Camshaft Timing Chains, Removing and Installing
Camshaft timing chains, removing and installing
Special tools and equipment
^ Locating bolt 3242
^ Trim removal wedge 3409 (2x)
^ Multipoint socket T1 0035
^ Camshaft locator T40046 (2x)
^ Locator for Hall sender rotor ring T40047
^ Crankshaft adapter T40049
^ Drill bit diameter 3.3 mm (2x)
Removing
- Drain off engine oil.
- Remove engine.
- Separate engine/transmission assembly.
- Place engine on workbench or a firm surface and secure in position with wooden blocks.
WARNING:
^ Engine must be secure to avoid risk of accident
^ Do not set down engine on oil pan.
- Remove drive plate.
- Detach lifting tackle 3033 from engine.
- Remove timing chain covers.
- Attach engine to engine and transmission holder VAS 6095.
- Use 2 old drive plate bolts to attach crankshaft adapter T40049 to back of crankshaft.
- Turn crankshaft in direction of engine rotation (arrow) to no. 8 cyl. TDC ignition point ...
- ... slots (arrows) at front of camshafts must be parallel to and level with top edge of cylinder head.
- If necessary, turn camshafts slightly in one direction or the other at hex to permit insertion of camshaft locator T40046.
- If camshaft locator cannot be inserted, give crankshaft 1 complete turn (360°).
- Detach camshaft locator again.
- Remove screw plug out of upper part of oil pan.
- Screw locating bolt 3242 into hole (20 Nm); if necessary, turn crankshaft back and forth slightly to fully center bolt.
- Press tensioner guide rail for left timing chain in direction of (arrow) and set chain tensioner with 3.3 mm diameter drill bit -item 1 -.
- Make color mark to indicate direction of left timing chain.
- Remove bolts -1- and -2- for camshaft chain sprocket/cam shaft adjuster with socket attachment T1 0035.
- Detach camshaft chain sprocket, camshaft adjuster and timing chain.
- Press tensioner guide rail for right timing chain in direction of (arrow) and set chain tensioner with 3.3 mm diameter drill bit -item 1 -.
- Make color mark to indicate direction of right timing chain.
- Remove bolts -1- and -2- for camshaft chain sprocket/cam shaft adjuster with socket attachment T1 0035.
- Detach camshaft chain sprocket, camshaft adjuster and timing chain.
Installing
^ Crankshaft fixed in TDC position with 3242
^ Timing mechanism drive chain installed; Refer to Drive Chain for Timing Mechanism Overview
Note:
^ Replace bolts tightened by turning through a specified angle as well as oil seals and gaskets.
^ When turning camshaft, none of the crankshaft cylinders should be at TDC, as this could result in valve/piston crown damage.
- Turn inner and outer sections of both camshaft adjusters in opposite directions as far as detent position (arrows).
^ In detent position, it must not be possible to turn inner and outer sections in opposite directions (slight play can still be felt)
- Check whether camshafts of both cylinder heads are at TDC.
^ Slots (arrows) at front of camshafts must be parallel to and level with top edge of cylinder head
- Insert camshaft locator T40046 in camshafts of left cylinder head (if necessary, turn camshafts slightly in one direction or the other at hex).
- Insert camshaft locator T40046 in camshafts of right cylinder head (if necessary, turn camshafts slightly in one direction or the other at hexagon).
- Replace all four camshaft bolts.
- Install left timing chain with chain sprocket and camshaft adjuster.
- Loosely screw in bolts -1- and -2-.
^ It must still be possible to turn chain sprocket and camshaft adjuster on camshaft without tilting them.
- Install right timing chain with chain sprocket and camshaft adjuster.
- Loosely screw in bolts -1- and -2-.
^ It must still be possible to turn chain sprocket and camshaft adjuster on camshaft without tilting them.
- Remove locating bolt 3242.
- Give crankshaft with adapter T40049 30° turn in direction opposite to that of engine rotation (arrow).
- Pull drill bit out of setting hole, thus releasing left chain tensioner.
- Insert plastic wedge 3409 as shown and move chain tensioner until it makes contact with plastic wedge 3409.
^ Approximately 0.5 mm extra is permissible
- Pull drill bit out of setting hole, thus releasing right chain tensioner.
- Insert plastic wedge 3409 as shown and move chain tensioner until it makes contact with plastic wedge 3409.
^ Approximately 0.5 mm extra is permissible
- Turn crankshaft with adapter T40049 in direction of engine rotation (arrow) to no. 8 cyl. TDC ignition point.
Note: In the event of inadvertent turning beyond TDC, turn crankshaft back again by 30° and approach TDC again.
- Screw locating bolt 3242 into hole (20 Nm); if necessary, turn crankshaft back and forth slightly to fully center bolt.
- Pre-tighten camshaft bolt -1- at exhaust camshaft of left cylinder head.
^ Tightening torque: 40 Nm
- Fix Hall sender rotor ring in position at adjuster of inlet camshaft of left cylinder head with locator T40047. - Position locator at bolt -1 -.
- Pre-tighten camshaft bolt -2- at inlet camshaft.
^ Tightening torque: 40 Nm
- Fix Hall sender rotor ring in position at adjuster of inlet camshaft of right cylinder head with locator T40047.
- Position locator at bolt -2-.
- Pre-tighten camshaft bolt -1- at inlet camshaft.
^ Tightening torque: 40 Nm
- Detach locator.
- Pre-tighten camshaft bolt -2- at exhaust camshaft of right cylinder head.
^ Tightening torque: 40 Nm
Note: Camshaft locators are not to be used to provide support when finish-tightening camshaft bolts.
- Remove camshaft locators T40046 at both cylinder heads.
- Finish-tighten camshaft bolt -1- at exhaust camshaft of left cylinder head.
^ Tightening torque: 100 Nm plus an additional 90° (1/4) turn
- Fix Hall sender rotor ring in position at adjuster of inlet camshaft of left cylinder head with locator T40047.
- Position locator at bolt -1 -.
- Finish-tighten camshaft bolt -2- at inlet camshaft.
^ Tightening torque: 100 Nm plus an additional 90° (1/4) turn
- Fix Hall sender rotor ring in position at adjuster of inlet camshaft of right cylinder head with locator T40047.
- Position locator at bolt -2-.
- Finish-tighten camshaft bolt -1- at inlet camshaft.
^ Tightening torque: 100 Nm plus an additional 90° (1/4) turn
- Detach locator.
- Finish-tighten camshaft bolt -2- at exhaust camshaft of right cylinder head.
^ Tightening torque: 100 Nm plus an additional 90° (1/4) turn
- Remove locating bolt 3242.
- Give crankshaft with adapter T40049 two turns in direction of engine rotation (arrow) until crankshaft is set to TDC again ...
- ... slots (arrows) at front of camshafts must be parallel to and level with top edge of cylinder head.
- Screw locating bolt 3242 into hole (20 Nm); if necessary, turn crankshaft back and forth slightly to fully center bolt.
- Insert camshaft locator T40046 in camshafts of left cylinder head.
- Insert camshaft locator T40046 in camshafts of right cylinder head.
^ Repeat adjustment if camshaft locators cannot be inserted
- Pull out plastic wedges 3409.
- Remove camshaft locators at both cylinder heads.
- Remove locating bolt 3242.
- Screw TDC mark screw plug with new oil seal into upper part of oil pan.
Perform further installation in reverse order, note the following:
- Install timing chain covers.
- Install drive plate.
- Bolt transmission to engine and install engine/transmission assembly.
Tightening torques