Timing Case, Remove and Install the Timing Case Must Be Removed and Installed for the Operations Listed in the Following:
- Timing Chain, Remove and Install
- Guide Rail, Remove and Install
- Crankshaft Sprocket, Remove and Install
- Oil Pump, Remove and Install
- Tension Rail, Remove and Install
- Timing Case Gasket, Replace
- Chain Tensioner, Remove and Install
Disconnect ground cable from battery.
Remove oil pan - see operation "Oil Pan, Remove and Install".
Remove air cleaner housing with air duct pipe, hot film mass air flow meter and air intake cover - see illustration "Air Duct X 10 XE", or "Air Duct X 12 XE".
Depressurise cooling system by opening coolant compensation tank cap.
Detach coolant hose (3) from coolant pump, compensation tank coolant line and radiator - collect coolant.
Detach thermostat housing (2) from coolant pump. Detach upper coolant hose (1) from radiator and remove together with thermostat housing.
Remove coolant hoses (4) and (5) from coolant pump.
Disconnect wiring harness plug from camshaft sensor (3), oil pressure switch (1) and coolant temperature sensor (2).
Unclip wiring trough from cylinder head cover and lay aside to rear.
Remove cylinder head cover - see operation "Cylinder Head Cover, Remove and Install".
Before removing the ribbed V-belt, mark its running direction.
Release fastening bolts (1) for coolant pump belt pulley.
X 10 XE: Installation Wrench KM-959 (M10) or KM-6017 (M12)
X 12 XE: Installation Wrench KM-6017
Release or detach ribbed v-belt (do not remove):
| I | For version without air conditioning: |
|---|---|
| Tension ribbed v-belt tensioner in direction of arrow (clockwise) and secure with Engagement Pin KM-955-2 (1) - detach ribbed v-belt. | |
| II | For version with air conditioning: |
| Tension ribbed v-belt tensioner in direction of arrow (clockwise) until ribbed v-belt tensioner is located in end position (tensioner must audibly engage). Detach ribbed v-belt and release v-belt tensioner (anticlockwise). |
Detach coolant pump belt pulley from coolant pump.
Remove right engine bracket - see operation "Engine Damping Block - Right, Remove and Install - X 10 XE", or operation "Engine Damping Block - Right, Remove and Install - X 12 XE".
Remove ribbed V-belt tensioner - see operation "Ribbed V-belt Tensioner, Remove and Install".
Remove alternator - see operation "Alternator, Remove and Install".
Move crankshaft in direction of engine rotation to just before "1st Cylinder TDC" position using fastening bolt for crankshaft hub.
The mark (3) on the crankshaft belt pulley must be 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).
For version with air conditioning: Detach compressor (1) from timing case and cylinder block, unclip air conditioning line and place compressor to one side.
The air conditioning system remains sealed.
Remove crankshaft belt pulley (1) - counterhold at the fastening bolt for the crankshaft hub.
Note installation position before removing crankshaft hub.
Release fastening bolt for crankshaft hub (2) (do not remove) - attach KM-956 (3) for this operation and counterhold.
Detach closure bolt (1) from cylinder block base plate.
Turn crankshaft slowly and uniformly.
Insert Positioning Pin 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 the positioning pin engages in base plate of cylinder block or crankshaft web to the stop.
In this position, the marking (3) on the crankshaft hub must point upwards.
Insert Positioning Tool KM-953 (1) into camshafts - KM-953 must engage in grooves of camshafts to the stop.
Detach coolant pump (1) from timing case and note dissimilar length bolts (arrows = short bolts).
Remove crankshaft hub (1) - ensure installation position is correct - marking on crankshaft hub points upwards.
Detach timing case (2) from cylinder head, cylinder block and cylinder block base plate.
When replacing timing case: transfer attaching parts.
Push back chain tensioner (1) and secure with KM-955-1 (2).
Detach sliding rail (3), guide rail (5) and tension rail (7).
Timing chain (4), drive sprocket (6) and timing case gasket.
Clean sealing surfaces and remove gasket residue.
If a two-part timing case gasket has been used, sealant must be removed in the vicinity of the cylinder head gasket (arrows).
Lever seal ring (1) out of timing case with suitable tool.
Do not damage sealing surfaces.
Clean sealing surfaces and remove gasket residue.
Coat seal lips of new seal ring with silicone grease (white).
Slide seal ring on KM-960 (2) and drive seal ring flush into timing case with KM-960.
Insert new coolant pump gasket (1) in timing case.
Ensure guide sleeves (arrows) are seated correctly.
Attach coolant pump to timing case with short bolts (2) - tightening torque 8 Nm / 6 lbf. ft.
Protruding elastomer for cylinder head seal (1) must be cut off flush and replaced by an approx. 2 mm thick bead of silicone sealing compound (grey) (2).
The bead of silicone sealing compound (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).
Position new timing case gasket - ensure guide sleeves (arrows) are seated correctly.
Mount drive sprocket (6) on crankshaft.
Install timing chain 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 Engagement Pin KM-955-1 (2) from chain tensioner (1).
Observe installation sequence.
Attach timing case - installation sequence:
- Handtighten all fastening bolts.
- Attach coolant pump/ timing case fastening bolts (1) to cylinder head and cylinder block - tightening torque 8 Nm / 6 lbf. ft.
- Attach timing case fastening bolts (2) and (3) to cylinder head, cylinder block and to base plate of cylinder block.
Timing case with M6 fastening bolt (2) to cylinder head, cylinder block and to base plate of cylinder block- tightening torque 8 Nm / 6 lbf. ft.
Timing case with M10 fastening bolts (3) to cylinder block, and base plate of cylinder block- tightening torque 35 Nm / 26 lbf. ft.
Remove Positioning Pin KM-952 and Positioning Tool 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.
Attach crankshaft hub to crankshaft with new bolt - for this, attach Holding Wrench KM-956 (4) and tighten fastening bolt for crankshaft hub - 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.
Move crankshaft approx. 720� in direction of engine rotation to just before "1st Cylinder TDC" position using fastening bolts for crankshaft hub.
The mark (3) on the crankshaft belt pulley must be 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).
Turn crankshaft slowly and uniformly.
Insert Positioning Pin 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 the positioning pin engages in base plate of cylinder block or crankshaft web to the stop.
In this position, mark (2) on crankshaft belt pulley must align with lug (1) on timing case.
Insert Positioning Tool KM-953 (1) into camshafts - KM-953 must engage in grooves of camshafts to the stop.
Position Positioning Tool KM-954 (1) on the phase sensor disc (2) and attach to timing case.
Disassemble or remove Positioning Tool KM-954, Positioning Tool KM-953 and Positioning Pin KM-952.
Attach coolant pump belt pulley to coolant pump - tightening torque 20 Nm / 15 lbf. ft.
For version with air conditioning: Attach compressor to timing case and cylinder block - tightening torque 20 Nm / 15 lbf. ft. Clip air conditioning line in bracket.
Install closure bolt for crankshaft lock in cylinder block base plate with new seal ring - tightening torque 60 Nm / 44 lbf. ft.
Install alternator - see operation "Alternator, Remove and Install".
Install ribbed v-belt tensioner - see operation "Ribbed V-belt Tensioner, Remove and Install".
Carefully (slowly) release ribbed v-belt tensioner after positioning v-belt.
Mount ribbed v-belt and tension using ribbed v-belt tensioner - ensure installation position and direction of travel is correct.
For vehicles without air conditioning: Remove Engagement Pin KM-955-2 when releasing tension.
Ribbed V-belt Routing
- without air conditioning
- with air conditioning
Install right engine bracket - see operation "Engine Damping Block - Right, Remove and Install - X 10 XE", or operation "Engine Damping Block - Right, Remove and Install - X 12 XE".
Install cylinder head cover - see operation "Cylinder Head Cover, Remove and Install."
Attach coolant hoses to coolant pump.
Attach wiring harness plug to coolant temperature sensor, camshaft sensor and to oil pressure switch. Attach wiring trough to cylinder head cover.
Attach lower coolant hose to radiator, compensation tank coolant line and coolant pump.
Attach upper coolant hose to radiator together with thermostat housing. Attach thermostat housing to coolant pump - tightening torque 8 Nm / 6 lbf. ft.
Install air cleaner housing with air duct pipe, hot film mass air flow meter and air intake cover - see illustration "Air Duct X 10 XE", or "Air Duct X 12 XE".
Install oil pan - see operation "Oil Pan, Remove and Install".
Connect ground cable to battery.
Top up cooling system - see operations "Cooling System, Top Up and Bleed" and "Cooling System, Check for Leaks".