Camshaft Timing Chain, Removing from Camshafts

Camshaft Timing Chain, Removing from Camshafts

Special tools, testers and auxiliary items required

• Crankshaft Holder (3242)

• Socket (T40058)

• Adjustment Pin (T40060) (Qty: 2)

• Adapter (T40061)

• Adapter (T40062)

• Two 3.3 mm Drill Bits

Requirement

• The engine and transmission are installed.

Removing

• If work will only be done on the cylinder head, it is only necessary to adjust the valve timing on the cylinder bank that was repaired.

- Drain the coolant. Refer to => [ Coolant, Draining ] Coolant, Draining.

- Remove the front exhaust pipe with catalytic converter.

- Remove the vacuum pump. Refer to => [ Vacuum Pump Overview ] Service and Repair.

- Remove the rear right coolant pipe. Refer to => [ Rear Coolant Pipe ] Rear Coolant Pipe.

- Remove the left rear coolant pipe. Refer to => [ Left Rear Coolant Pipe ] Left Rear Coolant Pipe.

• The following illustrations shows the steps on the drive chains from behind with the engine removed.

- Remove the bolts - 1 through 4 - and the left timing chain cover.

- Remove the bolts - 1 through 4 - and the right timing chain cover.

- Assemble the adapter (T40058) as follows:

• The large diameter - arrow 1 - faces the engine.

• The small diameter - arrow 2 - faces the adapter.

Components could be destroyed by the camshaft timing chain jumping off.

• Turn the crankshaft only in engine rotation direction - arrow -.

- Use the adapter (T40058) to rotate the crankshaft to Top Dead Center (TDC).

• The adjustment pin (T40060) has a flat part - 2 - which makes it easier to insert if the camshaft and the cylinder head are slightly offset.

• Insert the pin so that the lever - 1 - is perpendicular to the camshaft axis.

• Move the lever - 1 - 90° (1/4) turn - arrow - so that it is perpendicular to the camshaft axis and it is possible to attain the correct TDC position.

- Check whether the camshafts from both cylinder heads are in the TDC position.

• It must be possible to secure the camshafts using the adjustment pin (T40060).

• The lever - arrow - on the adjustment pin (T40060) must be perpendicular to the center axis of the camshaft for cylinder bank 1 (right side).

• The lever - arrow - on the adjustment pin (T40060) must be perpendicular to the center axis of the camshaft for cylinder bank 2 (left side).

• To collect leaking engine oil, place a clean cloth under the upper oil pan.

- Remove the plug - arrow - from the upper oil pan.

Risk of injury when touching the TDC hole with finger.

• Do not rotate crankshaft - 1 -.

- Install the crankshaft holder (3242) in the hole and tighten it to 20 Nm. Rotate the crankshaft back and forth slightly to center the holder completely, if necessary.

- To protect against cuts, wrap the point and the cutting edges of a 3.3 mm drill bit with insulating tape.

- Push the tensioning rail for the left camshaft timing chain in the - direction of the arrow - and secure the chain tensioner with the 3.3 mm drill bit - 1 -.

Danger of causing damage to the engine.

• To prevent small parts from accidentally entering the engine through the opening in the timing chain compartment, cover the opening with a clean cloth.

- Remove the bolt - 3 - and remove the tensioning rail.

- Remove the bolts - 1 - for the guide rail and the bolts - 2 - for the camshaft sprocket.

- Remove the camshaft sprocket and guide rail.

- To protect against cuts, wrap the point and the cutting edges of a 3.3 mm drill bit with insulating tape.

- Push the chain tensioner for the right camshaft timing chain in the - direction of the arrow - and secure the chain tensioner with the 3.3 mm drill bit - 1 -.

Danger of causing damage to the engine.

• To prevent small parts from accidentally entering the engine through the opening in the timing chain compartment, cover the opening with a clean cloth.

- Remove the chain tensioner bolts - 1 - and the camshaft sprocket bolts - 2 and 3 -.

- Remove the camshaft sprocket and chain tensioner.

Installing

• Tightening specifications, refer to => [ Left Camshaft Timing Chain Overview ] Left Camshaft Timing Chain Overview.

• Secure the crankshaft - 1 - in the TDC position using the crankshaft holder (3242).

• Replace any bolts that were tightened to an additional torque angle.

• Replace the TDC plug seal.

Risk of damaging valves and piston crowns.

• If the camshafts are rotated, the crankshaft may not rest with any piston at TDC.

- Check whether the camshafts for both cylinder heads are in the TDC position.

- Remove the adjustment pin (T40060) from both camshafts.

Risk of damaging valves and piston crowns.

• If the camshafts are rotated, the crankshaft may not rest with any piston at TDC.

• If the camshafts are not secured, it is possible to correct them slightly using the adapter (T40061) by installing the camshaft sprocket on the camshaft.

- Install the left camshaft timing chain with the camshaft sprocket, the guide rail and the tensioning rail.

• The slots in the camshaft sprocket must be at the middle position in relation to the threaded holes in the camshaft.

- Tighten the guide rail bolts - 1 - and the tensioning rail bolt - 3 -.

- Install two camshaft sprocket bolts - 2 - loosely.

• It must still be possible to rotate the camshaft chain sprocket on the camshaft and it must not tilt.

- Secure the left camshaft using the adjustment pin (T40060).

• The lever - arrow - on the adjustment pin (T40060) must be perpendicular to the center axis of the camshaft.

- Pull the drill bit - 4 - out of the alignment hole, thereby releasing the chain tensioner.

- Install the right camshaft timing chain with the sprocket and chain tensioner.

• The slots in the camshaft sprocket must be at the middle position in relation to the threaded holes in the camshaft.

- Tighten the chain tensioner bolts - 1 -.

- Install two camshaft sprocket bolts - 2 - loosely.

• It must still be possible to rotate the camshaft chain sprocket on the camshaft and it must not tilt.

- Secure the right camshaft using the adjustment pin (T40060).

• The lever - arrow - on the adjustment pin (T40060) must be perpendicular to the center axis of the camshaft.

- Pull the drill bit - 3 - out of the alignment hole, thereby releasing the right chain tensioner.

- Install the right camshaft sprocket using the adapter (T40062) and a torque wrench.

- Tighten the bolts - 1 and 2 - to 20 Nm in the - direction of the arrow - and hold

- Remove the adapter (T40062) and the adjustment pin (T40060).

- Tighten the remaining bolts for the right camshaft sprocket.

- Install the left camshaft sprocket using the adapter (T40062) and a torque wrench.

- Tighten the bolts - 1 and 2 - to 15 Nm in the - direction of the arrow - and hold.

- Remove the adapter (T40062) and adjusting pin (T40060).

- Tighten the remaining bolts for the left camshaft sprocket.

- Remove the crankshaft holder (3242).

Checking the Valve Timing

Components could be destroyed by the camshaft timing chain jumping off.

• Turn the crankshaft only in engine rotation direction - arrow -.

- Rotate the crankshaft two revolutions until the crankshaft is just in front of TDC.

- Secure the crankshaft - 1 - from turning using the crankshaft holder (3242) and tighten it to 20 Nm.

An inaccurate TDC setting will cause an inaccurate setting.

• If the crankshaft was only rotated slightly past TDC, first rotate it back approximately 10° and then rotate it in engine rotation direction again to TDC.

- Check whether the camshafts for both cylinder heads are in the TDC position.

Correcting the Valve Timing

- If one of the camshafts do not lock, loosen all the bolts - arrows - for that particular camshaft sprocket about 1 turn.

- Install the adapter (T40061) over the bolt heads.

- Rotate the camshaft using the adapter (T40061) just a little back and forth until it is possible to install the adjustment pin (T40060).

• The lever - arrow - on the adjustment pin (T40060) must be perpendicular to the center axis of the camshaft.

- Tighten the bolts for the camshaft sprocket with the adapter (T40061) and the adjustment pin (T40060) still attached to approximately 5 Nm.

- Remove the adjustment pin (T40060) and adapter (T40061).

- Tighten the camshaft sprocket bolts to their final torque.

- Repeat the procedure on the other cylinder bank, if necessary.

- Remove the crankshaft holder (3242).

- Check the valve timing once again.

Further installation is in the reverse order of removal. Note the following:

- Install the plug - arrow - for the TDC mark in the upper oil pan. Refer to => [ Upper Oil Pan Overview ] Upper Oil Pan Overview.

- Install the timing chain covers. Refer to => [ Timing Chain Covers ] Timing Chain Covers.