| Removal and Installation | | 15‐030A Universal flange holding wrench | | | 21‐202 Spark plug socket | | | 21‐226 Pliers, spark plug connector | | | 21‐540 Angle gauge, bolt tightening | | Never‐Seeze | ESE‐M1244‐A | | Bolt M6 x 60 | | | Silicon grease | A960‐M1C171‐AA | Remove | 1. Standard Preparatory Measures. • Make a note of the radio keycode. • Make a note of the pre‐set radio stations. |  | CAUTION: Disconnect the battery negative cable. | | | | 2. Remove the upper part of the battery ‐ engine compartment divider (push fit). | | | 3. Remove the bulkhead cover. | | | 4. Pull out the headlamp cover. | | | 5. Remove the upper part of the air cleaner housing together with the intake pipe. 1. Disconnect the mass air flow (MAF) plug. 2. Unplug the intake air temperature (IAT) sensor. 3. Disconnect the intake hose from the inlet manifold (one clamp). 4. Undo the clips. | | | 6. Remove the lower part of the air cleaner housing (push fit). Pull off the breather tube. | | | 7. Lift the vehicle. 8. Remove the engine undershield (four bolts, two nuts) (right‐hand side shown). | | | 9. Slacken and remove the drive belt. 10. Lower the vehicle. | | | 11. Unplug the camshaft position (CMP) sensor. | | CAUTION: Do not pull on the lead when removing the spark plug connector. If necessary, disconnect the HT lead from the ignition coil to avoid bending the lead. Turn the spark plug connector slightly before removing it to loosen the seal. | | | CAUTION: Pull the spark plug connector off along the axis of the spark plug (for angled spark plug connectors use Special Tool 21‐226). | 12. Disconnect the spark plugs. 13. Pull the power supply rail off the fuel injectors and lay it to one side. Take off the rubber fittings. | | | 14. Support the engine with a jack under the sump. 15. Remove the front engine mounting bracket. 1. Two nuts. 2. Three bolts. | | | 16. Remove the front hydraulic engine mounting (three bolts). Take out the rubber bush. | | | 17. Remove the front bracket for the engine mounting plate. 1. Undo the bolt on the engine mounting plate. 2. Remove the stud. | | | 18. Detach the alternator bracket from the cylinder head and loosen the alternator. • Raise the engine until the alternator top bolt can be reached. 1. Remove the nut. 2. Remove the upper alternator bolt. • Move the alternator over towards the cylinder head. | | | |  | NOTE: Push the engine back and lift it, until the lower bolts of the engine mounting plate are accessible. | 19. Detach the engine support plate. | | | 20. Remove the cylinder head cover (11 bolts/four nuts). | | | 21. Remove the timing chain upper cover. | | | 22. Set the crankshaft to TDC. | | | 23. Detach the upper chain guide. | | | 24. Remove the camshaft sprockets. | | | | | CAUTION: Prevent the retaining washer from dropping down. | | | NOTE: Secure the timing chain. | 25. Remove the chain tensioner. 1. Pull off the retaining washer. 2. Withdraw the chain tensioner pivot bolt using an M6 x 60 bolt. | | | | | CAUTION: Do not reuse the chain tensioner hydraulic plunger. | 26. Pull out the chain tensioner hydraulic plunger. | | | | | NOTE: Keep the bearing caps, camshafts and hydraulic tappets in order. | | | NOTE: Take off the front bearing caps together with the chain guide bracket. | 27. Remove the camshafts and the hydraulic tappets. 28. Remove the spark plugs with Special Tool 21‐202. | Install | | | | NOTE: Renew gaskets, circlips and self‐locking nuts. | 29. Thoroughly clean all mating faces and reusable parts, and check them for damage. 30. Set the piston of cylinder no. 1 to 25 mm before TDC (the crankshaft vibration damper should be in the position shown in the diagram). | | | | | CAUTION: After fitting and tightening the camshaft the crankshaft must not be turned for 15 minutes. | 31. Install the camshafts. • Oil the bearings. 1. Coat the hydraulic tappets with engine oil and insert them. | | NOTE: R is intake side, L is exhaust side. | 2. Coat the camshafts with engine oil and fit them so that cylinder no. 1 is at TDC but none of the cams are at full lift. | | NOTE: Fit the front bearing caps together with the chain guide bracket. | 3. Fit the camshaft bearing caps. The position markings must be readable from the rear. | | | 32. Set the camshafts and the crankshaft to TDC. | | | | | CAUTION: Do not install partially or fully released hydraulic plungers (new or used). | 33. Check the new chain tensioner hydraulic plunger. 1. Hydraulic plunger, latched 2. Hydraulic plunger, partially released 3. Hydraulic plunger, fully released (detent ring is visible). | | | | | CAUTION: Only use a new, latched hydraulic plunger. | 34. Install the chain tensioner hydraulic plunger. | | | | | CAUTION: Make sure the retaining washer does not drop down. | 35. Install the chain tensioner. 1. Insert the pivot pin with an M6 x 60 bolt. 2. Insert the retaining washer. | | | | | NOTE: The timing chain must be tensioned on its long side. | | | CAUTION: The camshaft sprockets must locate in the slots on the camshaft. | 36. Lay the timing chain in place (in TDC position). • Move the camshaft sprockets and the timing chain into installation position. If necessary turn the camshaft slightly. • Tighten the camshaft sprocket bolts finger tight. | | | | | NOTE: The timing chain may hang down slightly between the sprockets. | 37. Lay the timing chain in place (in TDC position) (continued). | | | | | NOTE: If the hydraulic plunger does not reach the chain tensioner, release it with the aid of the auxiliary tool as described in the following operating step. | 38. Release the chain tensioner hydraulic plunger. Press the chain tensioner down by hand and release the plunger. | | | 39. Prepare a special tool. Use approximately 220 mm of 2,5 mm welding rod. | | | 40. Tighten the camshaft sprocket bolts. | | | | | NOTE: If it is necessary to correct the valve timing, i.e. to release the chain, fit a new hydraulic plunger as described in the preceding step. | 41. Check the valve timing • Turn the engine to the next TDC (one crankshaft revolution). • The marks on the camshaft sprockets must face one another exactly level with the upper edge of the cylinder head. | | | 42. Check the valve timing (continued). Turn the engine once more in the normal direction of rotation and set it to the timing marks. | | | 43. Fit a new upper chain guide to the bracket. | | | | | NOTE: Align the upper edge of the cover with the mating face of the cylinder head cover (the step downwards should be no greater than 0,13 mm). | 44. Install the upper timing chain cover (seven bolts). | | NOTE: Apply lubricant (ESE‐M1244‐A) to the spark plug threads. | 45. Fit the spark plugs with Special Tool 21‐202 and tighten them to 18 Nm. | | | | | NOTE: Use a new gasket. | | | NOTE: Tightening sequence. | 46. Fit the cylinder head cover (11 bolts, four nuts). | | | | | NOTE: Lean the alternator towards the cylinder head. | | | NOTE: Push the engine back and lift it, until the lower bolts of the engine mounting plate are accessible. | 47. Fit the engine support plate. | | | 48. Fit the alternator bracket to the cylinder head and fit the alternator. 1. Screw in the upper alternator bolt and tighten both bolts. 2. Fit the nut. • Lower the engine into installation position. | | | 49. Install the front engine mounting plate. 1. Screw in the stud. 2. Fit the bolt on the engine mounting plate. | | | 50. Fit the front hydraulic engine mounting (three bolts). | | | 51. Fit the front engine mounting bracket. 1. Two nuts. 2. Three bolts. | | | 52. Connect the power supply rail to the fuel injectors. Push on the rubber fittings. 53. Connect the CMP sensor multiplug. | | CAUTION: Use a blunt object (e.g. a plastic cable tie) to apply the silicon grease to avoid damaging the spark plug connector seal. | | | CAUTION: Push on the spark plug connector along the axis of the spark plug. | | | NOTE: Coat the inside of the spark plug connectors with silicon grease (A960‐M1C171‐AA) to a depth of 5‐10 mm. | 54. Push on the spark plug connectors. 55. Raise the vehicle. | | | | | NOTE: Drive belt routing in accordance with the following steps. | 56. Pre‐tension the drive belt tensioner and lay the drive belt in place. | Only vehicles without air‐conditioning. Only on vehicles equipped with air conditioning: | | 59. Lower the vehicle. 60. Fit the lower part of the air cleaner housing. 1. Retainers, lower part. • Press the lower part into the retainers. 2. Push on the breather hose. | | | 61. Fit the upper part of the air cleaner housing with the intake pipe. 1. Do up the clips. 2. Connect the intake hose to the inlet manifold (one clamp). 3. Push on the IAT sensor connector. 4. Connect the MAF plug. | | | 62. Fit the headlamp cover. | | | 63. Fit the bulkhead cover. | | | 64. Install the upper part of the battery ‐ engine compartment divider (push fit). 65. Connect the battery negative lead. 66. Finishing operations. • Check fluid levels and top up as necessary. • Secure the wiring and hoses with cable ties. • Check the engine and cooling system for leaks. • Raise the vehicle. | | | 67. Fit the engine undershield (four bolts, two nuts) (right‐hand side shown). 68. Standard finishing operations (continued). • Enter the radio keycode. • Reprogram the pre‐set radio stations. • Reset the clock. • Carry out a road test to enable the PCM (EEC V) to gather data. | |
