NOTE: Install timing chains. These assembly operations can only be carried out on a removed engine.
Work order
ATTENTION: For any installation work, in particular in the engine compartment due to the dense layout, the following must be taken into account: lines of all types (e.g. fuel, hydraulic, activated charcoal absorber, cooling systems, air conditioning circuits, brake lines, vacuum hoses), as well as electrical wires must be laid as they were originally laid. Provide free space for all moving and hot components.
NOTE: Camshaft timing chains can only be removed with the engine removed. The following operations begin with the engine disassembled. Thus, it is possible to start the adjustment from the appropriate place, depending on how disassembled the engine is.
Install roller chain and countershaft chain tensioner with tensioner.
Adjust the position of the crankshaft in relation to the intermediate shaft. To do this, the ground tooth of the drive sprocket B must coincide with the joint of the bearing «TDC cylinder 1» (pic. 2.70).
Install both flangeless bolts for fastening the guide rail 2 and tighten them to a torque of 10 Nm.
NOTE: If a roller chain has been used before, the specified direction of rotation must be taken into account.
Fit guide bar 2 with roller chain 1 and both chain sprockets 3 and 4. Marking on roller chain sprocket 4 must be aligned with notch C or D on intermediate shaft shim (pic. 2.70).
When installing, make sure that the roller moves inside the guide plate from the crankshaft to the intermediate shaft without any sagging.
Screw chain sprockets 3 and 4 onto the intermediate shaft by hand.
NOTE: Please note that all sprocket mounting bolts must be replaced.
Install the chain tensioner on the opposite side.
Unlock the locking gear of chain tensioner A with a small screwdriver and press the tensioning bar against the chain tensioner.
Install the chain tensioner in this position and tighten it with a torque of 8 Nm.
Lock the vibration damper with the T10069 locking key.
Tighten the new fastening bolt of sprockets 3 and 4 for the intermediate shaft chain drive to a tightening torque of 60 Nm + 1/4 rev. (90°).
Remove counterholder T10069.
Recheck the position of crankshaft B in relation to intermediate shaft C or D (pic. 2.70).
Bring the engine back to TDC cyl. 1.
Install the camshaft drive roller chain.
Bring the installed camshafts in the cylinder head to TDC cyl. 1.
NOTE: If necessary, turn the camshafts with wrench 32 to the correct position.
NOTE: The T10068A camshaft ruler must not be inserted into the grooves.
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