Note. The camshafts can be turned without the risk of the valves colliding with the pistons when the crankshaft is brought to the position 45°before TDC of the first cylinder piston.
Note. The timing chain can be replaced without dismantling the engine. Using the tools listed below, the new chain can be connected to the old chain, passed around the sprockets and minted (see Section Timing Chain Replacement).
Attention! If assembled incorrectly, the valves may collide with the piston crowns!
General information
The following special tools are required to perform the removal and installation procedures for the timing drive components:
- Camshaft lock pin x4 - No. 111589031500;
- Camshaft key - No. 119589000100;
- Crankshaft hub / pulley puller - No. 103589003300;
- Flywheel/drive plate locking tool - No. 116589014000;
- Tool for installing gas distribution chain links - No. 000589584300;
- A set of stamp holders for installing gas distribution chain links - No. 103589016300;
- Gas distribution chain weakeners - No. 110589035900;
- Pulley locking tool - No. 603589004000.
Pay attention to the following points:
- Unless otherwise stated, turn the engine in the normal direction only;
- Observe the tightening torques of the fasteners stipulated by the regulations;
- With the appropriate configuration, do not forget to mark the installation position of the CKP sensor before removing it;
- Do not turn the crankshaft using the camshaft sprockets, as well as other timing sprockets;
- Do not turn the crankshaft and camshafts with the timing chain removed.
Servicing Timing Drive Components
Timing drive design
1 - Crankshaft sprocket; 2 - Bearing finger; 3 - Tensioner guide; 4 - Chain tensioner; 5 - Asterisk of a final camshaft; 6 - Upper chain guide; 7 - Intake camshaft sprocket; 8 - Chain guide of the right cylinder head; a = 8.1 mm; b = 9 mm; 9 - Guide pin; 10 - Guide pin; 11 - Intermediate sprocket; 12 - Guide pin; 13 - Guide pin; 14 - Internal chain guide of the left cylinder head; a = 8.1 mm; b = 9 mm; 15 - Intake camshaft sprocket; 16 - Upper side chain guide; 17 - Asterisk of a final camshaft; 25 - Gas distribution chain (216 double links); 26 - Outer chain guide of the left cylinder head; a = 8.1 mm; b = 9 mm; 27 - Guide pin; 28 - Guide pin; 29 - Cylinder block chain guide; a = 8.1 mm; b = 9 mm; 30 - Bolted bearing finger; 31 - Bolted bearing finger
Installation details of timing drive elements
1 - Setting marks for bringing the engine to the TDC position of the end of the compression stroke of the first cylinder; 2 - Rods with a diameter of 6.5 mm for fixing the camshafts; 3 - When installing the chain, make sure that the protrusions of the camshaft adjuster (3) were in position «delays».; 4 - The camshaft can be locked against rotation with a key.; 5 - Removing the chain tensioner assembly
1. Disconnect the negative cable from the battery.
2. For the purpose of simplification of cranking of the engine turn out all spark plugs.
3. Bring the crankshaft to position 45°before TDC of the first cylinder piston.
4. Insert the locking rods into the camshafts (2) 6.5 mm in diameter.
5. When installing the chain, make sure that the tabs on the intake camshaft adjuster (3) were in position «delays».
Attention! If assembled incorrectly, the valves may collide with the piston crowns!
Before proceeding with the repair procedures, remove the tensioner assembly, - do not tilt the assembly during removal.
Note. The exhaust camshaft of the right cylinder head must be locked with a locking rod before the tensioner is removed.
1. The camshaft can be locked from turning with a key (4).
2. After completing the necessary reconditioning, reinstall the tensioner.
3. Torque the NEW intake and exhaust camshaft adjuster bolts to 18 Nm (type A bolt with separate washer) or 20 Nm + 60° (type B bolt with built-in washer).
Note. During repair work, the type A bolt should be replaced with a disposable type B bolt.
4. On the 119.97 engine, replace the regulator spring if its dimensions do not meet the requirements Specifications.
5. Tighten the NEW intake camshaft adjuster bolt to 7 Nm (type A bolt with separate washer) or 5 Nm + 90° (type B bolt with built-in washer).
Note. During repair work, the type A bolt should be replaced with a disposable type B bolt.
On models prior to 07/94, be sure to lubricate the crankshaft pulley center bolt and washer prior to installation (s).