Left camshafts (Discovery 3)

Special tool

Device for fixing the camshaft pulley 303-1145/1	Device for removing the camshaft pulley bolt 303-1145/2	Wrench for camshaft pulley bolt 303-1145/3
Device for mounting the camshaft oil seal 303-1119

Removing

1. Disconnect the wire "masses" from the battery. For more information refer to Specification.

2. Remove the front camshaft oil seal. For more information refer to Front Camshaft Seal (12.13.44)

3. Remove a cover of the left head of cylinders. For more information refer to Left Valve Cover (12.29.43)

4. Remove the fuel pump drive belt. For more information refer to High Pressure Fuel Pump Belt - VIN Range: SALLA000304->END OF 06 MY (12.10.27)

5. Install the special tool on the rear camshaft pulley.

• Rotate the crankshaft so that the special tool is parallel to the engine mounting bracket.
• Screw in the fixing bolt of the special tool.

6. Install the special tool on the rear camshaft pulley mounting bolt.




7. Using special tools, remove and discard the rear camshaft pulley mounting bolt. Turn the crankshaft clockwise to block the rear camshaft pulley.



8. Remove special tools.

9. Remove the rear camshaft pulley.



10. Remove the fuel pump drive belt rear cover. Turn out a bolt of fastening of a back cover of a belt of a drive of the fuel pump.




11. Hold the secondary timing chain tensioner piston.

• Install the secondary timing chain tensioner.
• Insert a pin with a diameter of 1.5 mm (0.060 inch) into the secondary timing chain tensioner piston.

12.

CAUTION: Gradually and evenly loosen the camshaft bearing caps.

Remove the camshaft bearing caps. Remove 18 bolts.



13. Remove the camshafts with the secondary timing chain tensioner assembly.

• Remove the 2 remaining bolts.
• Release the left secondary timing chain tensioner.

14. Remove the left secondary timing chain tensioner.



15. Remove the left camshafts.

• Remove the secondary timing chain from the left camshafts.
• Remove and discard the left camshaft rear oil seal.

Installation

1. Fit the secondary timing chain onto the camshafts.


2.

CAUTION: Do not release the pin securing the secondary timing chain tensioner until all camshaft bearing caps have been installed.

Install the secondary timing chain tensioner. Align the marks on the camshafts with the marks on the secondary timing chain.



3. Install the camshafts with the secondary timing chain tensioner assembly. Lubricate the journals and camshaft cams.

4. Install the left secondary timing chain tensioner. Tighten 2 fixing bolts (tightening torque 10 Nm).

5. Install the camshaft bearing caps.

• Do not install the camshaft bearing caps at this stage yet.
• The bolts are tightened in the specified sequence in four stages.
• Stage 1: tightening torque 1 Nm.
• Stage 2: tightening torque 5 Nm.
• Stage 3: tightening torque 10 Nm.

6. Apply sealant to both camshaft bearing caps as shown. For more information refer to Specification.



7. Install the exhaust camshaft bearing caps.

• The bolts are tightened in the specified sequence in three stages.
• Stage 1: tightening torque 1 Nm.
• Stage 2: tightening torque 5 Nm.
• Stage 3: tightening torque 10 Nm.

8. Release the secondary timing chain tensioner piston. Remove lock pin.

9. Establish a back cover of a belt of a drive of the fuel pump. Screw in the bolt securing the rear cover of the fuel pump drive belt.

10. Using the special tools, install a new camshaft rear oil seal.



11. Install the rear camshaft pulley.

• Apply loctite 242 to the new camshaft pulley bolt.
• Install a new camshaft pulley bolt.

12. Install the special tool on the rear camshaft pulley. Screw in the fixing bolt of the special tool.



13. Install the special tool on the bolt securing the rear camshaft pulley.



14.

CAUTION: Be sure to follow the torque wrench adjustment procedure. Failure to follow this instruction may result in damage to the vehicle.

Calculate the torque value for the torque wrench.

• Step 1: Multiply the amount of torque required by the usable length of the torque wrench (1).
• Step 2: Add the usable length of the special tool (2) to the useful length of the torque wrench.
• Step 3: Divide the amounts calculated in step 1 by the amount calculated in step 2.
• Step 4: Adjust the torque wrench according to the value calculated in step 3.

15.

CAUTION: Be sure to follow the torque wrench adjustment procedure. Failure to follow this instruction may result in damage to the vehicle.

Using the special tools, tighten the rear camshaft pulley mounting bolt (tightening torque 40 Nm).



16.

CAUTION: Be sure to follow the torque wrench adjustment procedure. Failure to follow this instruction may result in damage to the vehicle.

Using the special tools, tighten the rear camshaft pulley mounting bolt an additional 75 Nm. Rotate the crankshaft counterclockwise to block the rear camshaft pulley.

17. Remove special tools.

18. Install the fuel pump drive belt. For more information on refer to High Pressure Fuel Pump Belt - VIN Range: SALLA000304->END OF 06 MY (12.10.27)

19. Establish a cover of the left head of cylinders. For more information on refer to Left Valve Cover (12.29.43)

20. Install the front camshaft oil seal. For more information on refer to Front Camshaft Seal (12.13.44)

21. Connect the wire "masses" to the battery. For more information on refer to Specification.