Removal

Changing Balancer Shaft Chain / Timing Chain In Car

To Remove






1. Remove the battery cover and the battery.
2. Remove the battery tray.
3. Open the expansion tank cap.

Warning:
The cooling system is under pressure. Hot coolant and steam can escape.
^ Open the cap slowly to release the pressure.
^ Carelessness can cause eye and burn injuries






4. Remove the upper engine cover.
5. Remove the ignition discharge module and the spark plugs.
6. Remove the crankcase ventilation pipe. Remove the connector to the solenoid valve.
7. Remove the mass air flow sensor and the intake hose
8. Remove the by-pass valve with pipe.
9. Remove the camshaft cover.
10. Raise the car and remove the front right wheel.






11. Remove the right-hand belt circuit cover.





12. Remove the right-hand wing liner.






13. Zero the engine by turning the crankshaft in the engine's direction of rotation until the timing marks on the pulley and timing cover are aligned.






14. Remove the engine lifting eye and the turbocharger intake pipe and solenoid valve.
15. Remove the turbocharger heat shield.






16. Remove the oxygen sensor connector and the cable tie.
17. Remove the two upper nuts on the front exhaust pipe.






18. Remove the nut to the right-hand engine pad.






19. Remove the fan cowling.
20. Raise the car.






21. Remove the front spoiler shield.
22. Drain off the coolant.
23. Position a receptacle under the car and drain the engine oil.






24. Remove the oil filter.
25. Undo the oil pipe on the oil filter adapter housing.






26. Remove the front exhaust pipe.






27. Remove the front torque arm.
Front bracket with through bolt: Remove from below.
Other: Remove from above.
Cars with rear torque arm: Remove the torque arm.






28. Remove the protective cover between the engine and gearbox.
29. Detach the crankcase ventilation hose and remove the oil sump. Raise the engine slightly using a column jack. Place a wooden block in between.
30. Fit a 83 94 868 Flywheel locking attachment on the starter ring gear.
31. Lower the car and position a jack under the engine and raise it slightly at the AC compressor. Place a wooden block in between.






32. Remove the bracket to the right-hand engine mounting and the engine pad.
33. Fit 83 95 238 Wedges between the oil filter adapter and subframe, and between the inner drive shaft universal joint and subframe, and lower the engine.

Note: Handle the drive shaft universal joint gaiter with care.






34. Unload the belt tensioner and remove the multigroove belt.
35. Remove the generator's lower bolt and the outer lower bolt which screws into the timing cover on the intermediate shaft bearing bracket.






36. Remove the crankshaft pulley.

Note: Check that the timing cover marking corresponds with the pulley before it is lifted off.

37. Remove the crankshaft seal.
38. Remove the oil pump. Use 82 93 086 Circlip pliers �120-200 mm.Check for any damage.






39. Remove the power steering pump from the bracket and move it aside.
40. Remove the power steering pump mounting bracket.
41. Remove the hose clips and hoses on the coolant pump inlet.
42. Detach the two longitudinal coolant pipes from the engine block.
43. Detach the two longitudinal coolant pipes from the coolant pump.
44. Undo the coolant pipe bolt slightly (at the turbocharger) from the coolant pump.
45. Remove the coolant pipe from the coolant pump.






46. Undo the coolant pump retaining bolts.
47. Carefully work the pump free from the bracket and from the pump's connecting piece on the engine block.
48. Remove the connection sleeve from the cylinder block.






49. Remove the AC bracket right-hand upper bolt which screws into the timing cover.
50. Remove the two bolts in the subframe holding the front torque arm. (On relevant models)






51. Remove the nut on the rear engine mounting.






52. Man: Lock 4th gear by inserting 87 92 335 Lock pin. Undo the clamp slightly and pull the selector rod out of the linkage.
53. Unload the left-hand engine pad by positioning a jack under the gearbox.






54. Remove the left-hand engine pad.
55. Man: Remove the gearbox mounting and the ground cable.
56. Position a 83 95 238 Wedge between the gearbox and subframe and lower the jack.






57. Fit 83 96 178 Lifting eyes with bolt and washers or an M10 nut between the cylinder head and bracket.






58. Connect an engine lift and raise the engine.






59. Move the engine slightly to the left and remove the belt tensioner.
60. Remove the idler pulley.
61. Remove the generator upper retaining bolt. Move the generator aside.
62. Remove the generator bracket.






63. Remove the plug for the chain tensioner and the chain tensioner. Retain the spring and pin.
64. Remove the camshaft sprockets.
65. Remove the timing cover bolts. Move the engine to the left. Raise and lower the engine respectively to gain access to all bolts.
66. Remove the timing cover. Move the engine to the left. Raise and lower respectively to remove the cover.

Note: Handle the cylinder head gasket with care.






67. Remove the upper guide and the chain tensioner for the balancer shaft chain.
68. Remove the pivoted balancer shaft chain guide.
69. Remove the idler pulley for the balancer shaft chain and the chain.
70. Remove the fixed guide for the balancer shaft chain and timing chain.

Note: The balancer shafts will move inwards in the engine when the balancer shaft pinion bolts are removed.






71. Remove the balancer shaft pinions. Use the old balancer shaft chain as counterhold when removing by placing the chain around the crankshaft sprocket and balancer shaft pinion. Hold together with pliers.






72. Fit the new pinions with the chain as counterhold.
Tightening torque: 25 Nm (18 ft. lbs.)

Important: The pinion with the smaller thrust ring marked INL must be fitted on the inlet side and the pinion with the larger thrust ring marked EXH must be fitted on the exhaust side.









73. Remove the oil pump driver and sprocket from the crankshaft.
74. Remove the timing chain guard and remove the chain complete with sprocket.
75. Remove the timing chain moving chain guide. Prise slightly to remove the guide.
76. Clean the sealing surfaces of the oil sump and the timing cover, and wash the oil sump and the timing cover. Remove the baffle plate and suction strainer before washing.
77. Replace the O-ring to the oil sump strainer.