Main Repair Instructions Reassembly
With all sealing surfaces clean and in perfect condition, install new chain port gaskets. Match gaskets to cylinder head gaskets per hole code (arrows).
Note the hole code identification.
(1 hole or 2 holes as indicated by the cylinder head gasket)
The gaskets between the cylinder head and timing case are symmetrical. Install the graphite coated side toward the cylinder heads. "Tack" to the cylinder heads in several places with "Curil K2".
Install timing case (new or reused, depending on the chassis number) and hand tighten 6 mm bolts into the cylinder heads. Install the 3 new self-sealing (micro-encapsulated) bolts (arrows) into the lower timing case and tighten to specifications. Tighten bolts in cylinder head to specification in a criss-cross even pattern.
Tightening torque: 10 N-m (7 ft.lbs.).
NOTE As previously mentioned, if self-sealing bolts are unavailable, use blue Loctite(R) to seal regular bolts supplied in the gasket kit.
Reinstall right bank camshaft and verify correct timing. Dowel pins (or drillings) face inside. Install cam journal bearing caps. Tighten to specification evenly from the center to each end position.
Tightening torque: 15 N-m (11 ft.lbs.).
Reinstall oiler line with spray holes toward camshaft. If the assembly has only one hollow bolt, it must be installed in the No. 3 bearing cap as that camshaft journal has an annular groove (arrow) for the oil pipe supply. Always use new bolt sealing washers (P/N 07 11 9 963 041).
Secure both camshafts in position with tool 11 3 190.
Begin timing chain installation at the crankshaft and work in the opposite direction of rotation. Attach the left and right cam sprockets so that near equal adjustment travel is provided in the slotted bolt holes. Install the sprocket bolts "hand tight".
Attach chain guide rail and install chain adjuster with new sealing ring. Tighten 6 mm sprocket bolts (arrows) to specification.
Tightening torque: 10 N-m (7 ft.lbs.).
Remove flywheel locating pin and camshaft positioners.
Rotate the engine once by hand and recheck the cam timing. If necessary, reinstall special tools and readjust.
Reinstall lower chainguide with single bolt and lower tab interlock. (Note latching tabs (arrow). This view is not visible with lower cover In place.)
1 Adjusting screw
2 Lock nut
3 Screw plug
4 Sealing ring (renew)
5 Compression sprlng
6 Tensioning piston
Tightening torque for screw plug: 40 N-m (29 ft.lbs.).
CAUTION Cylindrical end of the spring must face towards the piston.
Adjust chain tensioner.
- Loosen adjusting screw until it no longer makes contact.
- Rotate engine once by hand in the normal direction of rotation.
- Measure dimension A.
- Press tensioning rail against spring force to maximum travel point and measure dimension B.
- Adjust nominal value to specifications with adjusting screw and firmly tighten locknut. Install new anti-tamper cap.
Nominal value = A - B = 6 + 0.5 mm.
Reinstall rocker arms with tool 11 3 180.
Use previously stated removal step (page 4) in reverse order and review Special Notes.
Seal the joining edges of the timing case/cover and the oval gasket hole to the lower case with "3 bond 1207 black" sealant. Do not overapply.
Attach paper gaskets with the graphite sides toward the timing case. Use a small amount of "Curil K2" to locate gaskets.
Install timing case cover/case bolts "hand tight".
Tighten timing case cover/lower cover bolts (arrows) to specification in a 1.2.3 sequence.
Tighten cover/case bolts to speciflcations.
Tightening torque: 10 N-m (7 ft.lbs.).