Timing Chain: Service and Repair
Timing gear chains, replacementSpecial tools: 5703, 5712
Sprockets and strainers behind the chain tensioners must be replaced if chains are replaced.
Disconnect the battery ground lead
Drain coolant
Open drain cock on left-hand side of cylinder block. A hose can be connected to drain tap to assist in collecting coolant.
Remove:
- oil tube from oil cooler. Counterhold nipples on oil cooler to prevent them from loosening.
- electrical leads from thermal sensor on radiator.
- fan shroud from radiator.
- radiator + hoses.
- fan shroud.
Remove splash guard beneath engine
Loosen alternator and power steering pump drive belts
Remove power steering pump and bracket from engine
First remove pump and hang it up with a steel wire. The remove bracket.
Detach and move aside compressor
Remove:
- fan
- pulley + drive belts.
Remove left-hand valve cover
Remove:
- air intake duct
- vacuum pump
- valve cover
Remove right-hand valve cover
Remove:
- oil filler cap, place it on intake manifold
- control pressure regulator bolts (5 mm allen wrench). Place regulator on intake manifold
- connector for ignition system
- valve cover
Turn crankshaft to overlap position for no. 1 cylinder
Pulley mark 1 should be opposite 0-mark. Rocker arms for cylinder 1 should not have clearance.
Note: There are two marks on the pulley
1 = T.D.C. cyl 1 and 2 = T.D.C. cyl 6.
Lock the flywheel
Remove cover plate on left-hand side of transmission housing.
Install locking sector 5112 to ring gear at upper bolt.
Remove crankshaft pulley
Use 36 mm socket.
Take care that key on crankshaft does not fall down.
Remove locking sector 5112.
Remove timing gear cover
Move wiring harness on timing gear cover to one side.
Plug hole to oil pan with paper.
Loosen camshaft center bolt
Use 10 mm allen wrench.
If necessary, use a screwdriver to counterhold.
Loosen timing gear chains.
Turn each lock 1/4 turn counter-clockwise and push in the piston.
Remove:
- oil pump sprocket and chain
- chain tensioners and oil strainer
- bent and straight chain dampers
- camshaft sprockets and chains
Remove from crankshaft:
- outer sprocket
- spacer sleeve (early versions) and key
- inner sprocket and key
If necessary, use a puller.
Clean and check condition of chain tensioners and dampers
Caution! Do not disassemble tensioners. If lock falls out it will be necessary to replace tensioner.
Make sure that oil passages in tensioners are not blocked.
Make sure that dampers are not worn or damaged. If necessary install new parts.
Tap out timing gear cover seal
Clean gasket surfaces on:
- cylinder block
- timing gear cover
- valve covers
Use a plastic scraper.
Oil crankshaft, sprockets and spacer sleeve
Install:
- inner key
- inner sprocket. Note! The line on the sprocket should face outwards
- space sleeve (early versions)
- outer key
- outer sprocket
Install:
- new strainers in cylinder block
- chain tensioners
- straight chain dampers
- bent chain dampers. Apply locking fluid (P/N 116 1053-2) to bolts
Set crankshaft and left-hand camshaft
Key in crankshaft should point towards left-hand camshaft.
Groove in camshaft should point upwards and rocker arms for no.1 cyl. should not have clearance.
Install left-hand camshaft chain and sprocket
Place chain on camshaft sprocket, with mark on sprocket between the two marks on chain.
Place chain on inner crankshaft sprocket, with mark on chain opposite mark on sprocket.
Stretch chain on pulling side (side against straight chain damper).
Install camshaft sprocket. Make sure that camshaft sprocket fits in groove in camshaft.
Install center bolt.
Set crankshaft and right-hand camshaft
Install crankshaft nut. Turn crankshaft clockwise so that key points directly downwards.
Groove in camshaft should point outwards, (see fig.) and rockerarms for no.6cyl. should not have clearance.
Install right-hand camshaft chain and sprocket
Place chain on camshaft sprocket, with mark on sprocket between the two marks on chain.
Place chain on crankshaft sprocket, with mark on chain opposite mark on sprocket.
Stretch chain on pulling side (side against straight chain damper).
Install camshaft sprocket. Make sure that camshaft sprocket fits in groove in camshaft. If necessary rotate crankshaft slightly.
Install center bolt.
Tighten both camshafts center bolt
Tighten to a torque of 70-90 Nm (52-66 ft lb). Use a screwdriver to counterhold.
Turn locks 1/4 turn clockwise for both chain tensioners
Set chain tension
Turn crankshaft two revolutions.
Remove crankshaft nut.
Note! The key in the crankshaft should point upwards to prevent it falling out of its groove.
When the crankshaft has been rotated, the marks for the chains and sprockets do not coincide. It is necessary to rotate the crankshaft a larger number of turns to obtain the correct position
Install chain and sprocket for oil pump
Apply locking fluid (P/N 116 1053-2) to bolts.
Remove protective paper Install timing gear cover
Use new gasket.
Smear the four lower bolts for cover with locking fluid (P/N 116 1056-5).
Tightening torque 10-15 Nm (7-11 ft lb).
Clamp wiring harness to cover.
Fit "off-load" roller to timing gear cover.
Install new seal in timing gear cover
Grease the seal. Use drift 5103 for installation.
Install crankshaft pulley
Install locking sector 5112 to transmission housing at lower bolt.
Make sure that key does not fall out.
Use 36 mm socket.
Tighten to a torque of 240-280 Nm (177-207 ft lb).
Install cover plate to transmission housing
Remove locking sector 5112.
If necessary, adjust valve clearance.
Cut the gaskets for the timing gear cover
Cut the gaskets so that they are flush with cylinder block.
Install valve covers
Use new gaskets. Apply sealing agent (PIN 116 1026-8) to a few places to secure gaskets.
Tighten to a torque of 10-15 Nm (7-11 ft lb).
Install (right-hand side):
- connector for ignition system
- control pressure regulator (allen wrench 5 mm)
- oil filler cap
Close drain cock in left-hand side of cylinder block
Install (left-hand side):
- vacuum pump, use new gasket. Make sure that pump shaft is on top of camshaft
- air inlet duct
Install:
- pulley, drive belts and fan
- bracket and power steering pump. Install drive belt
- set belt tension
- splash guard
Install compressor
Set belt tension.
Install fan shroud and radiator
Move fan shroud over fan.
Install radiator and secure fan shroud and fluid reservoir for power steering.
Connect oil tubes to oil cooler. Counterhold the nipples on the cooler to prevent damage.
Reconnect leads to thermal contact on radiator.
Reconnect all hoses.
Reconnect battery ground lead
Fill with coolant. Warm-up engine and check function
Top-up with coolant if necessary.
Check/adjust:
- ignition timing
- idle speed and CO content
Specifications:
