Removal
1. Disconnect the intake pipe 1 from the throttle body. Unscrew the spark plug protective cover 2 (figure 2.24).
Figure 2.24. Disconnect intake pipe 1 from the throttle body. Unscrew the spark plug protective cover 2.
2. Remove the spark plugs using the 3122 B spark plug wrench (figure 2.25).
3. Remove the cylinder head cover.
4. Disconnect the coolant pipes from the thermostat housing.
Caution! Make sure that the oil seal (arrow) does not fall out when removing the upper timing cover (figure 2.26).
5. Disconnect the upper cover of the distribution mechanism.
6. Loosen the camshaft pulley mounting bolts.
Figure 2.25. Remove the spark plugs using the 3122 B spark plug wrench.
Figure 2.26. Make sure that the oil seal (arrow) does not fall out when removing the upper timing cover.
7. Set the crankshaft to 20° after TDC (figure 2.18).
8. Remove the timing chain tensioner.
9. Unscrew the mounting bolts and remove the upper damper bar 1 (figure 2.27).
Figure 2.27. Unscrew the mounting bolts and remove the upper damper bar 1.
10. Lock the camshafts through the inspection holes using locking pins 3436 (figure 2.19).
11. Secure the camshaft drive chain 1 using mounting wedges 3409 in the cylinder head 3. Cover the timing mechanism with a rag 4 (figure 2.28). Turn down both chain rollers on camshaft drive chain link 2.
12. Remove the outer cover 1, the middle cover 2 and the chain link 3 (figure 2.29).
Figure 2.28. Secure the camshaft drive chain 1 using mounting wedges 3409 in the cylinder head 3. Cover the timing mechanism with a cloth 4. Grind down both chain rollers on the camshaft drive chain link 2.
Figure 2.29. Remove outer cover 1, middle cover 2 and chain link 3.
13. Attach the new drive chain with chain link 1 to the old chain 2 (figure 2.30). Remove mounting blades 3409. Unscrew the camshaft pulley mounting bolts 3
Figure 2.30. Attach the new drive chain with chain link 1 to the old chain 2. Remove mounting wedges 3409. Unscrew the camshaft pulley mounting bolts 3.
14. Replace the drive chain by slowly rotating the crankshaft in the direction of its rotation.
15. Set the crankshaft to 20' after TDC (figure 2.18).
16. Remove the old chain.
17. Lock the camshafts using locking pins 3436 (figure 2.19). Install camshaft gears 1.
18. Install the chain on the camshaft gears 3 and install a new chain link 2 with a new middle lining 1 (figure 2.31). Tighten the camshaft gear mounting bolts 3 in two stages: stage I = 20 Nm; stage II = 1/4 turn (90°).
Figure 2.31. Install the chain on the camshaft gears 3 and install a new chain link 2 with a new middle lining 1.
Tighten the camshaft gear mounting bolts 3 in two stages.
19. Insert the new outer cover plate 1 into the rivet tool 3442 (arrow) (figure 2.32).
Figure 2.32. Insert the new outer cover plate 1 into the riveting tool 3442 (arrow).
20. Install the 3442 rivet tool onto the chain link and press the outer plate until it stops (figure 2.33).
21. Install the punch (arrow) of the rivet tool 3442 as shown in the figure 2.34.
22. Install the 3442 riveting tool onto the chain link and rivet the chain pins individually.
Spindle tightening torque: 35 Nm.
23. Visually inspect the chain pin rivets and re-rivet them if necessary.
Figure 2.33. Install riveting tool 3442 on the chain link and press the outer plate until it stops.
Figure 2.34. Install the punch of rivet tool 3442 (arrow) as shown in the figure.
24. Remove camshaft locking tool 3436.
25. Check the valve timing.
26. Tighten the upper damper bar 1 (figure 2.27).
Tightening torque: 10 Nm.
27. Install the timing chain tensioner.
28. Install the upper timing cover.
29. Screw in the spark plugs. Tightening torque: 25 Nm.
30. Install the control head cover.
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