Camshaft Timing Chain, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Locking Pin 3242
Crankshaft Key T40049
2 - Camshaft Adjustment Pins T40060
Camshaft Correction Tool T40061
Chain Sprocket Tensioner T40062
3.3 mm diameter drill bit (quantity: 2)

Removal

The transmission is removed.

CAUTION:

Risk of damaging valves and piston crowns.

Turn the crankshaft and camshafts only with the chain drive completely installed.

-- Remove the timing chain cover lower section. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Attach the Crankshaft Key T40049 the back of the crankshaft using two old drive plate bolts -arrows-.

Fig 1: Identifying Key T40049 At Rear On Crankshaft And 2 Old Bolts For Dual-Mass Flywheel

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NOTE:

The Camshaft Adjustment Pins T40060 has a flat part -2- which makes it easier to insert if the camshaft and the cylinder head are slightly offset.

Fig 2: Identifying Adjustment Pin T40060

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Insert the pin so that the bolt -1- is perpendicular to the camshaft axle.

Move the bolt -1- 90° -arrow- so that it is perpendicular to the camshaft axle and it is possible to attain the correct "TDC" position.

Fig 3: Checking Camshafts TDC Position

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CAUTION:

Components could be damaged by the camshaft timing chain jump off.

Only rotate the crankshaft in the direction of engine rotation.

-- Use the Crankshaft Key T40049 to rotate the crankshaft to "TDC" :

-- Check whether camshafts of both cylinder heads stand in "TDC" position.

It must be possible to secure the camshafts with the Camshaft Adjustment Pins T40060.
The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).

Fig 4: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060
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-- Remove the bolt -arrow- for the "TDC" marking from the upper part of the oil pan by using a long hex socket wrench with a ball head.

Fig 5: Identifying Locking Bolt Of Upper Part Of Oil Pan

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-- Install the Crankshaft Holder3242 in the hole and tighten to 20 Nm. Turn the crankshaft -1- back and forth slightly to completely center the bolt, if necessary.

Fig 6: Identifying Crankshaft Holder 3242

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

Fig 7: Identifying Chain Tensioner Secured Using 3.3 Mm Diameter Drill Bit

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

CAUTION:

If the running direction is reversed on a used camshaft timing chain, it could be damaged.

Paint arrows to mark the timing chain running direction so it can be installed again.

-- Remove the Camshaft Adjustment Pins T40060 from both camshafts.

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

Fig 8: Identifying Bolts -1- For Guide Rail And Bolts -2- For Camshaft Chain Sprocket

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

-- Remove the camshaft chain sprocket, guide rail and left camshaft timing chain.

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

Fig 9: Identifying 3.3 mm Diameter Drill Bit -1- To Install Chain Tensioner Guide Rail On Right Camshaft Timing Chain

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

Fig 10: Identifying Chain Tensioner Guide Rail Installed On Right Camshaft Timing Chain

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CAUTION:

If the running direction is reversed on a used camshaft timing chain, it could be damaged.

Paint arrows to mark the timing chain running direction so it can be installed again.

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

-- Remove the camshaft chain sprocket, chain tensioning and right camshaft timing chain.

Installation

Fig 11: Identifying Crankshaft Holder 3242

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Tightening specifications. Refer to CAMSHAFT TIMING CHAINS OVERVIEW .
Secure the crankshaft -1- in "TDC" position using the Locking Pin 3242.
The timing mechanism drive chain is installed. Refer to TIMING MECHANISM DRIVE CHAIN, REMOVING AND INSTALLING .

NOTE:

Replace any bolts that were tightened with an additional turn.

CAUTION:

Risk of damaging valves and piston crowns.

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

-- Check whether camshafts of both cylinder heads stand in "TDC" position.

Fig 12: Identifying Check Of Camshafts For Both Cylinder Heads In TDC Position And Adjustment Pin T40060

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It must be possible to secure the camshafts with the Camshaft Adjustment Pins T40060.
The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).

Fig 13: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060
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-- Remove the Camshaft Adjustment Pins T40060 from both camshafts.

Fig 14: Identifying Adapter T40061 And Adjustment Pin T40060

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CAUTION:

Risk of damaging valves and piston crowns.

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

NOTE:

If the camshafts are not secured, it is possible to correct them slightly with the Camshaft Correction Tool T40061 by Installation the camshaft chain sprocket on the camshaft.

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

Fig 15: Identifying Left Camshaft Timing Chain, Camshaft Chain Sprocket, Guide Rail And Tensioning Rail

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

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

-- Install both camshaft chain sprocket bolts -2- loosely.

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

-- Secure the left camshaft with the Camshaft Adjustment Pins T40060.

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft.

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

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

Fig 16: Identifying Drill Bit -4- And Alignment Hole

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

-- Tighten the chain tensioner bolts -1-.

-- Install both camshaft chain sprocket bolts -2- loosely.

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

-- Secure the right camshaft with the Camshaft Adjustment Pins T40060.

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft.

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

-- Pre-tighten the right camshaft chain sprocket using the Chain Sprocket Tensioner T40062 and torque wrench to 20 Nm in -direction of arrow- and hold.

Fig 17: Identifying Bolts -1 And 2-, Torque Wrench, Adapter T40062 And Adjustment Pin T40060

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-- Fasten bolts -1- and -2-.

-- Remove the Chain Sprocket Tensioner T40062 and Camshaft Adjustment Pins T40060.

-- Tighten the remaining bolts for the right camshaft chain sprocket.

-- Pre-tighten the left camshaft chain sprocket using the Chain Sprocket Tensioner T40062 and torque wrench to 15 Nm in -direction of arrow- and hold.

Fig 18: Identifying Adapter T40062 On Left Camshaft Chain Sprocket

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-- Fasten bolts -1- and -2-.

-- Remove the Chain Sprocket Tensioner T40062 and Camshaft Adjustment Pins T40060.

-- Tighten the remaining bolts for the left camshaft chain sprocket.

-- Remove the Locking Pin 3242.

Fig 19: Identifying Crankshaft Holder 3242

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Fig 20: Identifying Key T40049 At Rear On Crankshaft And 2 Old Bolts For Dual-Mass Flywheel

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CAUTION:

Components could be damaged by the camshaft timing chain jump off.

Turn crankshaft only in direction of engine rotation -arrow-.

-- Turn the crankshaft two turns using the Crankshaft Key T40049 until it is just in front of "TDC".

-- Lock the crankshaft -1- from turning using the Crankshaft Holder3242 to 20 Nm.

Fig 21: Identifying Crankshaft Holder 3242

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CAUTION:

An inaccurate "TDC" setting will cause an inaccurate setting.

If the crankshaft was turned past "TDC" : Turn the crankshaft again 2 turns until it is just in front of "TDC". Then use the Crankshaft Holder3242 to keep crankshaft from turning.

-- Check whether camshafts of both cylinder heads stand in "TDC" position.

Fig 22: Checking Camshafts TDC Position

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It must be possible to secure the camshafts with the Camshaft Adjustment Pins T40060.
The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 1 (right).

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft on cylinder bank 2 (left).

Fig 23: Identifying Perpendicular Pin -Arrow- On Adjustment Pin T40060
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Correcting the valve timing

Fig 24: Identifying Bolts -Arrows-

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

-- Mount the Camshaft Correction Tool T40061 over the bolt heads.

Fig 25: Identifying Adapter T40061 And Adjustment Pin T40060

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-- Turn the camshaft by the Camshaft Correction Tool T40061 just a little back and forth until it is possible to insert the Camshaft Adjustment Pins T40060.

The bolt -arrow- in the Camshaft Adjustment Pins T40060 must be perpendicular to the center line of the camshaft.

-- Tighten the bolts for the camshaft chain sprocket with the Camshaft Correction Tool T40061 and the Camshaft Adjustment Pins T40060 still attached to approximately 5 Nm.

-- Remove the Camshaft Adjustment Pins T40060 and Camshaft Correction Tool T40061.

-- Tighten the camshaft chain sprocket bolts to final torque.

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

-- Remove the Locking Pin 3242.

-- Check the valve timing once again, refer to CAMSHAFT TIMING CHAIN, REMOVING AND INSTALLING .

Install in reverse order of removal. Note the following:

-- Tighten the bolt for the "TDC" marking in the oil pan upper section. Refer to OIL PAN UPPER SECTION OVERVIEW .

-- Install the timing chain cover lower section. Refer to LOWER TIMING CHAIN COVER, REMOVING AND INSTALLING .

-- Fill engine oil and check the oil level. Refer to Maintenance Booklet 406.