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Timing Case, Remove and Install

Note:   Note differing designs! New components for DOHC-0-petrol engines:


TN 2004 - New components in MY 2004 LUREF_1.gif

  • TN 2005 - Camshaft control from end of MY 2004 to MY 2005 LUREF_1.gif
  • TN 2005 - Camshaft control from MY 2005 LUREF_1.gif
  • TN 2005 Adjusting the phase sensor disc LUREF_1.gif
  • TN - 2005 Camshaft sensor
  • TN 2005 - Timing case
  • TN 2005 - Timing chain tensioner LUREF_1.gif

Note:   The timing case must be removed and installed for the operations listed in the following:

1

Timing Chain, Remove and Install

 

 

2

Guide Rails, Remove and Install

 

 

3

Crankshaft Sprocket, Remove and Install

 

 

4

Oil Pump, Remove and Install

 

 

5

Tension Rail, Remove and Install

 

 

6

Timing Case Gasket, Replace

 

 

7

Chain Tensioner, Remove and Install


Object Number: 2398427  Size: DEFAULT

  Remove

Disconnect earth cable from battery.

Remove oil pan – see operation "Oil Pan, Remove and Install".

Remove air cleaner housing with hot film mass air flow meter and air intake cover - see illustration "Air Ducts X 12 XE" or "Air Ducts Z 12 XE" or "Air Ducts Z 14 XEP".

Remove ribbed V-belts – see operation "Ribbed V-belts, Remove and Install".

Remove ribbed V-belt tensioner – see operation "Ribbed V-belt Tensioner, Remove and Install".

Remove alternator – see operation "Alternator, Remove and Install".

Open coolant drain bolt – collect escaping coolant.

Remove thermostat housing and coolant hose (5) from coolant pump and radiator.

Detach coolant hoses (6), (7) and (8) from coolant pump.

Disconnect wiring harness plug from camshaft sensor (1), oil pressure switch (2) and coolant temperature sensor (3).

Unclip wiring trough (4) from cylinder head cover and lay aside to rear.

Object Number: 2398438  Size: DEFAULT

Detach pulley (1) from coolant pump.

Caution

Note guide sleeves when removing coolant pump.

  Remove

Detach coolant pump (2) from timing case and note dissimilar length bolts (arrows = short bolts).

Object Number: 2398439  Size: DEFAULT

For version with air conditioning: Detach compressor from timing case and cylinder block and lay aside to front.

Caution

The air conditioning system remains sealed.

  Remove

Detach engine vent hose (2) from cylinder head cover.

Disconnect wiring harness plug (4) from ignition module.

Detach ignition module cover (1) from cylinder head cover in direction of arrow.

Remove fastening bolts (6) and disconnect ignition module (5) from spark plugs using KM-6009 (3) – do not tilt as otherwise the spark plug connectors can be damaged.

Detach cylinder head cover (7) from cylinder head.

Object Number: 2398440  Size: DEFAULT

  Adjust

Turn crankshaft slowly and smoothly.

Move crankshaft in direction of engine rotation to just before "1st Cylinder TDC" position using fastening bolt for crankshaft hub.

  Inspect

The mark (3) on the crankshaft pulley is located just before the lug (2) on the timing case.

In this position the cams for the 1st cylinder (1) are located just before "TDC" (both cams point outwards).

Object Number: 2398441  Size: DEFAULT

  Remove

Remove crankshaft belt pulley (1) – counterhold at the fastening bolt for the crankshaft hub.

Release fastening bolt for crankshaft hub (2) (do not remove) – attach KM-6013 (3) for this and counterhold with KM-956 (4).

Object Number: 2398442  Size: DEFAULT

Detach closure bolt (1) for cylinder block base plate.

  Adjust

Insert KM-952 (2) into opening and, at the same time, at the fastening bolt of the crankshaft hub, slowly further turn crankshaft in the engine rotational direction until KM-952 engages in base plate of cylinder block or crankshaft webs to the stop.

  Inspect

In this position, the marking (3) on the crankshaft hub must point upwards.

Object Number: 2398443  Size: DEFAULT

  Install

Insert KM-953 (1) into camshaft – KM-953 must engage in grooves of camshafts to the stop.

Object Number: 2398444  Size: DEFAULT

  Remove

Remove crankshaft hub (1).

Detach timing case (2) from cylinder head, cylinder block and cylinder head base plate.

Object Number: 2398445  Size: DEFAULT

Push back chain tensioner (1) and lock with KM-955-1 (2).

Remove sliding rail (3), guide rail (5) and tension rail (7).

Timing chain (4), drive sprocket (6) and timing case gasket.

  Clean

Clean sealing surfaces and remove gasket remnants.

Caution

If a two-part timing case gasket has been used, sealant must be removed in the vicinity of the cylinder head gasket (arrows).

Object Number: 2398446  Size: DEFAULT

  Remove

Lever seal ring (1) out of timing case with suitable tool.

Caution

Do not damage sealing surfaces.

  Clean

Clean sealing surfaces and remove gasket remnants.

  Install

Slide seal ring on KM-960 (2).

Drive seal ring flush into timing case using KM-960.

Object Number: 2398447  Size: DEFAULT

  Remove

Insert new coolant pump (1) seal into timing case.

Caution

Ensure guide sleeves (arrows) are seated correctly.

  Install

Attach coolant pump to timing case with short bolts (2) – tightening torque 8 Nm / 6 lbf. ft.

Object Number: 2398448  Size: DEFAULT

Caution

Cut off elastomer projections of cylinder head gasket (1) so they are flush and replace with an approx. 1 mm thick bead of silicon sealant (grey) (2).

The bead of silicon sealant (grey) (2) can be applied directly if there is no protruding elastomer.

The timing case must be mounted within 10 minutes of applying the silicon sealant (grey).

Object Number: 2398449  Size: DEFAULT

  Install

Install new timing case gasket – ensure correct seating of guide sleeves (arrows). Place drive gear (6) onto crankshaft.

Install timing chain (4) on drive sprocket and camshaft sprockets. Thereby ensure that tension side (exhaust side) of timing chain is tensioned.

Attach tension rail (7) to cylinder block – tightening torque 20 Nm / 15 lbf. ft.

Attach guide rail (5) to cylinder block – tightening torque 8 Nm / 6 lbf. ft.

Attach sliding rail (3) to cylinder head – tightening torque 8 Nm / 6 lbf. ft.

  Remove

Remove KM-955-1 (2) out of chain tensioner (1).

Object Number: 2398450  Size: DEFAULT

Caution

Observe installation sequence.

  Install

Attach timing case.

Installation sequence:

  1. Hand-tighten all fastening bolts.
  2. Attach coolant pump/ timing case fastening bolts (1) to cylinder head and cylinder block – tightening torque 8 Nm / 6 lbf. ft.
  3. Attach timing case fastening bolts (2) and (3) to cylinder head, cylinder block and to base plate of cylinder block.

 

Attach timing case with M6 fastening bolts (2) to cylinder head, cylinder block and to base plate of cylinder block- tightening torque 8 Nm / 6 lbf. ft.

Attach timing case with M10 fastening bolts (3) to cylinder block, and base plate of cylinder block- tightening torque 35 Nm / 26 lbf. ft.

Object Number: 2398451  Size: DEFAULT

Caution

Remove KM-952 and KM-953 – Special Service Tools must not be used to counterhold.

Ensure installation position of crankshaft hub (2) is correct – mark (1) must point upwards.

  Install

Attach crankshaft hub to crankshaft with new fastening bolts – attach KM-6013 (4) for this operation and counterhold with KM-956 (5) – tightening torque 150 Nm / 111 lbf. ft. + 45°.

Attach crankshaft belt pulley (3) to crankshaft hub – counterhold at the fastening bolts for the crankshaft hub – tightening torque 8 Nm / 6 lbf. ft.

Object Number: 2398452  Size: DEFAULT

  Adjust

Move crankshaft approx. 720° in direction of engine rotation to just before "1st Cylinder TDC" position using fastening bolt for crankshaft hub.

  Inspect

The mark (3) on the crankshaft pulley is located just before the lug (2) on the timing case.

In this position, the cams for the 1st cylinder are located just before "TDC" (both cams point outwards).

Object Number: 2398441  Size: DEFAULT

  Adjust

Turn crankshaft slowly and smoothly.

Insert KM-952 (3) into opening and, at the same time, at the fastening bolt of the crankshaft hub, slowly further turn crankshaft in the engine rotational direction until crankshaft locking pin engages in base plate of cylinder block or crankshaft webs to the stop.

  Inspect

In this position, the mark (2) on the crankshaft pulley must be flush with the lug (1) on the timing case.

Object Number: 2398453  Size: DEFAULT

  Inspect

Insert KM-953 (1) into camshaft – KM-953 must engage in grooves of camshafts to the stop.

Note:   If KM-953 cannot be inserted, then a basic adjustment should be performed – see operation "Timing, Adjust".

Object Number: 2398444  Size: DEFAULT

Position KM-954 (1) on the phase sensor disc (2) and attach to timing case.

Note:   If KM-954 cannot be inserted, then a basic adjustment should be performed – see operation "Timing, Adjust".

Object Number: 2398454  Size: DEFAULT

  Remove

Remove or disassemble KM-954, KM-953 and KM-952.

  Install

Install closure bolt in cylinder block base plate with new seal ring – tightening torque 60 Nm / 44 lbf. ft.

  Clean

Clean sealing surfaces and remove gasket remnants.

Procedure

Cut off protruding cylinder head gasket (1) flush with cylinder head/ timing case and replace with an approx. 2 mm thick bead of silicon sealant (grey) (dimension I).

Caution

The cylinder head cover must be mounted within 10 minutes of applying the silicon sealant (grey).

Object Number: 2399469  Size: DEFAULT

  Install

Insert new seal (2) in cylinder head cover (1).

Attach cylinder head cover to cylinder head – tightening torque 8 Nm / 6 lbf. ft.

Connect ignition module to spark plugs and attach to cylinder head – tightening torque 8 Nm / 6 lbf. ft.

Attach ignition module cover to cylinder head cover.

Connect wiring harness plug to ignition module.

Attach engine vent hose to cylinder head cover.

Object Number: 2398455  Size: DEFAULT

For version with air conditioning: Attach compressor to timing case and cylinder block – tightening torque 20 Nm / 15 lbf. ft.

Attach pulley to coolant pump – tightening torque 20 Nm / 15 lbf. ft.

Attach or connect wiring harness plug to coolant temperature sensor, camshaft sensor and to oil pressure switch.

Clip wiring trough to cylinder head cover.

Attach coolant hoses to coolant pump.

Attach upper coolant hose to radiator and attach thermostat housing to coolant pump with new gasket – tightening torque 8 Nm / 6 lbf. ft.

Install alternator – see operation "Alternator, Remove and Install".

Install ribbed V-belt tensioner – see operation "Ribbed V-belt Tensioner, Remove and Install".

Install ribbed V-belt – see operation "Ribbed V-belt, Remove and Install".

Install air cleaner housing with hot film mass air flow meter and air intake cover - see illustration "Air Ducts X 12 XE" or "Air Ducts Z 12 XE" or "Air Ducts Z 14 XEP".

Install oil pan – see operation "Oil Pan, Remove and Install".

Connect earth cable to battery.

  Inspect

Charge cooling system – see operations "Cooling System, Charge and Bleed" and "Cooling System, Check for Leaks".


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J Engine and Engine Aggregates > DOHC Petrol Engine > Seals and Seal Rings > Repair Instructions > Timing Case, Remove and Install

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