Special tools
- Crankshaft pulley locking tool – No.MOT.1789.
- Flywheel locking tool – No.MOT.919-02.
- Timing chain cover removal tool – No.MOT.1716.
General precautions
- Disconnect battery earth lead.
- Remove spark 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
Removal
- Removal/installation of timing chain requires:
- Engine/transmission removal.
- Engine at TDC on No.1 cylinder.
- Ensure crankshaft sprocket timing mark at 6 o’clock position [1] .
- Ensure timing marks on each camshaft sprocket aligned with timing marks on cylinder head [2] .
- Fit flywheel locking tool [3] .
- Lock timing chain tensioner in retracted position:
- Depress tensioner rail [4] .
- Insert suitable pin to lock tensioner plunger [5] .
- Remove timing chain tensioner, tensioner rail and chain guide.
- Remove timing chain.
Installation
- Ensure crankshaft sprocket timing mark at 6 o’clock position [1] .
- Ensure timing marks on each camshaft sprocket aligned with timing marks on cylinder head [2] .
- Install timing chain.
- Ensure coloured or painted chain links aligned with timing marks on each camshaft sprocket and crankshaft sprocket [6] & [7] .
- Install timing chain tensioner, tensioner rail and chain guide.
- To release tensioner plunger after installation:
- Remove locking pin [5] .
- Remove flywheel locking tool [3] .
- Turn crankshaft two turns clockwise to No.1 cylinder at TDC.
- Ensure crankshaft sprocket timing mark at 6 o’clock position [1] .
- Ensure timing marks on each camshaft sprocket aligned with timing marks on cylinder head [2] .
- Tighten new crankshaft pulley bolt as follows [8] :
- Tighten crankshaft pulley bolt to 68 Nm.
- Slacken crankshaft pulley bolt.
- Tighten crankshaft pulley bolt to 30 Nm + 60°.
NOTE: DO NOT start engine without auxiliary drive belt fitted as damage may occur to crankshaft pulley.