Contents: Removal camshafts, timing phase…⬇ Installing camshafts ⬇ Installing camshaft adjusters and…⬇ Installing the timing chain and…⬇ Removal/installation of timing valves ⬇
1. The details of the installation of the gas distribution mechanism, its drive and the housing of the adjustment of the timing phases are shown in the accompanying illustrations. When turning the engine, the camshaft phase adjusters must be installed and the chain must be put on them.
11.1a Timing Belt Parts
1 Intake camshaft
2 Camshaft Caps
3 Exhaust camshaft
4 Nut, 5 Nm, then tighten to an angle of 45°
5 Sealing rings, if there is a leak, replace the entire set, when installing the housing 6 lubricate the mating surfaces of the sealing rings, when replacing do not stretch the rings beyond the limit
6 Timing phase adjustment housing
7 Bolt, 8 Nm, installed on fixing sealant D000 600A2
8 Shaft phase regulator 3, marked "32A"
9 Shaft phase regulator 1, marked "24E"
10 Bolt, to be replaced, 60 Nm, then tighten to an angle of 90°; when tightening, the mating surfaces of the adjuster and bolt must be dry
11 Cylinder head height (a - not less than 139.9 mm)
12 Fuel injection pump drive sprocket
13 Bearing shaft, lubricate before assembly
14 Valves, processing (except for grinding) not allowed; exhaust - sodium filled
15 Centering sleeve
16 Cylinder head
17 Fuel injection pump pusher
18 Hydraulic valve clearance compensator
19 Oil deflector cap
20 Timing chain
21 Fixer
22 Rocker
23 Valve spring
24 Valve spring plate
25 Split valve lock crackers
11.1b Timing Phase Adjustment Housing Installation Details
1 Chain guide, fixed to body 2
2 Timing phase adjustment housing, lubricate the mating surfaces of the sealing rings before installation
3 Bolt, 8 Nm, installed on fixing sealant D000 600A2
4 Bolt, 3.8 Nm
5 Valve No.1 for adjusting the phases of the intake shaft ("N₂05")
6 Valve No.1 for adjusting the phases of the exhaust shaft ("N318")
11.1c Timing drive and oil pump installation details
1 Timing phase adjustment housing
2 Bolt, 8 Nm, screwed in with fixing sealant D000 600A2
3 Timing chain
4 Exhaust shaft phase regulator
5 Sealing ring, subject to replacement
6 Oil pump
7 Bolt, 8 Nm, subject to replacement
8 Chain tension bar 3
9 Chain tensioner 3, 50 Nm, crank the engine only with the tensioner installed
10 Sealing ring
11 Axial bolt of the bar 8, 10 Nm
12 Sprocket for chain 17
13 Sprocket for chain 3
14 Bolt grade 10.9, to be replaced, 60 Nm, then tighten to 90° angle
15 Tensioner (with bar) of chain 17; crank the engine only with the tensioner installed
16 Crankshaft sprocket
17 Oil pump drive chain
18 Chain guide bar 17
19 Bolt without bushing, for bar 18, 10 Nm
20 Bolt, 10 Nm
21 Bolt, 23 Nm
22 Bolt, to be replaced, 60 Nm, then tighten to an angle of 90°, when tightening the mating surfaces must be dry
23 Chain guide bar 3
24 Fuel injection pump drive sprocket
25 Intake shaft phase regulator
26 Valve No.1 for adjusting the phases of the exhaust shaft ("N318")
27 Valve No.1 for adjusting the phases of the intake shaft ("N₂05")
28 Chain guide bar 3, fixed to housing 1
Removal camshafts, timing phase adjusters and drive chains
2. Remove the air duct and air cleaner with the connecting hose going to the throttle body assembly (see Chapter 4).
3. Remove the upper part of the intake manifold (see Chapter 4).
4. Remove the cylinder head cover (see Section 9).
5. Remember or mark the wiring connections and disconnect the connectors shown in Illustration 9.25. Release the wiring.
6. Remove the vacuum pump (see Section 9).
7. Loosen the fasteners of the upper and lower coolant pipes on the upper timing chain cover, and then unscrew the bolts (see illustration 9.31) and remove the top cover. Cover the opening of the lower timing chain cover with a clean cloth to prevent any parts from falling into it.
8. Turn the crankshaft with support T10172 clockwise until the TDC marks are aligned (see illustration 9.29a) and insert the T10068A template into the slots in both camshafts (see illustration 9.45).
9. Fix the position of the fuel injection pump drive sprocket using the T10363 device (see accompanying illustration). In this case, the mark (A) on the fuel injection pump hub should be facing upwards.
11.9 Fixing the position of the fuel injection pump drive sprocket
Note: If the vacuum pump drive stud is not vertical, remove the T10068A template and rotate the crankshaft until the stud is vertical and the template can be installed.
10. Unscrew the timing chain tensioner (see illustration 9.30).
11. When tightening/loosening the timing adjusters, hold the camshafts with an open-end wrench SW27 (see illustration 9.32), in this case, the T10068A template should not be installed.
12. Remove the bolts (1 and 2 in illustration 9.33) fasteners of the timing phase regulators and remove both regulators.
13. Remove 4 bolts (1 in illustration 9.35) from the timing phase adjustment housing (2) and remove it from the shafts in the direction of the arrow.
14. For the intake shaft (And on the accompanying illustration) remove its covers in the sequence 1-13-3-11-7, and then loosen cover mounting bolts No.5 and No.9 in a cross pattern and remove them. For the exhaust shaft (B), remove its covers in the sequence 2-14-4-12-8, and then loosen cover mounting bolts No.6 and No.10 in a cross pattern and remove them.
11.14 Inlet (A) and outlet (B) camshafts and their covers
15. Carefully lift the camshafts and set them aside on a clean surface. Remove the rocker arms together with the hydraulic compensators and set them aside on a clean surface so that they can then be installed in their original positions.
Installing camshafts
16. Apply to the mating surfaces of covers No.7 and No.8 (see accompanying illustration) lubricating paste G052 723A2.
11.16 Camshaft cover mating surface
17. Make sure that all rocker arms are correctly positioned on the ends of the valves and fixed on the hydraulic compensators. Lubricate the mating surfaces of the camshafts and place them in the cylinder head. The shafts can be identified by the marks between the pairs of cams for cylinders 4 and 5: the exhaust shaft is marked "OZN 101", and the intake shaft is marked "OZN 102". The camshaft cams for cylinder No.1 should be facing each other (see Figure 9.29).
18. Install the camshaft bearing caps so that their protrusions (And on the accompanying illustration) were facing outward. For the intake shaft (And in illustration 11.14) tighten the bolts of its covers No.5 and No.9 in a cross pattern with a force of 5 Nm, and then tighten them to an angle of 45°. Then tighten the fasteners of covers 1-13-7-3-11 in the same way. For the exhaust shaft (B), tighten the bolts of its covers No.6 and No.14 in a cross pattern with a force of 5 Nm, and then tighten them to an angle of 45°. Then tighten the fasteners of covers 2-14-8-4-12 in the same way.
11.18 Installation position of the camshaft cover
19. Insert the T10068A template into the slots in both camshafts (see illustration 9.45).
20. Unhook the oil pick-up (2 on the accompanying illustration) from the rear side of the camshaft adjustment housing (1) and remove any dirt. Install the oil intake manifold in place. Lubricate the camshaft sealing rings. Lubricate the mating surface with the sealing rings in the camshaft adjustment housing and slowly push the housing over the sealing rings into the installation position.
11.20 Timing phase adjustment housing oil intake
21. Apply to bolts (see accompanying illustration) fastenings of the timing phase adjustment housing with fixing sealant D000 600A2 and tighten them with a force of 8 Nm.
11.21 Timing phase adjustment housing mounting bolts
22. Install the timing chain adjusters with the timing chain (see subsection below).
23. Clean the mating surfaces on the upper timing chain cover and on the cylinder head from old sealant using a suitable chemical agent. If necessary, replace the O-rings in the upper timing chain cover.
Note: Install new O-rings without lubrication.
Degrease the specified mating surfaces, apply D176 501A1 sealant to the upper chain cover, immediately install the cover, tighten all bolts (see illustration 9.31) its fasteners by hand, and then tighten with a force of 8 Nm.
24. Tighten the timing chain tensioner to 50 Nm.
25. Install the vacuum pump and cylinder head cover (see Section 9).
26. Install the upper part of the intake manifold (see Chapter 4).
Installing camshaft adjusters and timing chain
27. Turn the crankshaft with support T10172 clockwise until the TDC marks are aligned (see illustration 9.29a). In this case, the camshaft cams for cylinder No.1 must be facing each other (see illustration 9.29b).
28. Insert the T10068A template into the slots in both camshafts (see illustration 9.45).
29. Fix the position of the fuel injection pump drive sprocket using the T10363 device (see illustration 11.9). In this case, the mark (A) on the fuel injection pump hub should be facing upwards.
30. Thanks to the presence of pins (see accompanying illustration), regulators can only be installed on shafts in one position.
11.30 Centering pins of camshaft adjusters
31. First install the intake camshaft timing adjuster with the timing chain on it. The timing chain to the fuel injection pump drive gear should not sag; when the timing chain is laid with tension, the regulator should be easy to install and tighten by hand. The arrow on the regulator "24E" should be aligned with the right mark on the timing phase adjustment housing (see illustrations 10.5a-b)
32. Count 16 timing chain rollers to the right, starting from the sprocket tooth that is opposite the "24E" arrow, and mark the 16th roller with a colored pencil (see illustration 10.6).
33. The timing phase adjusters are locked in the idle state, i.e. when setting the timing phases, the rotor does not turn. If the adjusters are not locked, turn them in both directions until they lock. If you cannot lock the adjusters, replace them.
34. Connect the "32A" regulator to the timing chain so that the 16 rollers counted earlier are located between the "24E" and "32A" arrows of the regulators. Install the "32A" regulator with the timing chain on the exhaust shaft. The "32A" arrow on the regulator must be aligned with the right mark on the timing phase adjustment housing (see illustrations 10.5a-b). The regulator should be easy to install and tighten by hand.
Note: A slight deviation of the arrow on the regulator from the mark on the body is allowed.
35. Remove tools T10363 and T10068A. Tighten the timing chain tensioner to 50 Nm.
36. Turn the crankshaft 2 revolutions and make sure that the arrows on the adjusters match the marks on the timing phase adjustment housing (see illustrations 10.5a-b).
37. Hold the corresponding camshaft by the flats with an open-end wrench (see illustration 9.32) tighten the new adjuster bolts to 60 Nm and then tighten them to a 90° angle.
38. Install the lower timing chain cover (see Section 8).
Installing the timing chain and crankshaft chain (oil pump drive)
39. Installation is performed with the following parts removed: flywheel, engine oil pan, lower timing chain cover and cylinder head. Depending on the degree of engine disassembly, adjustment may begin from the appropriate position. The oil pan is installed only after the lower timing chain cover has been installed.
40. Set the crankshaft to the TDC position of piston No.1. In this case, the beveled tooth of the crankshaft sprocket (see accompanying illustration) should be positioned at the joint level. Tighten both guide bar axle bolts to 10 Nm and slide the bar onto them.
11.40 TDC position
41. Install the shaft (1 on the accompanying illustration) oil pump so that the chamfer (arrow) is horizontal and opposite the mark (2). Place the crankshaft chain on the guide and place it on the crankshaft. Install the used chain so that its direction of movement is the same.
11.41 Position of the oil pump shaft
42. Insert the large sprocket into the chain so that the mark on the sprocket is opposite the mark located behind on the cylinder block (arrow B in the accompanying illustration). Install the sprocket onto the oil pump shaft. If the sprocket cannot be installed, rotate the oil pump slightly. Make sure that the chamfered tooth (A) is aligned with the joint and that the mark on the sprocket is opposite the mark (B) on the cylinder block.
11.42 Crankshaft chain timing marks
43. Install the crankshaft chain tensioner. To do this, first loosen the locking tooth in the tensioner using a small screwdriver and press the bar away from the tensioner (see accompanying illustration). Then install the tensioner with the bar pressed down and tighten the bolts (see illustration 13.13) its fastening with a force of 8 Nm.
11.43 Pressing the bar away from the tensioner
44. If the cylinder head is removed, install it. Insert the T10068A template into the slots in both camshafts (see illustration 9.45). Route the timing chain from above through the opening in the cylinder head or in the cylinder head gasket. Insert the small sprocket with the chain installed on it into the cutout (see accompanying illustration) and tighten the sprocket fastener by hand.
11.44 Installing the small sprocket
45. Holding the crankshaft from turning with the counter support T10172 (see illustration 7.4). tighten the new bolt of both sprockets on the oil pump shaft to 60 Nm, then tighten to an angle of 90°.
Note: Use only grade 10.9 bolt. Insert guide (2 on the accompanying illustration) through the opening in the cylinder head and tighten its bolts (1 and 3). Insert the guide (4) and tighten its bolt (5).
11.45 Fastening the timing chain guide strips
46. Insert an asterisk (1 on the accompanying illustration) fuel injection pump drive together with the chain put on it with the groove (arrow) facing up. Make sure that the chain sits tightly on the sprocket.
11.46 Installing the fuel injection pump sprocket
47. Lubricate the vacuum pump shaft (4 in illustration 9.33) clean engine oil and push it in together with the sleeve (5).
48. Fix the position of the fuel injection pump drive sprocket using the T10363 device (see accompanying illustration). In this case, the mark (A) on the fuel injection pump hub should be facing upwards.
49. Install the camshaft adjusters (see subsection above).
Removal/installation of timing valves
50. Remove the air duct and air cleaner (see Chapter 4).
51. Remember or mark the wiring connections and disconnect the connectors shown in Illustration 9.25. Release the wiring.
52. Remove the vacuum pump (see Section 9).
53. Completely unscrew the three outer bolts securing the cylinder head cover (12-14 in Illustration 9.6).
54. Loosen the fasteners of the upper and lower coolant pipes on the upper timing chain cover.
55. Give away the fasteners (arrows in the accompanying illustration) and remove the upper timing chain cover. Cover the opening of the lower timing chain cover with a clean cloth to prevent any parts from falling into it.
11.55 Fastening the upper timing chain cover
56. Remove the bolts (see accompanying illustration) tighten the valves 5 turns, pull the valves out to the bolts, then completely unscrew the bolts and remove the valves. Do not subject the valves to vibration.
11.56 Timing phase adjustment valve mounting bolts
57. Make sure that there are no scratches or dirt on the valves or their seating surfaces in the timing adjustment housing. Install the valves into the housing by pressing them evenly by hand until they stop. Tighten the valve mounting bolts to 3.8 Nm.
58. Clean the sealing surfaces of the upper timing chain cover and the cylinder head from old sealing materials using a suitable chemical agent. If necessary, replace the sealing rings in the upper timing chain cover.
59. Make sure the gasket (arrows in the accompanying illustration) fits correctly to the cylinder head cover. If necessary, remove any remaining sealant at points (A). Clean the mating surfaces from grease. Apply a thin bead of D176 501A1 sealant to the clean mating surface of the upper timing chain cover.
11.59 Cylinder head cover gasket
60. Apply a small amount of D454 300A2 sealant to the areas of the upper timing chain cover shown in Illustration 9.7.
61. Slide the slightly inclined upper timing chain cover onto the timing valves. Do not allow the cylinder head cover gasket to move back. First, push the cover upwards (1 on the accompanying illustration) under the cylinder head cover gasket, and then slide the cover onto the centering pins in the direction of the arrow (2).
11.61 Installing the upper timing chain cover
62. Again, check that the cylinder head cover gasket is correctly positioned: it should not be shifted backwards.
63. Tighten the upper timing chain cover mounting bolts by hand, then tighten them to 8 Nm.
64. Tighten the three outer cylinder head cover mounting bolts (12-14 in Illustration 9.6) with a force of 10 Nm.
65. Install the vacuum pump.
66. Install the remaining parts in the reverse order of removal.