOTE: During service procedures, refer to the component location illustration above and component notes below.
COMPONENT NOTES
Camshaft Sprocket For Double Chain (1)
- Removing and installing, refer to Camshaft, Lifters and Pushrods.
Sensor Wheel (2)
- For camshaft Position Sensor.
- Contact surface of timing chain and sensor wheel must be dry when installing.
- Removing and installing, refer to Camshaft, Lifters and Pushrods.
Camshaft Sprocket Bolt (3)
- Tighten to: 100 Nm (74 ft. lbs.).
- To remove and install counter-hold with 24 mm open jaw wrench on camshaft.
- Oil the bolt head contact surface when installing.
Pivot Pin (4)
- Tighten to: 25 Nm (18 ft. lbs.)..
Seal (5)
- Always replace.
Chain Tensioner For Double Chain (6)
- Bleed before installing as follows:
- Push a piece of wire (0 0.8 mm) through the hole of the pressure piston (arrow) up to ball valve and press pressure piston and housing together onto stop.
NOTE: If the pressure piston moves out again, repeat bleeding procedure.
- Only rotate engine with tensioner installed.
Double Chain (9)
- Mark single and double chains before removing them (paint or mark an arrow pointing in direction of normal engine rotation).
NOTE: Do not mark the chain using a center punch or with any method that scratches or deforms the metal surfaces..
Intermediate Shaft Sprocket Bolt (10)
- Tighten to: 100 Nm (74 ft. lbs.).
Tensioner Rail Bolt (12)
- Tighten to: 10 Nm (7 ft. lbs.).
Chain Tensioner Rail With Tensioning Plate For Single Chain (13)
- Before installing, release locking splice in chain tensioner with a small screwdriver and press tensioning plate against chain tensioner.
- Only rotate engine with chain tensioner installed.
Crankshaft Sprocket (14)
- Integral part of crankshaft.
- Ground down tooth aligned with main bearing joint = TDC for No. 1 Cyl.
Single Chain (15)
- Mark direction of rotation before removing (installation position).
Guide Rail For Single Chain (16)
- Remove together with single chain.
Locating Pin Without Collar (17)
- Tighten to: 25 Nm (18 ft. lbs.).
- For guide rail (item 16).
Locating Pin With Collar (18)
- Tighten to: 25 Nm (18 ft. lbs.).
- For guide rail (item 21).
Guide Rail Bolt (19)
- Use thread lock fluid D6, or equivalent.
- Tighten to: 20 Nm (15 ft. lbs.).
Guide Rail Bolt (20)
- Tighten to: 20 Nm (15 ft. lbs.).
Bolt (22)
- Use thread lock fluid D6, or equivalent.
- Tighten to: 20 Nm (15 ft. lbs.).
PROCEDURE
1. Install cylinder head, refer to Cylinder Head Assembly.
2. Place guide rail on locating pin. Insert short securing bolt with locking fluid "D6", or equivalent, and tighten both bolts to: 20 Nm (15 ft. lbs.).
3. Place double chain on intermediate shaft (NOTE DIRECTION OF ROTATION OF DOUBLE CHAIN).
4. Fit camshaft sprocket and double chain to camshaft for cylinders 2, 4 and 6 (short camshaft) and hand tighten.
5. Fit camshaft sprocket with sensor wheel for camshaft position sensor (G40) and double chain to camshaft for cylinders 1, 3 and 5 and hand tighten.
NOTE:
- Ensure that the contact surfaces of the timing chain and sensor wheel are dry when installing.
- Oil contacting surfaces of bolts when installing.
6. Remove camshaft jig tool No. 3268, or equivalent.
7. Tighten camshaft sprocket mounting bolts to: 100 Nm (74 ft. lbs.).
NOTE:
- Only counter-hold with 24 mm open jaw wrench on the camshaft -Arrow-.
- The camshaft jig must not be fitted when tightening/loosening the sprockets.
8. Coat sealing surface of sealing flange with AMV 188 001 02 and install.
9. Tighten mounting bolt to: 10 Nm (7 ft. lbs.).
10. Replace sealing flange oil seal.
11. Coat camshaft sprocket cover sealing flange with AMV 188 001 02.
12. Prepare cylinder head gasket for cover assembly as follows:
- Remove old sealant from 3 mm holes in the cylinder head gasket -Arrows-.
- Fill 3 mm holes in the cylinder head gasket with sealant part No. AMV 188 001 02 or equivalent.
NOTE: With cylinder head installed holes are only half visible.
13. Oil engine speed sensor O-ring and insert in camshaft sprocket cover.
14. Install camshaft sprocket cover. insert all mounting bolts and tighten slightly.
15. First tighten 8 mm securing bolt to: 25 Nm (18 ft. lbs.) then 6 mm securing bolts to: 10 Nm (7 ft. lbs.).
16. Install double chain chain tensioner and tighten to: 30 Nm (22 ft. lbs.).
NOTE: If the chain tensioner has been pulled apart, bleed chain tensioner before installing.
CAUTION: Only turn with chain tensioner installed, otherwise single or double chain will jump.
17. Turn crankshaft two full turns in running direction and check valve timing.