Timing chain and camshaft sprocket

/ 9-3 (9440) / 2004 / 2. Engine / 4-cylinder petrol / Basic engine / Adjustment/replacement / Timing chain and camshaft sprocket

To remove

1.	Remove the upper engine cover.

2.	Detach the mass air flow sensor connector and the intake hose from the air filter housing cover. Remove the cover and the air filter.

3.	Detach the intake hose and remove the air filter housing. Detach the connector for the A/C pressure sensor.

4.	Undo the fuel pipes from the snap fasteners and remove the bolts for the bracket from the camshaft cover.

5.	Remove cover over ignition coils.

6.	Unplug ignition coil connectors. Unplug connector to turbocharger solenoid valve and undo cable clips.

7.	Remove the bolts, pick up and move aside each ignition coil. Start with ignition coil for cyl. 1.

8.	Detach crankcase ventilation hose from camshaft cover.

9.	Undo and carefully move away the cable duct from the cylinder head and camshaft cover.

10.	Remove the turbocharger heat shield.

11.	Undo ground cable from camshaft cover.

12.	Remove the camshaft cover.

13.	Raise the car and remove the front right wheel.

14.	Remove the right wing liner. CV: Remove Chassis reinforcement, front subframe, CV .

15.	Relieve the belt tensioner with 83 96 095 Relieving tool, belt circuit B207 and remove the belt. Mark the direction of rotation on the belt.

16.	Remove the belt tensioner.

17.	Lower the car and zero the engine by turning the crankshaft in the direction of engine rotation until the mark on the crankshaft pulley agrees with the mark on the timing cover. The cams on cylinder 1 intake and exhaust camshaft must be pointing in/up.

18.	Remove the chain tensioner. Use 83 96 129 Oil filter tool, B207, and camshaft drive chain tensioner .

19.	Remove the lock ring from the chain tensioner and remove the piston.

20.	Fit 83 96 178 Lifting eyes, kit, B207.

21.	Fit 83 94 850 Lifting beam and 83 95 287 Holder . Relieve the engine and remove the engine bracket.

22.	Lower the engine about 3 cm using the lifting beam.

23.	Raise the car and remove the crankshaft pulley with 83 95 360 Holding tool, crankshaft pulley (shaft only) and 83 96 210 Holding tool, crankshaft pulley, B207 .

24.	Place a receptacle under the car to collect any oil and carefully remove the timing cover.

25.	Cut off the part of the timing cover gasket that goes round the engine mounting and remove the gasket.

26.	Remove the crankshaft seal. Lower the car.

27.	Remove the plug from the cylinder head.

28.	Remove the upper bolt from the chain guide on the inlet side.

29.	Remove the upper timing chain guide rail.

30.	Remove the lower chain guide bolt. Pull down the chain guide. Detach the lower section of the chain.

31.	Remove the camshaft sprockets. Use a spanner to grip the camshaft flats when the bolts are loosened. Lift up the chain.

32.	Remove the tensioner guide by lifting it up. Inspect the condition of the guide. Replace if necessary.

To fit

1.	Clean all sealing surfaces.

2.	Clean the camshaft and sprocket contact surfaces from oil and grease.

3.	Fit the tensioner guide.

4.	Lay the chain on the intake sprocket and lower the chain. Fit the sprocket on the camshaft and insert the bolt.

5.	Raise the car.

6.	Fit the chain on the crankshaft sprocket and fit the chain guide. Fit the lower bolt. Tightening torque 10 Nm (7 lbf ft)

7.	Lower the car.

8.	Fit the exhaust sprocket and enter the bolt.

9.	Fit the upper bolt. Fit the plug on the cylinder head.

10.	Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position.

11.	Place the plunger in the chain tensioner sleeve. Fit the circlip and check that it is fitted correctly in the groove. Note Check that the O-ring and gasket are intact. If damaged, replace the chain tensioner assembly.

12.	Fit the chain tensioner. Tightening torque 75 Nm (55 lbf ft)

13.	Release/activate the chain tensioner by carefully pressing on the transmission chain or chain control (as shown). Use a screwdriver. Check that the tensioner releases.

14.

Remove the exhaust camshaft and intake camshaft bearing caps no. 2 and no. 7. Position 83 96 046 Adjustment tool, camshaft (B207 150-175 hp) and 83 96 079 Adjustment tool, camshaft (B207 200 hp) by pressing down the tool by hand onto the camshafts without tightening the bolts. Rotate the camshaft with a wrench on the camshaft flats until the tool fits. Tighten the adjustment tools' bolts. Important When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 10 Nm (7 lbf ft)

15.	Cut off the part of the gasket that is round the engine mounting and position the new timing cover gasket.

16.	Fit the timing cover. Tightening torque 20 Nm (15 lbf ft).

17.	Position the 83 96 202 Fitting tool, front crankshaft seal B207 protective collar on the crankshaft. Lubricate the new sealing ring with acid-free Vaseline and position it on the fitting tool.

18.	Position the fitting tool on the crankshaft. Tighten the sealing ring using the crankshaft pulley bolt until it is flush with the timing cover. Remove the tool.

19.	Fit the crankshaft pulley with a new bolt. Use 83 95 360 Holding tool, crankshaft pulley (shaft only) and 83 96 210 Holding tool, crankshaft pulley, B207 . Tightening torque 100 Nm + 75° (74 lbf ft + 75°)

20.	Check that the markings on the crankshaft pulley and the timing cover are aligned. Tighten the camshaft gears a first time. Use a spanner to grip the camshaft flats. Tightening torque 30 Nm (22 lbf ft)

21.	Remove the adjustment tools and fit the bearing caps. Tightening torque 8 Nm (6 lbf ft)

22.	Continue to tighten the camshaft gears to the final torque. Use a spanner to grip the camshaft flats. Tightening torque 85 Nm + 30° (63 lbf ft +30°)

23.

Turn the crankshaft 2 rotations in the engine direction of rotation until the markings on the crankshaft pulley and the timing cover are aligned. Remove the bearing caps and refit 83 96 046 Adjustment tool, camshaft (B207 150-175 hp) and 83 96 079 Adjustment tool, camshaft (B207 200 hp) to check that the camshaft setting is correct. Remove the adjustment tools and fit the bearing caps. Important When fitting the tools, use the screws accompanying the new tools EN-48366 and EN-48368. Tightening torque 8 Nm (6 lbf ft)

24.	Fit the upper timing chain guide rail.

25.	Lower the car and lift the engine with the lifting beam. Fit the engine bracket.

26.	Fit the bolts to the engine bracket. Tightening torque 70 Nm + 60° (52 lbf ft + 60°)

27.	Remove 83 94 850 Lifting beam with holder. Remove 83 96 178 Lifting eye kit, B207 .

28.	Fit the camshaft cover with new seal. Tightening torque 10 Nm (7 lbf ft)

29.	Connect the ground cable to the camshaft cover.

30.	Connect the crankcase ventilation hose to the camshaft cover.

31.	Fit the cable duct and bracket to the camshaft cover.

32.	Fit the ignition coils. Tightening torque 8 Nm (6 lbf ft)

33.	Plug in the ignition coil connectors. Make sure the cable is lying correctly and does not get pinched by the cover. Plug connector to turbocharger solenoid valve and cable clips.

34.	Fit cover over ignition coils.

35.	Press the fuel lines and breather lines into the clips on the camshaft cover. Connect the quick release coupling for the breather line.

36.	Connect both fuel lines to the fuel rail while gripping the lower nut. Use new seals. Tightening torque 10 Nm (7 lbf ft)

37.	Fit the turbocharger heat shield.

38.	Fit the air filter housing and connect the intake hose. Plug in the connector for the A/C pressure sensor.

39.	Fit the air cleaner and air cleaner cover. Connect the intake hose and the mass air flow sensor connector.

40.	Fit the upper engine cover.

41.	Raise the car and fit the belt tensioner. Tightening torque 50 Nm (37 lbf ft).

42.	Relieve the belt tensioner with 83 96 095 Relieving tool, belt circuit B207 and fit the belt in the marked direction of rotation. Check that the belt is positioned correctly over all the pulleys. CV: Fit Chassis reinforcement, front subframe, CV.

43.	Lower the car somewhat and fit the right wing liner.

44.	Fit the front right wheel. See Wheels.

45.	Lower the car completely.

46.	Check engine oil level. Top up as necessary.

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