Necessary preliminary tasks

• Remove CYLINDER HEAD COVER 
• Remove all SPARK PLUGS
• Remove CHAIN TENSIONER .
• Remove CRANKSHAFT RADIAL SEAL  at front
• Remove drive belt TENSIONER 
• Remove VIBRATION DAMPER 

Remove fastener (1) in direction of arrow.

Installation: 

Install fastener (1) with bore facing outwards.

Fig 1: Removing Fastener

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Rotate crankshaft at central bolt into TDC position.

Slide special tool 11 0 300 in direction of arrow into special tool bore and secure crankshaft.

Fig 2: Sliding Special Tool (11 0 300)

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If the flywheel is secured in the correct special tool bore with special tool 11 0 300 , the engine can no longer be moved at the central bolt.

Screw special tool 11 9 280 onto hub of vibration damper.

Release central bolt (1).

Tightening torque 11 21 1AZ .

Remove hub towards front.

Fig 3: Releasing Central Bolt

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Open plug (1).

Tightening torque 11 31 7AZ .

Fig 4: Identifying Plug

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Open plug (1).

Tightening torque 11 11 7AZ .

Installation: 

Replace aluminum screws. 

Fig 5: Identifying Plug

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Release bearing pin (1) from timing chain module on cylinder head.

Tightening torque 11 31 5AZ .

Fig 6: Identifying Timing Chain Module Bearing Pin (Cylinder Head)

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Release bearing pin (1) from timing chain module on crankcase.

Tightening torque 11 31 4AZ .

Fig 7: Identifying Timing Chain Module Bearing Pin (Crankcase)

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Secure special tool 11 4 283 to cylinder head with bolts (1).

Fig 8: Securing Special Tool (11 4 283) To Cylinder Head With Bolts

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Mount special tool 11 4 281 on inlet and exhaust camshafts.

Do not remove special tool 11 4 280 .

Remove INLET AND EXHAUST ADJUSTMENT UNIT .

Release bolts (1) from timing chain module on cylinder head.

Tightening torque 11 31 3AZ .

Remove chain module with timing chain and sprocket wheel upwards in direction of arrow.

Fig 9: Removing Chain Module

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Fig 10: Locating Sprocket Wheel

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Pull timing chain (1) upwards until sprocket wheel (2) engages chain guide (3).

Install timing chain (1) and sprocket wheel (2) in this position.

Installation: 

Always hold timing chain (1) under tension. Timing chain (1) may jam on chain guide (3).

Fig 11: Identifying Timing Chain, Sprocket Wheel And Chain Guide

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Install hub with central bolt.

Tighten down special tool 11 5 200 with screws (1) to hub.

Fig 12: Tightening Special Tool (11 5 200) With Screws

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Remove TENSIONER  for drive belt.

Screw in special tool 11 4 362 from special tool kit 11 4 360 .

Mount special tool 11 9 280 on 11 5 200 .

Support special tool 11 9 280 on special tool 11 4 362.

Special tool 11 0 300 secures crankshaft.

Tighten central bolt to jointing torque.

Tightening torque 11 21 1AZ .

Mark central bolt and hub with paint.

Fig 13: Tightening Central Bolt Using Special Tools (11 9 280)

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Mark special tools with colored line (1).

See picture.

If necessary, tighten central bolt to torsion angle with special tool 00 9 140 .

Tightening torque 11 21 1AZ .

Fig 14: Identifying Colored Line On Special Tool

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Tighten central bolt with a second person helping.

Tightening torque 11 21 1AZ .

Install INLET AND EXHAUST ADJUSTMENT UNITS .

Install CHAIN TENSIONER .

Fig 15: Tightening Central Bolt

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Crank engine twice.

Check TIMING .

If necessary, adjust VALVE TIMING .

Assemble engine.