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Upper timing chain

Upper timing chain

To remove


1. Zero the engine, see Valve timing, checking steps 1-20. The crankshaft must be locked with adjustment tool 83 95 352.


2. Disconnect the fuel lines from the fuel distribution pump and move them to one side.

3. Dismantle the upper timing chain tensioner.


4. Dismantle the lower timing chain tensioner.

5. Remove all the inspection gauges.

6. Dismantle the camshaft gear using an open spanner in the hexagonal recess on the camshaft as a backstop.


7. Remove the camshaft gear and secure the chain so that it does not fall down.

8. Undo the four bolts on the fuel distribution pump sprocket and remove the sprocket.

Important

The centre nut must under no circumstances be undone.


9. Pull up the chain and remove it.


To fit


1. Position the new chain together with the fuel distribution pump sprocket and tighten the bolts on the sprocket by hand.

Important

The arrow on the sprocket must be aligned with the recess on the flange and the hole in the pump.



2. Fit the camshaft gear into the chain and position it on the camshaft.

3. Insert 83 95 337 Adjustment tool, fuel pump into the fuel distribution pump's recess.

4. Fit the chain tensioner for the lower timing chain with a new gasket.

Tightening torque: 60 Nm (44 lbf ft).


5. Remove the inspection gauge from the fuel distribution pump and tighten the bolts on the sprocket.

Tightening torque: 20 Nm (15 lbf ft).

6. Reposition the inspection gauge 83 95 337 in the recess on the fuel distribution pump.

7. Position inspection gauge 83 95 386 on the camshaft and cylinder head. The camshaft can be turned slightly if necessary with an open spanner in the hexagonal recess on the camshaft at the same time as the gauge is put into the correct position.


8. Make sure the camshaft gear runs freely on the camshaft and fit a new bolt. Tighten it by hand.

9. Mount the adapter for the Adjustment tool, timing chain 83 95 394 on the camshaft sprocket and mount the adjustment tool on the cylinder head.


10. Secure the position of the adapter on the camshaft gear by turning it slightly anticlockwise with a ratchet handle. Tighten the adjuster screw on the tool.

Important

Inspection gauge 83 95 337 must be easy to remove and fit the whole time. If this is not the case, the tool's adjuster screw can be loosened slightly.


11. Tighten the bolts on the camshaft gear.

Tightening torque 90 Nm (67 lbf ft) + 60°.

12. Fit the chain tensioner for the upper timing chain with a new gasket.

Tightening torque: 60 Nm (44 lbf ft).

13. Remove all tools and gauges.

14. Turn the crankshaft with the centre bolt on the pulley two revolutions until it reaches the mark for top dead centre in cylinder 1. Make sure both cams for cylinder 1 point upwards.


15. Insert 83 95 352 Adjustment tool, crankshaft into the hole for the crankshaft position sensor. Push the tool somewhat inward at the same time as turning the crankshaft to its zero point. The tool will then go into a recess in the crankshaft and lock it.

16. Make sure the marks on the crankshaft pulley and the timing cover are aligned. The arrow on the single cam chain sprocket on the fuel distribution pump must also be aligned with the recess in the pump.

17. Insert 83 95 337 Adjustment tool, fuel pump into the fuel distribution pump's recess.

18. Fit Adjustment tool, camshaft 83 95 386 to the camshaft and cylinder head.

19. Remove all the inspection gauges.

20. Cover the opening in the timing cover with a lint-free cloth and remove any remains from the old gasket from the sealing surface. Clean also the sealing surface on the pump cover.

21. Apply a string of silicone sealant about 2 mm thick to the pump cover, remove the cloth from the timing cover and fit the pump cover.

Tightening torque 6 Nm (4 lbf ft).


22. Fit the right-hand engine mounting bracket on the engine and tighten the engine mounting on the engine.

Tightening torque: 47 Nm (35 lbf ft).

23. Lower the engine and tighten the right-hand engine mounting.

Tightening torque: 47 Nm (35 lbf ft).

24. Raise the car and fit the crankshaft position sensor with a new O-ring.

Tightening torque: 8 Nm (6 lbf ft).

25. Apply Molycote 1000 to the studs on the turbocharger, position the front part of the exhaust pipe with a new gasket and mount new nuts.

26. Tighten the front exhaust pipe to the turbocharger.

Tightening torque 25 Nm (19 lbf ft)


27. Fit the belt tensioner, tightening the top bolt first.

Tightening torque: 42 Nm (31 lbf ft).

Tighten the bottom bolt.

Tightening torque: 23 Nm (17 lbf ft).


28. Fit the multigroove V-belt on all the pulleys. Relieve the tension on the belt tensioner by turning it anticlockwise (towards the rear of the car) with a 19 mm spanner and fit the belt on its pulley. Make sure the belt is positioned correctly on all the pulleys.

29. Refit the lower engine cover, the cover in the right-hand wheel housing and the wheel.

Tightening torque, wheels 110 Nm (81 lbf ft).

Lower the car to the floor.


30. Fit a new gasket on the vacuum pump and fit the pump together with the adapter.

Important

The vacuum pump must be fitted in the same position as it was previously.


Tightening torque: 8 Nm (6 lbf ft).

31. Connect the vacuum hose for the brake servo to the vacuum pump.

Tightening torque: 18 Nm (13 lbf ft).

Connect the vacuum hose to the bottom of the vacuum pump.

32. Clean off any gasket remains from the sealing surfaces.

33. Position a new gasket on the camshaft cover. There are sleeves on the bolts on which the gasket fits.

34. Apply sealing compound 87 81 841 to the sealing surface, see illustration.


35. Position the transmission cover on the cylinder head and tighten the bolts.

Tightening torque: 8 Nm (6 lbf ft).

36. Connect the fuel lines to the fuel pump and press the lines into their mountings. Fit the wiring harness duct to the cylinder head.


37. Refit the turbo delivery pipe with a new O-ring.

38. Refit the air cleaner with mass air flow sensor and hoses.


39. Connect the crankcase ventilation hose to the camshaft cover and refit the engine cover.