Special tools
- Camshaft locking pin x 2 – No.T40060.
- Crankshaft alignment tool – No.T40049.
- Crankshaft locking pin – No.3242.
- Crankshaft pulley alignment tool – No.T40058
- Injection pump/balancer shaft locking pin – No.3359.
General precautions
- Disconnect battery earth lead.
- Remove glow plugs to ease turning engine.
- Turn engine in normal direction of rotation (unless otherwise stated).
- Observe tightening torques.
- If fitted: Mark position of crankshaft position (CKP) sensor before removal.
- Do NOT turn crankshaft via camshaft or other sprockets.
- Do NOT turn crankshaft or camshaft with timing chain removed.
Valve timing procedures
- Timing chains located at rear of engine.
- Removal/installation of timing chain(s) requires:
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- Sump removal.
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- Gearbox/drive plate removal.
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- Turn crankshaft until just before TDC on No.1 cylinder. Tool No.T40049.
- Remove blanking plug from sump [1] .
- Slowly turn crankshaft pulley clockwise until locking pin can be inserted in crankshaft [2] . Tool No.3242.
- Remove timing chain LH & RH upper covers [3] & [4] .
- Remove the camshaft sprocket bolt positioned at 5 o’clock on RH camshaft sprocket [5] .
- Remove the camshaft sprocket bolt positioned at 7 o’clock on LH camshaft sprocket [6] .
- Ensure balancer shaft can be locked in position [7] . Tool No.3359.
- Ensure both camshafts can be locked in position [8] . Tool No.T40060.
NOTE: If camshaft locking pins cannot be fitted valve timing is incorrect.
- Lock timing chain tensioners in retracted position before carrying out engine repairs:
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- Push plunger into tensioner housing [9] .
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- Insert 3,3 mm pin to lock tensioner plunger [10] .
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NOTE: Upper chain tensioner bolts MUST only be used once.
- If necessary, slacken bolts of each camshaft sprocket 1 turn [11] .
- Rotate camshaft until camshaft locking pin can be fitted [8] . Tool No.T40060.
- Rotate camshaft locking pin to alignment position [12] . Tool No.T40060.
NOTE: The side pin of camshaft locking pin must be in line with centre of camshaft sprocket.
- Ensure threaded holes positioned centrally in slots of camshaft sprocket and balancer shaft sprocket [13] & [14] .
NOTE: Camshaft sprocket bolts MUST only be used once.
- Tighten camshaft sprocket bolts to 5 Nm [11] .
- Remove camshaft locking pins [8] & [12] . Tool No.T40060.
- Tighten camshaft sprocket bolts to 23 Nm [11] .
- Remove crankshaft locking pin [2] . Tool No.3242.
- Release timing chain tensioner after repairs [10] .
- Install blanking plug [1] .