Special tools
- Flywheel timing pin – No.303-698.
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
- Remove crankshaft position (CKP) sensor.
- Turn crankshaft clockwise to setting position.
NOTE: Engine at 50° before TDC on No.1 cylinder.
- Fit flywheel timing pin [1] .
- Ensure timing mark on each camshaft sprocket aligned at 12 o’clock position [2] & [3] .
- Insert 6 mm drill bits into camshaft sprockets [4] .
- Slacken bolts of each camshaft sprocket and high-pressure fuel pump sprocket bolts [5] & [6] .
- Lock timing chain tensioner in retracted position:
- Release pawl [7] .
- Push lock in [8] .
- Insert suitable pin to lock tensioner plunger [9] .
- Remove tensioner.
- Remove tensioner rail, chain guides and timing chain.
Installation
- Ensure flywheel timing pin inserted [1] .
NOTE: Engine at 50° before TDC on No.1 cylinder.
- Align copper coloured chain links with timing mark on each sprocket [2] , [3] & [10] .
- Ensure timing chain is taut between sprockets on non-tensioned side.
- Remove pin from tensioner [9] .
- Tighten bolts of each camshaft sprocket [5] . Tightening torque: 35 Nm.
- Tighten high-pressure fuel pump sprocket bolts [6] . Tightening torque: 33 Nm.
- Remove flywheel timing pin [1] .
- Remove 6 mm drill bits [4] .
- Turn crankshaft two turns clockwise.
- Fit flywheel timing pin [1] .
- Ensure 6 mm drill bits can be fitted [4] .
- If not, repeat timing chain installation.
- Remove flywheel timing pin [1] .
- Remove 6 mm drill bits [4] .
- Tighten crankshaft pulley bolts [11] . Tightening torque: 45 Nm + 90°.
NOTE: Crankshaft pulley bolts MUST only be used once.