2. Remove all spark plugs.
3. Remove the chain tensioner.
4. Remove the front crankshaft oil seal.
5. Remove the drive belt tensioner.
6. Remove the torsional vibration damper.
7. Remove the locking mechanism (1) in the direction indicated by the arrow.
Note: When installing, it is necessary to install the locking mechanism (1) with the hole facing outward.
8. Turn the engine crankshaft by the central bolt to the TDC position.
9. Insert tool 110300 in the direction of the arrow into the locking hole and lock the crankshaft.
Attention:
- On vehicles with SA205 (automatic transmission), there is a large hole close to the locking hole for TDC positioning. This hole should not be confused with the locking hole.
- If the flywheel is locked in the correct locking hole using tool 110300, the engine will no longer turn by the center bolt.
Attention:
- To loosen the central bolt (1), do not remove tool 110300.
- To loosen the central bolt (1), an assistant is needed to hold it from turning.
10. Screw tool 119280 onto the vibration damper hub.
11. Loosen the central bolt (1). Tightening torque: 100 Nm + 360°.
12. Remove the hub moving forward.
13. Unscrew the threaded plug (1).
Tightening torque: 25 Nm.
14. Unscrew the threaded plug (1).
Tightening torque: 50 Nm.
Note: Replace aluminum bolts when installing.
15. Loosen the bolts (1) of the timing chain module on the cylinder head.
Tightening torque: 14 Nm.
16. Loosen the bolts (1) of the drive chain module on the crankcase.
Tightening torque: 20 Nm.
Please note: To remove the central bolts of the intake and exhaust control assemblies, use tool 114280.
17. Secure tool 114283 to the cylinder head with bolts (1)
Note: Place tool 114282 on the intake side.
18. Install tool 114281 on the intake and exhaust camshafts.
Note: Do not remove tool 114280.
19. Remove the intake and exhaust actuators.
20. Loosen the bolts (1) of the timing chain module on the cylinder head.
Tightening torque: 9 Nm.
21. Remove the chain module with the drive chain and sprocket by moving it upwards.
Attention:
- Pay attention to the direction when installing the sprocket (2).
- Bead (see arrow) on the sprocket (2) points towards the engine.
- Incorrect installation will result in engine damage.
22. Pull the drive chain (1) upwards until the sprocket (2) is locked in the guide bar (3) of the chain.
23. Install the drive chain (1) and sprocket (2) in this position.
Note: During installation, it is necessary to keep the drive chain (1) taut at all times. It is possible to clamp the drive chain (1) with the chain guide bar (3).
24. Insert the hub with the central bolt.
25. Secure tool 115200 with bolts (1) to the hub.
26. Remove the drive belt tensioner.
27. Screw in tool 114362 from tool kit 114360.
28. Install tool 119280 on 115200.
29. Support tool 119280 on tool 114362.
30. Tool 110300 secures the crankshaft.
31. Tighten the center bolt to the specified torque.
Tightening torque: 100 Nm + 360°.
32. Mark the center bolt and hub with color.
33. Mark the devices with a colored dash (1).
Attention:
- When tightening the central bolt to the specified angle, do not remove the device.
- If necessary, tighten the central bolt to the specified angle using tool 009140.
Tightening torque: 100 Nm + 360°.
34. Tighten the central bolt with an assistant.
Tightening torque: 100 Nm + 360°.
35. Install the VANOS actuators on the intake and exhaust sides.
36. Install the chain tensioner.
37. Turn the engine two revolutions.
38. Check the valve timing.
39. If necessary, adjust the valve timing.
40. Assemble the engine.