Special tools
- Camshaft holding tool – No.1.871.008.600.
- Camshaft locking tool x 2 – No.1.871.000.900.
- Crankshaft pulley holding tool 1 – No.1.871.000.200.
- Crankshaft pulley holding tool 2 – No.2.000.001.000.
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
- Removal/installation of timing chain requires:
- Sump removal.
- Remove blanking plugs from camshaft housing [1] .
- Install camshaft locking tools [2] .
- Flat sections on camshaft locking tool must be in horizontal position [3] .
- Turn crankshaft in direction of rotation until both camshaft locking tools are heard to engage.
- Insert a suitable pin in bell housing hole to lock crankshaft [4] .
- Compress timing chain tensioner and lock with pin [5] .
- Remove timing chain, crankshaft sprocket and camshaft sprocket as an assembly.
- Install timing chain, crankshaft sprocket and camshaft sprocket as an assembly.
- Remove tensioner locking pin [5] .
- Tighten camshaft sprocket bolt to 168±31 Nm.
NOTE: Crankshaft pulley hub bolt has LH thread.
- Remove camshaft gears as follows:
- Ensure camshaft locking tools correctly fitted [2] .
- Remove camshaft housing.
- Remove camshaft locking tools [2] .
- Slacken bolt of each camshaft gear [6] . Retain camshafts in position with camshaft holding tool.
- Remove camshafts and camshaft gears.
- Install camshaft gears as follows:
- Install camshafts and camshaft gears.
- Tighten bolt of each camshaft gear to 168±31 Nm [6] . Retain camshafts in position with camshaft holding tool.
- Install camshaft locking tools [2] .
- Flat sections on camshaft locking tool must be in horizontal position [3] .
- Install camshaft housing.