Camshaft Timing Chain: Installing

Fig 1: Identifying Markings On Cylinder Block

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-- Check the crankshaft at TDC. The flat area on the crankshaft -arrow- must be horizontal.

-- Draw the markings on the cylinder block -1-, as shown, with a waterproof marker.

-- Draw a marking -2- on the three stage chain sprocket tooth -1- with a waterproof marker.

Fig 2: Draw Marking On Three Stage Chain Sprocket Tooth

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-- Turn the intermediate sprocket and balance shaft to the markings -arrow-, do not loosen the bolt -1-.

Fig 3: Identifying Intermediate Shaft Sprocket

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NOTE:

The painted links of the drive chain must be positioned on the markings on the chain sprockets.

Do not pay attention to the position of any additional painted chain links that may also be present.

Fig 4: Identifying Painted Links

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-- Lay the balance shaft drive chain, the painted links -arrows- must be positioned with the markings on the chain sprockets.

-- Hook the camshaft timing chain with the markings -arrows- onto the camshaft pins.

Fig 5: Identifying Camshaft Pins

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-- Lay the oil pump drive timing chain onto the three stage chain sprocket.

Fig 6: Identifying Three Stage Chain Sprocket

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-- Tilt the three stage chain sprocket in the direction of the -arrow- toward the engine and secure it to the crankshaft. The marking -arrows- must be positioned opposite each other.

-- Install the Tensioning Pins T10531/2 -B- in the crankshaft and tighten by hand. Tighten tensioning bolt -A- hand-tight.

Fig 7: Identifying Camshaft Timing Chain And Drive Chain

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-- Position the painted chain link in the balance shaft drive chain -arrow- at the marking on the three stage chain sprocket. Install the timing chain tensioning rail and tighten the bolt -1-.

Fig 8: Identifying Bolt

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-- Install the balance shaft drive chain glide track and tighten the bolts -arrows-.

Fig 9: Identifying Balance Shaft Drive Chain Glide Track Bolts

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-- Install the timing chain tensioner -1-.

Fig 10: Balance Shaft Timing Chain, Tensioning Rail And Guide Rails

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-- Check the adjustment again. The painted chain links must line up with the markings on the chain sprockets.

Fig 11: Identifying Timing Chain Markings

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NOTE:

The painted links of the timing chain must be positioned on the markings on the chain sprockets.

Do not pay attention to the position of any additional painted chain links that may also be present.

Fig 12: Identifying Markings On Chain Sprockets

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-- Mount the timing chain on the intake camshaft.

-- Mount the timing chain on the exhaust camshaft.

-- Lay the timing chain on the crankshaft and hold it there.

-- Install the camshaft timing chain guide rail and tighten the bolts -A-.

Fig 13: Identifying Bolts

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-- Install the upper glide track -arrow-.

Fig 14: Identifying Upper Guide Track

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-- Turn the exhaust camshaft in the direction of the arrow -1- using the Adapter T40266. Slide the Camshaft Locks T40271/1 out of the chain sprocket splines -2- and release the camshaft.

Fig 15: Identifying Assembly Tool T40266

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-- Remove the Camshaft Locks T40271/1.

-- Install the timing chain tensioning rail and tighten the bolt -2-.

Fig 16: Identifying Tensioning Rail For Camshaft Timing Chain

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-- Turn the intake camshaft in the direction of the arrow -1- using the Adapter T40266. Slide the Camshaft Locks T40271/2 out of the chain sprocket splines -2- and release the camshaft.

Fig 17: Identifying Assembly Tool T40266 And Camshaft Clamp T40271/2

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-- Remove the Camshaft Locks T40271/2.

-- Check that the position of the colored chain link is aligned to the markings.

Fig 18: Identifying Markings On Chain Sprockets

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-- Install the oil pump drive chain tensioner. Tighten the bolt -1- and remove the Locking Pin (3 pc.) T40011. The chain tensioner wire clip must come in to contact with the oil pan upper section opening.

Fig 19: Identifying Locking Pin T40011

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-- Install the bolts -arrows- and tighten them.

Fig 20: Identifying Bolts

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-- Mount the bearing bracket and the bolts -arrows- hand-tight.

Fig 21: Identifying Bolts

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-- Remove the Tensioner Locking Tool T40267.

Fig 22: Securing Chain Tensioner With T40267

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-- Tighten the bolts -arrows-, refer to OVERVIEW - CAMSHAFT TIMING CHAIN .

Fig 23: Identifying Bolts

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-- Install the pilot valves -item  6.

-- Install the lower timing chain cover, refer to LOWER TIMING CHAIN COVER .

-- Install the vibration damper, refer to VIBRATION DAMPER .

-- Let the engine turn a second time in the direction of engine rotation.

-- Install the upper timing chain cover, refer to UPPER TIMING CHAIN COVER .

-- Install the ribbed belt tensioning damper, refer to RIBBED BELT TENSIONER .

-- Install the ribbed belt, refer to RIBBED BELT .

The rest of the installation is performed in reverse order of removal, noting the following:

-- After performing work on the chain drive the adaptation value in the engine control module must be adapted. To do this turn on the ignition and select the following menu items on the Vehicle Diagnostic Tester:

• 01 - Engine electronics 
• Guided functions 
• 01 - Adaptation after repair work on the chain drive