Remove and Install Upper Timing Case
REMOVING AND INSTALLING UPPER TIMING CASE- Remove both intake air manifolds, Removing Intake Manifold
- Remove both distributor housings, Removing Holding Cover For Distributor
- Remove fan.
CAUTION: Left-hand threads.
- Using special tool 11 5 050 brace against pulley and unfasten cap nut from water pump using special tool 11 5 040.
- Remove fan wheel with fan coupling from water pump.
Installation Note:
- Tighten down fan wheel using special tool 11 5 040.
Tightening torque = 40 - 50 Nm (30 - 37 ft lbs).
NOTE: When using special tool 11 5 040, 30 Nm (21 ft lb) on the torque wrench scale are equivalent to a tightening torque of 40 Nm (30 ft lb)..
- Unfasten screws and detach fan from fan coupling.
- Remove both cylinder head covers, Removing Cylinder Head Covers
- First unscrew the round rubber mounts (1), then the bolts and nuts, and take off the cover.
- Unscrew screws.
- Lift off timing case cover.
CAUTION: Don't let dowel sleeves fall into the timing case.
REMOVING LEFT AND RIGHT SPROCKETS
- Turn crankshaft until piston in cyl. no. 1 is at TDC.
Valves of cylinders 1 and 7 are closed.
Dowel pins in the camshafts face in.
- Adjust engine to TDC position with Special Tool 11 2 300.
- Remove special tool only after finishing the complete installation of the camshaft drive.
CAUTION: Always make absolutely sure that the special tool is removed before operating the engine again.
- Unscrew guide rails.
CAUTION: Cover chain recesses to prevent clips from falling into the crankcase.
NOTE: Clips are not installed in all engines.
- Press off the anti-tamper lock for the chain tensioner with a screwdriver or similar tool.
NOTE: Removal destroys the anti-tamper lock.
- Loosen the timing chain.
- Loosen nut (2).
- Loosen adjusting screw (1) several turns and then unscrew plug (3).
- Remove the tensioning piston.
CAUTION: Spring between the plug and piston.
Right Bank of Cylinders (1 ... 6):
- Unscrew bolts and take off sprocket.
Left Bank of Cylinders (7 ... 12):
- Unscrew bolts on sprocket and take off sprocket.
Left Bank of Cylinders (7 ... 12):
- Unscrew screw (1) on guide rail and pull up guide rail out of the lower holder.
REMOVING UPPER TIMING CASE
- Unscrew screws on upper timing case and pull timing case off of dowel sleeves on cylinder head.
- Make sure that dowel sleeves for the timing case cover cannot fall into the timing chain recess.
NOTE: Swing out timing case upward for version with removal of the camshaft.
INSTALLATION
- Install new gaskets.
NOTE:
The gaskets between the upper and lower timing cases match the thickness of the cylinder head gasket.
Identification: one or two holes. Only use gaskets with the same number of holes as the removed ones.
NOTE: Fill the joint for the perpendicular gasket on the lower timing case with "Black 3 Bond 1207 B" sealing compound.
Location of identification.
Gaskets between cylinder heads and timing cases are mirror-inverted. Hold gaskets on the cylinder head with several drops of "Curil K2" on the graphite surface.
- Install timing cases in reverse order of removal procedures.
CAUTION: Be careful not to damage the gaskets.
- Hold timing cases on cylinder head lightly with the screws.
- Then first tighten the screws of the lower timing case
- Tighten screws of the cylinder head last.
- Install camshaft with the dowel pin facing in (cyl. no. 1 in TDC). Tighten bearing caps from inside to outside. Tightening torque: 15 Nm (11 ft. lbs.).
- Install pipes with the oil ejection bores facing the camshaft.
CAUTION: Insert hollow bolt (1) In bearing cap no. 3.
- Replace gaskets. Tightening torque: 12 Nm (8.5 ft. lbs.).
NOTE: This camshaft bearing has a groove all around for supply of oil to the oil pipe.
- Hold both camshafts with Special Tool 11 3 190.
- Screw in bolts on both sprockets only finger tight.
- Mount the timing chain in opposite direction of engine rotation, beginning on the crankshaft.
NOTE: Mount timing chain on the sprockets in such a manner, that it can be tensioned in the adjusting range of the slots.
- Mount guide rails.
CAUTION: Cover timing chain recesses to prevent clips from failing Into the crankcase.
NOTE: Clips are not installed in all engines.
- Install guide rail and tighten with screw (1).
Location of Holder (Not visible after installation of lower timing case cover)
Install chain tensioner.
1 Adjusting screw
2 Locknut
3 Plug
4 Gasket (replace)
5 Spring
6 Tensioning piston
Tightening torque for plug: 40 Nm (29 ft. lbs.).
Adjusting Chain Tensioner
- Press tensioning rail once briefly towards the chain and measure dimension (A).
- Press tensioning rail against spring force up to stop and measure dimension (B).
- Subtract dimension (B) from dimension (A).
- Specified value: 5 ± 0.5 mm (0.20 ± 0.020 in).
- Adjust nominal value with the adjusting screw and tighten down lock nut.
- Install a new anti-tamper lock.
- Torque cam sprockets to 10 ± 1 Nm (7.5 ± 1 ft lb).
- Remove tool securing camshafts.
- Fill the joint between the gaskets and oval holes in the gaskets for the lower timing case with "Black 3 Bond 1207 B" sealing compound.
- Install paper gaskets with graphite surfaces facing the cylinder head. Hold gaskets in position with a small amount of "Curil K2".
- Hold timing case cover lightly with the screws in cylinder head direction.
- Then tighten screws in lower timing case direction.
- Finally tighten screws in cylinder head direction.
- Press down valve with Special Tool 11 3 180 and insert drag arm with slide.
NOTE: Always position each cam facing up and perpendicular to the cylinder head. Special tool must not bear on cams. Make sure that pertinent piston is not in top dead center.
CAUTION: Cover oil bores slides could fall into the engine.
- Install both cylinder head covers with new gaskets.
- Tighten nuts or bolts from inside to outside.
- Tightening torque: 10 Nm (7 ft. lbs.). Screw on rubber mounts (1).
NOTE: Counterhold nuts (2) with an opened wrench when installing rubber mounts (1).