Removal and Replacement
Camshaft chain, replacing
Special tools:
999 7196 Counterhold 999 7196 Counterhold
999 7198 Press tool 999 7198 Press Tool
999 5304 SEPARATOR 999 5304 Separator
999 5716 Reading off tool 999 5716 Reading Off Tool
999 7070 Mounting 999 7070 Mounting
999 5460 Lifting hook 999 5460 Lifting Hook
999 7235 Position setter 999 7235 Position Setter
999 7236 Position setter 999 7236 Position Setter
Note! Since the illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Disconnect the battery negative cable. See: Battery, disconnecting Battery Disconnecting.
This work requires the car to be raised. See Jacking points, body Service and Repair.
Remove:
- the valve covers. See: Valve cover/gasket, replacing, B8444S Service and Repair
- the auxiliaries belt/tensioner acc. to: Auxiliaries belt/belt tensioner, replacement, B8444S Service and Repair
- the right front wheel.
Removal
Removing vibration damper
Remove the protective cover, 2 x nuts.
Push the protection towards the vibration damper.
Remove the center screw, use: 999 7196 Counterhold 999 7196 Counterhold
Install 999 7198 Press tool 999 7198 Press Tool in the center hole on the crankshaft.
Install 999 5304 Separator 999 5304 Separator on the vibration damper.
Pull off the vibration damper.
Detaching the generator (GEN)
Remove the front 1 x M8 screw.
Removing right engine pad
Remove the right-hand engine pad/bracket, See: Engine pad, right, replacement, B8444S Engine Pad, Right, Replacement Install tool: 999 5550 Supp. 999 5550 Supp. in the mounting hole in the oil sump.
Remove:
- 999 5716 Reading off tool 999 5716 Reading Off Tool , converted with: 999 7070 Mounting 999 7070 Mounting and 999 5460 Lifting hook 999 5460 Lifting Hook.
Remove the power steering pump, 3 x M8. Place the power steering pump to one side.
Note! Plug the connection.
Remove the screw and clamp for the power steering hose and place to one side.
Remove:
- the 4 x M6 screws
- the pulley for the water pump.
Remove:
- the engine bracket and idler pulley
- the idler pulley.
Remove:
- the 25 screws in the front cover
- the front cover. Discard the gaskets.
Note! cover the hole in oil pan using a piece of paper.
Initial setting, engine
Use position setting tool:999 7235 Position setter 999 7235 Position Setter to align the position on the crankshaft with the guide on the engine block.
Install position setting tool:999 7236 Position setter 999 7236 Position Setter.
Removing the camshaft chain
Remove the position setting tool: 999 7235 Position setter 999 7235 Position Setter.
Lock the chain tensioner using a drift.
Remove:
- the 2 x M6 screws for the chain tensioner
- the chain tensioner
- the 2 x rails
- the camshaft chain.
Installation
Note! For tightening torques, see Specifications, B8444S Tightening Torque
Installing the camshaft chain
Note! adjust the color marking on the camshaft chain to the marking on the gear.
Install:
- the camshaft chain
- both rails, 3 x M8. Tighten. See: Tightening torque, B8444S Tightening Torque.
- the chain tensioner, 2 x M6. Tighten, see: Tightening torque, B8444S Tightening Torque.
Remove the drift from the chain tensioner.
Minimize the slack of the chain by turning the crankshaft slightly.
Installing the front cover
Note! The front cover must be cleaned before installing. Use a razor blade or plastic scraper.
Apply liquid gasket 307 57050 as illustrated. The bead diameter must be greater than 1 mm.
Note! Install the front plate within 5 minutes. (curing time for liquid gasket).
Fold the front panel in at the lower edge.
Install:
- the 23 x M8 screws for the front side. Tighten, see: Tightening torque, B8444S Tightening Torque
- the 2 x M8 screws for the oil sump. Tighten, see: Tightening torque, B8444S Tightening Torque.
Install:
- the engine bracket and the idler pulley. Tighten. See: Tightening torque, B8444S Tightening Torque.
- the idler pulley. Tighten, see: Tightening torque, B8444S Tightening Torque.
Caution! The washer must be correctly installed.
Install:
- the pulley for the water pump
- the screws, 4 x M6. Tighten.
Install:
- the power steering pump
- the screws, 3 x M8. Tighten.
Install the clamp and the screw, 1 x M6, for the power steering hose. Tighten.
Install the front screw for the alternator, 1 x M8. Tighten.
Install lifting beam:
- 999 5716 Reading off tool 999 5716 Reading Off Tool , converted with: 999 7070 Mounting 999 7070 Mounting and 999 5460 Lifting hook 999 5460 Lifting Hook.
Remove tool:
- 999 5550 Supp. 999 5550 Supp..
Install the right-hand engine pad/bracket. See: Engine pad, right, replacement, B8444S Engine Pad, Right, Replacement.
Installing the vibration damper
Caution! The direction of cleaning should be around the flange.
Clean the surface for the sealing ring on the vibration damper with cloth 951 1024.
Note! If necessary, replace the front crankshaft seal. See: Crankshaft seal, front, replacing, B8444S, TF-80SC AWD Service and Repair
Install tool 999 7198 Press tool 999 7198 Press Tool in the center hole on the crankshaft
Install tool:
- 999 7196 Counterhold 999 7196 Counterhold
- drift: 999 7198 Press tool 999 7198 Press Tool and press in the vibration damper to its limit position using the old center screw
Remove:
- the center screw, discarded
- 999 7198 Press tool 999 7198 Press Tool
- 999 7198 Press tool 999 7198 Press Tool and 999 7198 Press tool 999 7198 Press Tool
Insert a new screw for the vibration damper and tighten. See Tightening torque, B8444S Tightening Torque
Remove tool: 999 7196 Counterhold 999 7196 Counterhold.
Install:
- Protective cover
- the nuts, x2, tighten.
Install:
- valve covers. See: Valve cover/gasket, replacing, B8444S Service and Repair
- the auxiliaries belt/tensioner acc. to: Auxiliaries belt/belt tensioner, replacement, B8444S Service and Repair
- right front wheel. See Installing wheels Service and Repair.
Finishing
Start the engine and run the engine to normal operating temperature. Check the function of the engine. Check for leakage. Fill with fluids if necessary.