Table of contents: Upper timing chain covers ↓ Lower timing chain cover ↓ Removal the timing chain from the… ↓ Removal and installation the timing… ↓
1. The installation details of the timing chain and its cover are shown in the illustrations. The timing chains are located on the rear of the engine.
29.1a. Timing chain cover installation details:
1 - Cover mounting bolts 4, subject to replacement;
2 - Rotor of the CKP sensor;
3 - Rear crankshaft oil seal;
4 - Lower timing chain cover;
5, 14 - Centering bushings, 2 pcs.;
6, 10 - Gasket, subject to replacement;
7 - Lower cover mounting bolt 8, subject to replacement;
8 - Left upper timing chain cover;
9/11 - Upper cover mounting bolt 8/12, subject to replacement;
12 - Right upper timing chain cover;
13 - Lower cover mounting bolt 12, subject to replacement;
15 - Starter mounting aperture cover;
16 - Sealing element, 2 pcs.;
17 - SKR sensor "G28";
18 - Crankshaft position sensor cover;
19 - Bolt, 9 Nm.
29.1b. Timing chain installation details:
1 - Bolt, 9 Nm;
2 - Chain slip protection;
3 - Crankshaft with timing chain drive sprocket;
4, 7, 12 - Guide bar;
5, 8, 15 - Bolt, 23 Nm;
6 - Guide pin of bar 4, subject to replacement, 5 Nm, then tighten to an angle of 90°;
9 - Intake camshaft sprocket, for driving the shafts of the left cylinder head; installed with the letters backwards;
10 - Guide pin of bar 7, subject to replacement, 5 Nm, then tighten to an angle of 90°;
11 - Balance shaft sprocket;
13 - Guide pin of the bar 12, 23 Nm;
14 - Intake camshaft sprocket, for driving the right cylinder head shafts: installed with the letters facing backwards;
16 - Guide pin of bar 12, subject to replacement, 5 Nm, then tighten to an angle of 90°;
17 - Guide pin of the bar 18, 23 Nm;
18 - Tensioner bar;
19 - Chain tensioner 21;
20 - Bolt, to be replaced, 5 Nm, then tighten to an angle of 90°;
21 - Timing chain.
Upper timing chain covers
2. When removing the left cover, unscrew the bolts (1 in the illustration) and remove the heat shield (if any), and then remove the left cylinder head cover (see section 31).
29.2. Heat shield bolts on the left cylinder head.
3. When removing the right cover, remove the right cylinder head cover (see Section 31), unscrew the bolts (arrows in the illustration), loosen the clamps (1-3), disconnect the air hoses and push the air tube back.
29.3. Fastening the air pipe on the right cylinder head.
4. Remove the bolts in the following sequence (7-1 in the illustration), carefully release the cover from the glued joint and remove it.
29.4. Timing chain upper cover bolt tightening sequence.
5. Using a plastic drill brush, remove old sealant from the cover grooves and from the mating surfaces of the chain cover/cylinder head. At the same time, do not allow dirt to enter the lubrication system. Clean mating surfaces from oil and grease.
Note: After subsequent application of sealant, the lid must be installed within 5 minutes.
6. Place the gasket on the lower timing chain cover (1 in the illustration) and apply sealant (arrow) to the joints of the covers with the cylinder head.
29.6. Gasket (1) and sealant beads (arrow) on the lower timing chain cover.
7. Completely fill the grooves on the upper timing chain cover with sealant (1 and 2 in the illustrations).
29.7a. Diagram of applying sealant to the left upper timing chain cover.
29.7b. Diagram of applying sealant to the right upper timing chain cover.
In this case, the sealant should protrude 1.5-2.0 mm above the mating surface of the cover.
8. Install the cover and tighten its new bolts in the sequence (1-7 in Illustration 29.4) in several approaches: first by hand until the bolts are fully seated, then with a force of 8 Nm, then check the force of 8 Nm (it may decrease after the lid has settled), and then pull it to a 90° angle.
9. Install the remaining removed parts.
Lower timing chain cover
10. Remove the drive disc (see Section 28).
11. Remove the turbocharger (see Chapter 4).
12. Remove both upper timing chain covers (see subsection above).
13. Remove the bolts (arrows in the illustration) and tilt the turbocharger bracket (1) to the side.
29.13. Turbocharger bracket fasteners.
14. Loosen and remove the timing chain lower cover mounting bolts in the following sequence: (24-1 in the illustration). Carefully release the cover from the glued joints and remove it. Remove the rear crankshaft oil seal from the cover (see Section 28).
29.14. Sequence of unscrewing (24-1) the bolts of the lower timing chain cover.
15. Using a plastic drill brush, remove old sealant from the cover grooves and from the mating surfaces of the chain cover/cylinder head/cylinder block. At the same time, do not allow dirt to enter the lubrication system. Clean mating surfaces from oil and grease.
Note: After subsequent application of sealant, the lid must be installed within 5 minutes.
16. Apply beads of sealant to the mating surface of the cover (1, 2 and 4 in the illustration), completely filling the grooves.
29.16. Timing chain lower cover seals.
The sealant should protrude 1.5-2.0 mm above the mating surface. Apply 1.5-2.0 mm thick beads of sealant around holes (3 and 5).
17. Make sure that there are two centering bushings in the cylinder block. Install the cover and tighten its bolts in the following order (see illustration 29.14):
- Tighten the M6x20 steel bolts (24, 22, 21, 23) with a force of 9 Nm;
- tighten the bolts (1-20) to 3 Nm and then check this torque (it may decrease after the gasket has settled);
- Tighten the bolts (1-20) to an angle of 90°.
18. Install the new rear crankshaft oil seal (see Section 28) and the remaining removed parts. Before installing the AT, clean the threads in its mounting holes in the cylinder block.
Removal the timing chain from the camshafts only
19. The power unit cannot be removed.
20. Remove the upper timing chain covers (see the relevant subsection above).
Note: After working on the right cylinder head only, there is no need to remove the upper timing chain cover on the right cylinder head.
21. Using the T40058 tool, turn the crankshaft clockwise to the TDC position (see illustrations 4.73a-b), as described in paragraphs 22-23.
22. The label on the pulley must be in the "12 o'clock" position (see illustration).
29.22. Mark on the crankshaft pulley in the TDC position.
23. Check that the camshafts are at TDC by locking them with the T40060 tool (see paragraph 9 of Section 9 and accompanying illustrations).
29.23a. Fixing the right intake camshaft sprocket at TDC.
29.23b. Fixing the left intake camshaft sprocket at TDC.
24. Place a cloth under the upper section of the oil pan to collect any leaking oil. Unscrew the plug from the upper section of the oil pan and through the resulting service hole, screw the locking pin No. 3242 into the crankshaft locking hole (with a force of 20 Nm), - see illustration.
29.24. The locking hole in the crankshaft, visible through the service hole in the upper section of the oil pan.
If necessary, rotate the crankshaft forward/backward slightly to completely align the bore centers.
25. Install the timing chain locking tool T40246 as shown in the illustration, in the following sequence:
29.25. Fixing the timing chain tensioner.
- Tighten the M6x40 bolts (2) by hand;
- Tighten the M6x20 bolts (1) by hand;
- Tighten the M6x40 bolts (2) to 8 Nm;
- Tighten the M6x20 bolts (1) to 8 Nm.
26. Seal the opening in the timing belt with a cloth to prevent small parts from getting into the engine. Remove the T40060 tool from both intake camshafts and remove the bolts (see illustrations) and remove the sprockets together with the chain.
29.26a. Left intake shaft sprocket mounting bolts.
29.26b. Right intake shaft sprocket mounting bolts.
27. Before installation, make sure that the crankshaft is locked at TDC with locking pin No. 3242 (see illustration 29.24). Ensure that the camshafts of both cylinder heads are also at TDC by inserting the T40060 tool into their holes in accordance with paragraph 9 Section 9 (see illustrations).
29.27a. Fixing the right intake camshaft at TDC.
29.27b. Fixing the left intake camshaft at TDC.
28. If it is not possible to install these devices, slightly turn the corresponding shaft using the T40061 adapter (see illustration), secured with standard sprocket mounting bolts.
29.28. Turning the left intake camshaft.
Caution: When turning the camshafts, the crankshaft must not be in the position corresponding to the TDC of any piston. Otherwise, valves and pistons may be damaged. After checking, remove the T40060 tools and do not turn the shafts any further.
29. Install the sprocket together with the chain on the left intake shaft so that the centers of the elongated holes in the sprocket are located above the conical holes in the camshaft. Tighten the two bolts (1 in illustration 29.29a) sprockets so that it remains possible to rotate the sprocket on the shaft without axial displacement.
29.29a. Locking the shaft with the T40060 tool on the left cylinder head.
Lock the shaft with tool T40060 (arrow). Repeat the same steps on the right cylinder head (see illustration 29.29b).
29.29b. Locking the shaft with the T40060 tool on the right cylinder head.
30. Remove the timing chain retainer T40246 (see illustration 29.25). Ask an assistant to apply a force of 20 Nm to the right intake shaft sprocket in the direction of the arrow (see illustration) and simultaneously tighten the bolts (1 and 2) securing the sprocket with a force of 23 Nm.
29.30. Creating force when tightening the sprocket bolts.
After this, without releasing the sprocket of the right intake shaft, tighten the bolts (1 in illustration 29.29a) left intake shaft sprocket mounts. Release the right intake camshaft sprocket and tighten the remaining sprocket bolts on both camshafts to 23 Nm.
31. Unscrew locking pin No. 3242 (see illustration 29.24) and check the timing adjustment as described below.
32. Turn the crankshaft clockwise two revolutions, exactly to the next TDC position, and again lock the crankshaft at TDC with locking pin #3242, tightening it to 20 Nm. If the crankshaft has turned past TDC even slightly, turn it approximately two more revolutions to a position approximately 10° before TDC, and then carefully turn it exactly to TDC.
33. Make sure that all camshafts are at TDC: it should be possible to lock them with T40060 tools (see paragraph 23). If the camshafts cannot be locked, adjust the timing as described below.
34. Loosen all bolts (see illustration 9.26a) fastening the sprocket of the corresponding camshaft by approximately one turn, install the adapter T40061 on the bolts (by analogy with illustration 29.28), turn the shaft slightly forward/backward and insert the T40060 tool (see illustration 29.23b). Holding the shaft in this position, tighten the sprocket mounting bolts to 5 Nm. Then remove adapter T40061 with tool T40060 and finally tighten the bolts to 23 Nm. Repeat this procedure on the other cylinder head, if necessary.
35. Unscrew locking pin No. 3242 and check the timing adjustment again (go to paragraph 32).
36. Tighten the service hole plug in the upper section of the oil pan with a new gasket to 25 Nm.
37. Install the timing chain covers (see the relevant subsection above).
Removal and installation the timing chain
Attention:
- Do not rotate the crankshaft or camshafts when the timing belt is not fully installed.
- If you plan to reuse the chain, mark the front side with paint so that you can install the chain in the same way later (movement of the chain used in the opposite direction is not allowed).
38. Remove the lower timing chain cover (see the relevant subsection above).
39. Install the T40049 tool onto the rear of the crankshaft using two old drive plate mounting bolts (see illustration).
29.39. Turning the crankshaft.
Length of bolts (not counting the head) should not exceed 22 mm: use washers if necessary. Using this tool, turn the crankshaft to TDC (see paragraphs 23-24).
40. Wrap a 3.3mm drill bit with electrical tape to prevent cutting yourself on it. Press the tensioner bar in the direction of the arrow (see illustration) and lock the tensioner by inserting the prepared drill (1).
29.40. Fixing the timing chain tensioner.
Unscrew the guide pin (2) and remove the tensioner bar.
41. Unscrew the bolt (see illustration) chain slip protection.
29.41. Timing chain anti-slip protection bolt.
42. Remove the T40060 tool from both camshafts and unscrew the bolts (see illustrations 29.26a-b) and remove the camshaft sprockets together with the timing chain.
43. Follow the steps described in paragraphs 27-29.
44. Secure the tensioner bar with the guide pin (2 in illustration 29.40) and release the tensioner by removing the drill (1).
45. Loosen the bolts (2 in the illustration) and lock the balance shaft (3) with tool No. 3359 for fixing the fuel injection pump, as shown in the illustration. If necessary, unscrew the bolts and set the balance shaft to the desired position. Tighten the bolts (2) by hand so that the sprocket (1) can still be rotated on the shaft without axial displacement.
29.45. Fixing the balance shaft.
46. Ask an assistant to apply a force of 20 Nm to the right intake shaft sprocket in the direction of the arrow (see illustration 29.30) and simultaneously tighten the bolts (1 and 2) securing the sprocket with a torque of 23 Nm. After this, without releasing the sprocket of the right intake shaft, tighten the bolts (1 in illustration 29.29a) left intake shaft sprocket mounts.
47. Without releasing the sprocket of the right intake shaft, tighten the bolts (2 in illustration 39.45) fastening the sprocket (1) of the balance shaft (3) and remove tool No. 3359 from it. Release the sprocket of the right intake shaft, remove tools T40060 from the camshafts and tighten the remaining bolts fastening the camshaft sprockets with a force of 23 Nm.
48. Perform the steps described in paragraphs 31-37. In this case, use the T40049 tool to turn the crankshaft (see illustration 29.39).