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Section Title
xx/xx Model 00-01-1
Timing Chain – Renew (21 314 0)Special Tools
21140
21–140Engine support bar
2114001
21–140–01Adaptor for 21-140
2114003
21–140–03Adaptor for 21-140
IA2114006
21–140–06Adaptor for 21-140
21168
21–168Crankshaft immobilising tool
Proprietary Tools
Scraper
Workshop Equipment
Transmission jack
Materials
Cable ties
Sealer for sump ESK-M4G269
Renew
1. General notes.
NOTE: Throughout the whole operation coverthe engine openings to make sure that nothingfalls into them.
� The position of ancillary components isdescribed looking from the transmissiontowards the engine.
� The hydraulic lines are not separated.
� When removing components, lay them inthe correct order to one side.
Section Title
xx/xx Model 00-01-2
2. Standard preparatory measures:
� Lay protective covers over the fenders.
� Make a note of the radio keycode.
� Make a note of the preset radio stations.
� Detach the battery cover.
�CAUTION: Disconnect the battery groundlead.
� If necessary cut the cable ties and renewthem on installation.
� Open the coolant expansion tank.
ELS2105041
3. Detach the steering intermediate shaft.
IAS2105320
4. Remove the nuts from the shroud for theradiator fan.
Raise the vehicle.
ELS2105021
5. Detach the engine undershield (left-handside shown).
Section Title
xx/xx Model 00-01-3
6. Drain the engine oil and the coolant.
Screw the drain plugs back in with new oilseals.
IAS2105321
7. Remove the radiator fan shroud.
� Disconnect the fan motor plug and detachthe wiring from the radiator fan shroud.
� Push the radiator fan shroud upwards out ofthe grommets and lift it out downwards.
IAS2105259
8. Remove the air conditioning multi-groovebelt.
� Take the pressure off the belt by turning thetensioning pulley clockwise.
� Remove the multi-groove belt.
IAS2105260
9. Remove the multi-groove belt for thealternator/power steering pump.
� Take the pressure off the belt by turning thetensioning pulley clockwise.
� Remove the multi-groove belt.
Section Title
xx/xx Model 00-01-4
IAS2105322
1
2
10. Remove the starter motor.
1 Disconnect the starter motor.
2 Remove the starter motor.
ELD2105231
11. Set the engine to TDC.
21–168
IAS2105323
NOTE: The special tool must locate firmlybetween the flywheel teeth.
12. Fit the crankshaft locking tool.
ELD2105170
31
2
5
4
13. Remove the crankshaft position (CKP)sensor and the wiring bracket.
1 Crankshaft position (CKP) sensor.
2 CKP sensor wiring bracket.
3 Camshaft position (CMP) sensor wiringbracket.
4 Bracket for the CKP sensor.
5 Crankshaft position (CKP) sensor.
Section Title
xx/xx Model 00-01-5
IAS2105324
14. Undo the vibration damper bolt about20 mm.
Undo the crankshaft locking tool (slidingkey).
IAS2105325
21–147
15. Pull off the vibration damper.
� Pull the vibration damper off the crankshaft.
� Remove the puller and unscrew and removethe bolt.
� Remove the vibration damper.
IAS2105326
21–051
16. Remove the crankshaft front oil seal.
Lower the vehicle.
IAS2105249
17. Remove the cover from the intakesystem.
Section Title
xx/xx Model 00-01-6
IAS2105248
4
2
3
1
5
18. Remove the air cleaner.
1 Remove the MAF sensor plug.
2 Remove the intake hose.
3 Remove the bolt from the intake pipe.
4 Remove the positive crankcase ventilation(PCV) hose.
5 Remove the two rubber retainers.
� Pull the air cleaner off the intake pipe andpull it upwards out of the grommets on thebody.
IAS2105250
3
1
2
19. Detach the cables.
1 Unhook the throttle cable and detach it fromthe bracket.
2 Unhook the cable of the speed controlsystem.
3 Detach the bracket for the speed controlsystem cable.
Section Title
xx/xx Model 00-01-7
IAS2105251
2
5
3
5
1
4 6
20. Remove the right-hand inlet manifold.
1 Disconnect the multiplug from the intake airtemperature sensor (IAT sensor).
2 Disconnect the plug from the idle air control(IAC) valve.
3 Disconnect the two vacuum hoses.
4 Remove the PCV hose and the vacuumhose.
5 Remove the connecting hoses.
6 Remove the bolts and pull the inlet manifoldoff the intake air plenum chamber (six bolts).
IAS21052521
32
4
21. Remove the air intake plenum chamber.
1 Remove the EGR valve from the air intakeplenum chamber (two bolts).
2 Disconnect the plug from the throttle position(TP) sensor.
3 Remove the variable resonance inductionsystem (VRIS).
4 Detach the intake air plenum chamber fromthe left-hand inlet manifold and lift it out.
IAS2105253
3
1
4222. Remove the left-hand inlet manifold.
1 Disconnect the vacuum hose.
2 Disconnect the PCV valve from the cylinderhead cover.
3 Remove the brake servo vacuum line.
4 Remove the six bolts.
Section Title
xx/xx Model 00-01-8
IAS2105254
23. Detach the hose and pull off the sparkplug connectors.
� Detach the PCV hose from the cylinder headcover and disconnect it.
� Pull off the spark plug connectors(right-hand side shown).
� Detach the bracket for the vacuum linesfrom the ignition coil.
IAS2105255
24. Disconnect the plugs.
1
ELS2105025
2
25. Detach the coolant hoses.
1 To the radiator.
2 To the expansion tank.
ELS2105026
26. Detach the coolant hose from the coolantpump.
Section Title
xx/xx Model 00-01-9
IAS2105256
27. Remove the ignition coil.
IAS2105257
28. Remove the power steering pump pulley.
IAS2105258
29. Remove the power steering pump (fivebolts) and the upper bolt of the alternatorbracket.
IAS2105299
30. Remove the upper bolt from the airconditioning compressor bracket.
Section Title
xx/xx Model 00-01-10
IAS2105300
31. Remove the tensioning pulley for the airconditioning compressor.
Raise the vehicle.
IAS2105301
32. Remove the bolts from the airconditioning compressor bracket.
Tie up the air conditioning compressor.
IAS2105261
33. Remove the tensioning pulley from thealternator/power steering pump.
ELS2105052
34. Disconnect the alternator and the powersteering pressure (PSP) switch plug.
Section Title
xx/xx Model 00-01-11
IAS21052622
1
35. Remove the alternator.
1 Loosen the upper bolt.
2 Remove the lower bolt.
IAS2105263
36. Remove the bracket of thealternator/power steering pump.
� Swivel the alternator upwards and removethe bracket.
� Lower the vehicle.
ELD2105164
37. Remove the fuel rails.
Disconnect the fuel injection valve plugs.
ELD2105167
38. Detach the thermostat housing bracketand disconnect the plugs.
� Thermostat housing bracket.
� Temperature gauge sender unit plug.
� Engine coolant temperature (ECT) sensorplug.
Section Title
xx/xx Model 00-01-12
ELD2105165
39. Remove the coolant pipe.
ELD2105166
40. Remove the coolant pipe (continued).
ELD2105168
41. Detach the thermostat housing.
� Remove the thermostat housing bolts.
� Remove the connector.
� Detach the coolant hose and remove thethermostat housing.
IAS2105303
42. Remove the upper bolt from the timingchain housing and remove the wiringloom bracket.
Section Title
xx/xx Model 00-01-13
IAS2105269
43. Remove the PCV bracket and disconnectthe fuel lines.
ELD2105180
44. Remove the cylinder head covers(left-hand side shown).
ELD2105182
45. Remove the upper chain guides (left-handside shown).
ELD2105184
46. Remove the timing chain guide on theright-hand cylinder head.
� Evenly prise out the blanking plug with ascrewdriver.
� Remove the chain guide bolt.
Section Title
xx/xx Model 00-01-14
IAS2105270
NOTE: The chain tensioner is immobilised oncethere is an audible click and when it hasreached its stop.
47. Slacken the timing chains.
� Remove the blanking plug from the chaintensioner using a 4,5 mm Allen key.
NOTE: Use the TORX T30 angled socket.
� Immobilise the chain tensioner by rotating itclockwise.
ELD2105185
NOTE: Undo the camshaft sprocket bolts tenturns.
48. Remove the camshaft sprockets.
ELD2105186
NOTE: Hold the timing chain to prevent it fallingin.
49. Remove the camshaft sprockets(continued).
� Lightly tap on the drive plates to loosenthem from the camshaft sprockets.
� Remove the camshaft sprocket bolts.
� Remove the camshaft sprockets, the driveplates and thrust washers and lay them toone side in order.
21–140
21–140–03
21–140–01
ELS2105040
50. Attach the engine support bar.
Raise the vehicle.
Section Title
xx/xx Model 00-01-15
S2105045
51. Detach the transverse brace from thefront crossmember (left-hand sideshown).
S1701023
52. Detach the wiring loom from the frontcrossmember.
IAS2105236
2
1
3
2
53. Remove the brackets and disconnect theplug.
1 Catalytic converter bracket from thetransmission.
2 Catalytic converter bracket from the catalyticconverter.
3 Bracket for the oil filter connector.
Power steering pressure switch multiplug.
IAS2105237
54. Remove the retaining plate for thecatalytic converter, remove the bolts andpush the retaining plate slightlybackwards.
Section Title
xx/xx Model 00-01-16
S1701027
55. Unscrew the adaptor plate bolt.
IAS2105238
1
2
56. Remove the front crossmember.
1 Engine mounting bolts.
2 Front crossmember bolts.
IAS2105239
57. Support the front crossmember with atransmission jack.
58. Lower the front crossmember 150 mmwith the transmission jack.
ELD2105178
59. Remove the PCV connector (right-handside shown).
Section Title
xx/xx Model 00-01-17
1
12
13
14
151665
24
22
21
2
20
19
18
4 3 7
8
9
10
11
17
23
ELD2105194
NOTE: Bolt-slackening sequence.
NOTE: The bolts have different lengths.
60. Remove the sump.
IAS2105305
2
1
61. Detach the coolant pump.
1 Coolant hose.
2 Coolant pump (ten bolts).
PZS2105309
NOTE: The chain guides may catch.
62. Remove the timing chain housing.
� Remove the lower bolts from the timingchain housing.
� Pull timing chain housing down off the guidepins on the cylinder head and lift it out to thefront.
Section Title
xx/xx Model 00-01-18
IAS21053061
25
3
4
63. Take out the left-hand timing chain.
64. Remove the right-hand timing chain.
1 Remove the left-hand chain guide.
2 Remove the upper chain guide bolt.
3 Remove the lower chain guide bolt.
4 Pull the timing sprocket off the crankshaftand remove the timing chain.
Take out the lower chain guide.
5 Take out the timing chains and chain guides.
65. Preparatory measures before assembly.
NOTE: Take care not to damage the matingfaces.
� Thoroughly clean all mating surfaces with ascraper, check them for damage andrenew them as necessary.
� Check any parts that are to be reused fordamage, and renew them if necessary.
IAS2105307
NOTE: The chamfer points away from thecylinder block.
66. Sprocket must be installed facing thecorrect way.
Section Title
xx/xx Model 00-01-19
IAS2105806
9 Nm3
9 Nm
5
9 Nm
1
2
4
67. Coat the mating faces between cylinderhead and timing chain housing withsealer (WSK-M4G320-A).
68. Fit the timing chain housing gasket usingsealer (WSK-M4G320-A).
69. Fit the right-hand timing chain.
1 Attach the lower chain guide.
2 Put the timing chain and the upper chainguide in position for installation.
3 Screw in the upper chain guide bolt.
NOTE: Correct seating of the Woodruff key inthe crankshaft.
4 Lay the timing chain on the sprocket andpush the sprocket onto the crankshaft.
5 Fit the lower chain guide.
NOTE: Hold the timing chain to prevent it fallingin.
70. Lay the left-hand timing chain on thesprocket and guide it through thecylinder head.
IAS2105304
71. Fit the chain guide so that it rests againstthe housing protrusion.
Section Title
xx/xx Model 00-01-20
PZS2105809
14 Nm
21–137
NOTE: The special tool must be free to move.
NOTE: Ensure that the timing chain housingseal is correctly seated.
72. Fit the timing chain housing.
� Move the timing chain housing intoinstallation position and push it onto theguide pins on the cylinder head.
� Align the timing chain housing using thespecial tool.
� Screw in the timing chain housing boltsfinger tight.
NOTE: Ensure that the timing chain housingand cylinder block mating faces are correctlyaligned with each other.
� Tighten the bolts of the timing chain housing.
� Remove the special tool.
IAS2105805
2
9 Nm
1
73. Fit the coolant pump.
1 Fit the coolant pump with a new gasket(ten bolts).
2 Fit the coolant hose.
Section Title
xx/xx Model 00-01-21
1
12
13
14
151665
24
22
21
2
20
19
18
4 3 7
8
9
10
11
17
23
12 Nm
ELD2105694
74. Fit the sump gasket.
Coat the ends of the gasket componentswith sealer (ESK–M4G269).
NOTE: Bolt tightening sequence.
75. Fit the sump.
� Bolts five and six: M6 x 115
� Bolts 23 and 24: M6 x 45
� All other bolts: M6 x 20
9 Nm
ELD2105678
76. Fit the PCV connector (right-hand sideshown).
77. Move the front crossmember intoinstallation position using atransmission jack.
Section Title
xx/xx Model 00-01-22
IAS2105738
50 Nm 2
80 Nm 1
78. Attach the front crossmember.
1 Bolts for the front crossmember.
2 Engine mounting bolts.
S1701027
79. Screw in the adapter plate bolt.
IAS2105737
80. Insert the bolts in the bracket and pushon the retaining plate for the bolts.
2
IAS210573625 Nm2
9 Nm
123 Nm 381. Fit the brackets and connect the
multiplug.
1 Bracket for the oil filter connector.
2 Catalytic converter bracket to the catalyticconverter.
3 Catalytic converter bracket to thetransmission.
PSP switch multiplug.
Section Title
xx/xx Model 00-01-23
S1701023
82. Attach the wiring loom to the frontcrossmember.
80 Nm
ELS2105545
83. Attach the transverse brace to the frontcrossmember (left-hand side shown).
21–140
21–140–03
21–140–01
ELS2105040
84. Detach the engine support bar.
Lower the vehicle.
IAS2105826
21–137
85. Install the crankshaft front oil seal.
Lock the crankshaft by moving the specialtool into position.
Section Title
xx/xx Model 00-01-24
IAS2105824
45 Nm90
86. Screw in the vibration damper bolt.
ELD2105231
87. Set the engine to TDC.
IAS2105275
NOTE: The drive plate follower must engage inthe bore on the camshaft sprocket.
88. Components attached to the camshaft.
IAS2105278
89. Set the camshafts to the timing marks.
� Push on the thrust washers and drive plates,screw in the bolts a few turns.
� Set the camshafts to the timing marks.
� Remove the drive plates.
Section Title
xx/xx Model 00-01-25
3 4
72 Nm
ELD2105228
NOTE: Do not rotate the camshafts or thecrankshaft.
90. Fit the camshaft sprockets.
NOTE: The timing chain must be tight betweenthe camshaft sprockets.
Pull the timing chain tight on the driving run(the opposite side to the chain tensioner),and working from this side attach thecamshaft sprockets (do not yet tighten thebolts).
IAS2105270
NOTE: The chain tensioner is released oncethere is an audible click and when it hasreached its stop.
91. Tighten the timing chains.
NOTE: Use the TORX T30 angled socket.
� Twist the chain tensioner anti-clockwise torelease it.
� Screw the blanking plug (4,5 mm Allen key)into the chain tensioner.
ELD2105233
92. Carefully turn the engine through tworotations and check the valve timings.
If necessary, follow steps 89. to 92. tocorrect the valve timings.
19 Nm
ELD2105682
93. Fit the upper chain guides (left-hand sideshown).
Section Title
xx/xx Model 00-01-26
ELD2105680
7 Nm94. Fit the cylinder head covers (left-hand
side shown).
IAS2105769
5 Nm
95. Attach the PCV bracket to the cylinderhead cover and connect the fuel pipes.
IAS2105803
20 Nm
9 Nm
96. Attach the wiring loom bracket and screwin the upper bolt on the timing chainhousing.
ELD2105668
9 Nm97. Fit the thermostat housing.
� Guide in the thermostat housing and attachthe coolant hose.
� Fit the connector.
� Fit the thermostat housing bolts.
Section Title
xx/xx Model 00-01-27
9 Nm
ELD2105666
98. Fit the coolant pipe.
19 Nm
ELD2105665
99. Fit the coolant pipe (continued).
9 Nm
ELD2105667
100.Fit the thermostat housing bracket andconnect the plugs.
� Thermostat housing bracket
� Temperature gauge sender unit plug.
� Engine coolant temperature (ECT) sensorplug.
9 NmELD2105664
101.Fit the fuel rails.
� Connect the fuel injection valve multiplugs.
� Raise the vehicle.
Section Title
xx/xx Model 00-01-28
IAS2105763
44 Nm
102.Fit the bracket for the alternator/powersteering pump.
IAS210576225 Nm 1
2
25 Nm
103.Fit the alternator.
1 Screw in and tighten the lower bolt.
2 Tighten the upper bolt.
ELS2105052
104.Connect the alternator and thePSP switch plug.
IAS2105761
44 Nm
105.Fit the tensioning pulley for thealternator/power steering pump.
Section Title
xx/xx Model 00-01-29
IAS2105801
44 Nm
106.Fit the bolts on the bracket for the airconditioning compressor.
IAS2105800
41 Nm
107.Fit the tensioning pulley for the airconditioning compressor.
IAS2105799
44 Nm
108.Screw in the upper bolt on the bracketfor the air conditioning compressor.
IAS2105758 25 Nm
44 Nm
109. Insert the upper bolt of the alternatorbracket and fit the power steering pump(five bolts).
Section Title
xx/xx Model 00-01-30
IAS2105757
25 Nm
110. Fit the power steering pump pulley.
IAS2105756
19 Nm1 9 Nm 2
111. Fit the ignition coil.
ELS2105026
112. Attach the coolant hose to the coolantpump.
1
ELS2105025
2
113. Attach the coolant hoses.
1 To the radiator.
2 To the expansion tank.
Section Title
xx/xx Model 00-01-31
IAS2105255
114. Connect the plugs.
IAS2105254
115. Push on the spark plug connectors andattach the vacuum hose.
� Attach the PCV hose to the cylinder headcover and connect it.
� Push on the spark plug connectors(right-hand side shown).
� Attach the bracket for the vacuum lines tothe ignition coil.
IAS2105753
4
3 2
16 Nm1
116. Fit the left-hand exhaust manifold.
1 Fit the six bolts.
2 Fit the brake servo vacuum line.
3 Insert the PCV valve into the cylinder headcover.
4 Connect the vacuum hose.
IAS21057529 Nm 4
32
1
117. Fit the air intake plenum chamber.
1 Push the air intake plenum chamber ontothe left-hand inlet manifold.
2 Attach the VRIS.
3 Connect the TP sensor plug.
4 Attach the EGR valve to the inlet manifold(two bolts).
Section Title
xx/xx Model 00-01-32
5
2
3
2
4
6 16 Nm 1
IAS2105751
118. Attach the right-hand inlet manifold.
1 Push the inlet manifold together with theconnecting hoses onto the air intake plenumchamber and fit the six bolts.
2 Fit the connecting hoses.
3 Connect the IAT sensor multiplug.
4 Push on the two vacuum hoses.
5 Connect the plug from the idle air control(IAC) valve.
6 Push on the PCV hose and the vacuumhose.
2
IAS2105750
3
1 9 Nm
119. Attach the cables.
1 Fit the bracket for the speed control systemcable.
2 Hook the speed control system cable inplace.
3 Attach the throttle cable to the bracket andhook it in place.
3
1
2
45
IAS2105748
120.Fit the air cleaner.
� Push the air cleaner into the grommets onthe body and onto the intake pipe.
1 Fit the two rubber retainers.
2 Attach the PCV hose.
3 Insert the bolt for the intake pipe.
4 Fit the intake hose.
5 Fit the MAF sensor plug.
Section Title
xx/xx Model 00-01-33
IAS2105249
121.Fit the intake system cover.
Raise the vehicle.
5
9Nm 1
3
2
9 Nm
9 Nm
9 Nm
4
ELD2105670
122.Fit the CKP sensor and the wiring clips.
1 Crankshaft position (CKP) sensor.
2 CKP sensor wiring clip.
3 Bracket for CKP sensor.
4 CMP sensor wiring clip.
5 Crankshaft position (CKP) sensor.
IAS2105822
2
44 Nm
1
123. Install the starter motor.
Fit the crankshaft locking tool.
1 Install the starter motor.
2 Connect the starter motor wiring.
IAS2105260
124.Fit the multi-groove belt for thealternator/power steering pump.
� Take the pressure off the belt by turning thetensioning pulley clockwise.
� Fit the multi-groove belt.
Section Title
xx/xx Model 00-01-34
IAS2105259
125.Fit the air conditioning multi-groove belt.
� Take the pressure off the belt by turning thetensioning pulley clockwise.
� Fit the multi-groove belt.
IAS2105321
126.Fit the radiator fan shroud.
� Hook the radiator fan shroud into theretaining tabs (four tabs).
� Connect the fan motor plug and attach thewiring to the radiator fan shroud.
ELS2105021
127.Attach the engine undershield (left-handside shown).
Lower the vehicle.
IAS2105320
128.Fit the nuts to the radiator fan shroud.
Section Title
xx/xx Model 00-01-35
18 Nm
ELS2105541
129.Connect the steering intermediate shaft.
IAS2105276
12
130.Adjust the throttle cable.
1 Pull off the clip from the throttle cable.
2 Pull the throttle cable out a few notches.
� Fully depress the accelerator pedal onceand push the clip back in place.
� Check whether the throttle valve opens fullywhen the accelerator pedal is fullydepressed, and repeat the adjustment ifnecessary.
131.Standard finishing operations.
� Connect the battery ground lead.
� Fit the battery cover.
� Top up the coolant.
� Close the coolant expansion tank.
� Top up the engine oil.
� Check the routing of hoses and wiring andcorrect them as necessary.
� Remove the protective covers.
� Enter the radio keycode.
� Reprogramme the preset radio stations.
� Reset the clock.
� Carry out a road test to enable the PCM togather data.
� Check the fluid levels and correct asnecessary.