Replacement

Changing Balancer Shaft Chain / Timing Chain In Car

To Fit









1. Fit the timing chain moving chain guide. Prise slightly to fit the guide.
2. Fit the timing chain pinion on the crankshaft.
3. Fit the timing chain and camshaft sprockets according to the markings on the chain and wheel.
Tightening torque: 63 Nm (46 ft. lbs.)
4. Fit the fixed guide for the balancer shaft chain and timing chain.
Tightening torque: 10 Nm (7 ft. lbs.)
5. Fit the chain tensioner.
Tightening torque: 63 Nm (46 ft. lbs.)
6. Fit the pin, spring and plug to the chain tensioner.
Tightening torque 22 Nm (16 ft. lbs.)






7. Fit the timing chain safety guard.
8. Fit the balancer shaft chain upper guide.
Tightening torque: 10 Nm (7 ft. lbs.)
9. Check that the chain tensioner plunger is correctly positioned. If the plunger can be depressed fully it must be turned 180°.
10. Turn the plunger on the balancer shaft chain tensioner 90�, press it in and turn it back 90�. Lock the tensioner in position by inserting a paperclip or similar into the hole on the top of the tensioner.
11. Fit the chain tensioner and the moving chain guide.
Tightening torque: 10 Nm (7 ft. lbs.)

Warning: Ii is very important for the function that the correct tightening torque is used when fitting.

12. Fit the balancer shaft chain pinion on the crankshaft.






13. Align the marks on the balancer shafts with the marks on the top of each bearing housing.
14. Fit the chain to the sprocket and fit this along with the idler sprocket.
Tightening torque: 25 Nm (18 ft. lbs.)
15. Check the setting of the balancer shafts and loosen the chain tensioner. Counterhold with the moving guide, remove the wire clip from the chain tensioner and slowly ease out the guide.
16. Check that there is a small amount of play by pushing in the tensioner.






17. Apply 90 297 970 Flange sealant in an approx. 1 mm thick line in the centre of the sealing surfaces according to the illustration. Apply a small dab of silicone flange sealant in the joins between the cylinder head and cylinder block.
18. Fit the timing cover by carefully twisting it into place. Move the engine to the left and raise and lower respectively to fit the timing cover and the bolts.






Note: Make sure that the cover does not make contact with the cylinder head gasket. Guide the gasket away with a screwdriver.

Tightening torque 22 Nm (16 ft. lbs.)






19. Fit the oil pump driver.
20. Make sure that the marking on the oil pump gear ring is facing outward and pump impeller with flange inward. Use a new O-ring, grease with Vaseline.
21. Oil and fit the pump gears, fit the pump cover in correct position using the locating arrows.
22. Fit the circlip with bevel facing outward and the opening downward. Fit a new crankshaft seal. Use 83 94 876 Fitting tool, crankshaft seal.
23. Fit the crankshaft pulley.
Tightening torque 175 Nm (129 ft. lbs.)
24. Fit the bolt to the intermediate shaft bearing bracket.






25. Fit the bolt to the AC compressor bracket.






26. Fit the bolts for the generator bracket and the generator.
Tightening torque, generator 47 Nm (35 ft. lbs.)
Tightening torque, generator bracket 24 Nm (18 ft. lbs.)
27. Fit the belt tensioner and the idler pulley.
Tightening torque, belt tensioner 59 Nm (44 ft. lbs.)
Tightening torque, idler pulley 47 Nm (35 ft. lbs.)
28. Man: Fit the gearbox mounting.
Tightening torque, man. 47 Nm (35 ft. lbs.)






29. Fit the left-hand engine pad. Centre the engine pad to the bolt holes. Remove the wedge.
Tightening torque bolts 40 Nm +45° (35 ft. lbs. +45°)
Tightening torque, nut 84 Nm (62 ft. lbs.)
30. Fit the main fuse box.
31. Lower the engine on the wedges at the oil filter adapter and the drive shaft universal joint. Remove the lifting eye.






32. Fit the connection sleeve to the cylinder block. Apply 30 06 442 White high-pressure grease paste to the seals. Polish the seat in the cylinder block with a fine emery cloth and fit two new O-rings.
33. Fit the coolant pump.
Tightening torque 22 Nm (16 ft. lbs.)






34. Fit the coolant pipe to the coolant pump and the turbocharger.
Tightening torque, banjo screw, turbocharger 25 Nm (18 ft. lbs.)
Tightening torque, banjo screw, coolant pump 20 Nm (15 ft. lbs.)
35. Fit the two longitudinal coolant pipes to the coolant pump.
Tightening torque: 10 Nm (7 ft. lbs.)
36. Fit the two longitudinal coolant pipes to the engine block.
37. Fit the hose clips and hoses to the coolant pump inlet.






38. Fit the intake manifold to the turbocharger with a new O-ring.
39. Fit the bracket for the power steering pump and the power steering pump.
Tightening torque 24 Nm (18 ft. lbs.)






40. Fit the camshaft cover according to the fitting sequence in the illustration.
41. Fit the spark plugs.
42. Fit the engine lifting eye.






43. Fit the fan cowling.






44. Fit the multigroove belt in accordance with the indicated rotation direction.






45. Fit the mass air flow sensor with hose and connector.






46. Raise the engine and fit the right-hand engine mounting.
Tightening torque: 47 Nm (35 ft. lbs.)
47. Fit the engine mounting bracket. Do not fit the nut yet.
Tightening torque, bolts 47 Nm (36 ft. lbs.)






48. Fit the crankcase ventilation pipe.
49. Fit the turbocharger solenoid valve and the connector.
50. Fit the ignition discharge module without plugging in the connector.






51. Raise the car and remove the flywheel locking attachment.
52. Apply an approximately 2 mm thick bead of flange sealant, part no. 90 543 772 to the oil sump sealing surface.
53. Check that the pipe to the oil adapter is firmly attached and that it is directed straight into the oil sump. Replace O-rings if necessary.
54. Lift up and position the oil sump. Thread all the bolts.
55. Tighten the oil sump bolts.
Tightening torque 22 Nm (16 ft. lbs.)
56. Fit the crankcase ventilation hose.
57. Fit the gearbox cover plate.






58. Fit the oil filter and connect the oil pipes with new O-rings.






59. Fit the front exhaust pipe.
Tightening torque 22 Nm (16 ft. lbs.)






60. Fit the torque arm.
Tightening torque, through bolt 90 Nm + 90� (66 ft. lbs. + 90°)
Tightening torque, bracket 70 Nm + 90� (52 ft. lbs. + 90°)
61. Lower the car and fit the nuts to the right-hand and rear engine pads.
Tightening torque, rear 47 Nm (35 ft. lbs.)
Tightening torque, right 105 Nm (78 ft. lbs.)






62. Tighten the upper nuts on the exhaust pipe flange and plug in the connector to the heated oxygen sensor. Secure the cable with cable ties.
Tightening torque 22 Nm (16 ft. lbs.)






63. Fit the turbocharger heat shield.
64. Fit the by-pass valve with pipe.






65. Connect the gear linkage to the selector rod.
66. Man: Engage 4th gear and fit 87 92 632 Lock pin in the gear-lever housing. Tighten the clamp on the gear linkage.
Tightening torque 22 Nm (16 ft. lbs.)
67. Remove the lock pins, check the gear positions and that the ignition key can be removed. Fit the plastic plug in the gearbox. Fit the gear lever gaiter.






68. Fit the battery tray and the battery. Fit the battery cover. Connect the battery cables.
69. Fit the upper engine cover.
70. Raise the car and fit the spoiler shield.






71. Fit the right-hand wing liner.






72. Fit the belt circuit's cover.
73. Fit the right wheel.
74. Pressure test the cooling system.
75. Fill with Coolant and close the expansion tank cap.
76. Fill with engine oil.
77. Run the starter motor until the oil pressure lamp goes out without the ignition discharge module connector being plugged in. Plug in the connector afterwards.

Note: A diagnostic trouble code is generated after running the starter motor.

78. Set the car clock and date.
79. Calibrate the AC system by pressing in the AUTO and OFF buttons at the same time.
80. Connect the diagnostic tool and erase the diagnostic trouble codes.