Repair instructions
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          GI-RM-0002 - Valve clearance adjustment
          DA-RM-05F001-00-001 - Check engine timing
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Instructions
Powertrain / Engine / Power Unit Service Procedures / DA-RM-05F001-00-001 - Check engine timing
Preparation work
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Care Point: Depressurise suspension system before disconnecting battery.
4.     
Care Point: Remove both sides.
5.     
Care Point: Make sure EPB calipers are in service mode before disconnecting battery.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides. Detach caliper from upright only, do not disconnect fluid hose.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Care Point: Remove both sides.
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Check engine timing
 
Care Point:
Block oil return galleries to prevent contamination.
 
1.   
Cover the area around the cylinder head to prevent contamination (arrows).
 
 
Care Point:
Make sure the engine always rotates in the correct direction of rotation (arrow).
 
2.   
Turn crank in the engine's direction of rotation.
 
3.   
Rotate crank to position with machined flat are on top (arrow). Additional flats are on both sides.
 
4.   
Remove timing pin plug (A). 20 Nm
 
5.   
Lower rear part of frame to gain access to crankshaft timing location plug.
 
6.   
Push down the transmission floor crossbeam (B) in direction ©).
 
 
Care Point:
Two technicians will be needed.
Care Point:
To fit crankshaft locking tool (F) rotate crankshaft (D) in clockwise direction (E).
 
7.   
Insert crankshaft locking tool (F) in direction (G). Crankshaft Locking Pin - Engine
 
8.   
Remove exhaust manifold heat shield to gain access to screws.
 
9.   
Remove bolts (H) and remove heatshield.(M6x16) 10 Nm
 
 
Care Point:
Before disassembling the engine the locking pins in the VCT phasers need to be checked for a positive connection to prevent incorrect valve timing when the engine is re-assembled.
 
10.  
Using flat edge of cam shaft (I), attempt to rotate each camshaft in the opposite direction of its rotation (maximum 20 degrees). If camshaft rotates independently from VCT phaser, the locking pin in the VCT phaser has failed and requires replacement.
Chain driven VCT/Camshaft - Rotate anti-clockwise.
None chain driven VCT/Camshaft - Rotate clockwise.
 
 
Care Point:
Two technicians will be needed.
Care Point:
To fit camshaft tool (L) rotate crankshaft (J) in clockwise direction (K).
 
11.  
Apply camshaft special tool (L) on the cornered shaft (M) from the camshaft (N).Camshaft locking/timing - Engine
 
12.  
Remove all special tools to unlock the camshafts and the crankshaft.
 
 
Care Point:
Replace O-ring.
 
13.  
Install timing pin plug (A) with new O-ring.20 Nm
 
 
Care Point:
Clean surfaces of all engine parts.
 
14.  
Install components in reverse order.
 
15.  
Check engine for leaks.
 
16.   
17.  
Check cooling system.
 
18.  
Read out and clear error memory.
 
   
   
   Note