Elements of the gas distribution mechanism (Discovery 3)

Special tool

Camshaft installation/locking tool 303-530

Position tool 303-645

Tool for tensioning the timing chain 303-532

Removing

NOTE: This procedure involves the removal and installation of the following parts: timing chains, chain guides, tensioners and sprockets.

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

2.

WARNING: It is forbidden to carry out work on a vehicle standing on only one jack. Always support the vehicle with jack stands.

Raise and support the vehicle.

3. Remove the engine front cover. For more information refer to Engine front cover (12.65.01)

4. Remove the crankshaft position sensor (TFR sensor). For more information refer to Crankshaft Position Sensor (TFR) (18.30.12)

5. Block the crankshaft.

• Reinstall the special tool.
• Screw in the screw.

6. Remove the valve timing solenoid housing (VCT) right camshaft.

• Turn out 3 bolts.
• Remove and discard o-rings.

7. Establish the special tool on a head of cylinders of the right number. Screw in three bolts.



8. Remove the right side timing chain tensioner assembly, right side. Turn out two bolts.



9. Remove the right side primary timing chain tensioner guide. Turn out a bolt.




10. Remove the right side timing chain primary. Loosen the chain guide bolt.



11. Remove the valve timing solenoid housing (VCT) left camshaft.

• Turn out two bolts.
• Remove the nut.
• Remove and discard o-rings.

12. Establish the special tool on a head of cylinders of the left number. Screw in three bolts.




13. Remove the left side primary timing chain tensioner. Turn out two bolts.



14. Remove the left side primary timing chain tensioner upper and lower guides. Turn out two bolts.

15. Remove the left side primary timing chain.



16.

CAUTION: Discard bolts as they are no longer needed.

Remove left camshaft sprockets as an assembly. Remove the two Torx head screws.



17. Remove the left side secondary timing chain tensioner and secondary timing chain. Turn out two bolts.



18.

CAUTION: Discard bolts as they are no longer needed.

Remove the crankshaft sprocket assembly. Remove the two Torx head screws.



19. Remove right side secondary timing chain tensioner and secondary timing chain. Remove the two remaining bolts.



20.

NOTE: Note the location of the crankshaft sprocket.

Remove the crankshaft sprocket. Remove the crankshaft sprocket pin.

Installation

1. Install the crankshaft sprocket cotter pin. Clean the contact surfaces of the parts.

2. Install the crankshaft sprocket.

3. Push in the left side timing chain tensioner piston. Hold the chain tensioner piston with a metal pin with a diameter of 1 mm.

4.

NOTE: The illustration shows the right side, on the left side the procedure is the same.

Install the left side secondary timing chain tensioner and chain onto the camshaft sprockets.



5. Screw in the left side timing chain tensioner tensioner bolts. Tighten the bolts (tightening torque 12 Nm).

6. Put on the left side primary timing chain. Make sure the loose side of the timing chain is on the tensioner side.

7. Install the left side primary timing chain tensioner guides. Tighten the bolts (tightening torque 12 Nm).

8.

CAUTION: While compressing the tensioner, do not release the ratchet until the tensioner piston is fully retracted into the hole. Failure to do so will result in damage to the ratchet.

Install the left side primary timing chain tensioner.

• Hold the chain tensioner piston with a metal pin with a diameter of 3 mm.
• Tighten the bolts (tightening torque 12 Nm).
• Remove the pin.

9.

CAUTION: Apply counterclockwise force to the special tool to tighten the primary timing chain from its working side.

CAUTION: The intake camshaft sprocket bolt MUST be tightened up to the exhaust camshaft sprocket bolt. Failure to follow this procedure will result in engine damage.

Install the special tool on the left side exhaust camshaft sprocket.

• Bolt of fastening of an asterisk of an inlet camshaft (tightening torque 120 Nm).
• Bolt of fastening of an asterisk of a final camshaft (tightening torque 120 Nm).

10. Install the valve timing solenoid housing (VCT) left camshaft.

• Install new o-rings.
• Tighten new bolts (tightening torque 22 Nm).
• tighten the nut (tightening torque 10 Nm).

11. Hold the piston of the right side secondary timing chain tensioner. Hold the chain tensioner piston with a metal pin with a diameter of 1 mm.



12. Install the right side secondary timing chain tensioner and the secondary timing chain onto the camshaft sprockets.

13.

NOTE: Lightly tighten Torx head bolts to secure sprocket to camshaft, sprockets MUST move freely.

Install the right side secondary timing chain tensioner and sprocket onto the camshafts. Install the Torx head bolts to secure the sprocket to the camshafts.

14. Screw in bolts of fastening of a tensioner of a secondary chain of a drive of GRM of the right side. Tighten the bolts (tightening torque 12 Nm).

15. Tension the secondary timing chain. Remove the metal pin.

16. Put on the right side timing chain. Make sure the loose side of the timing chain is on the tensioner side.

17. Install the right side primary timing chain tensioner guide. Tighten the bolts (tightening torque 12 Nm).

18.

CAUTION: While compressing the tensioner, do not release the ratchet until the tensioner piston is fully retracted into the hole. Failure to do so will result in damage to the ratchet.

Install the right side timing chain tensioner.

• Hold the chain tensioner piston with a metal pin with a diameter of 3 mm.
• Tighten the bolts (tightening torque 12 Nm).
• Remove the pin.

19.

CAUTION: The intake camshaft sprocket bolt MUST be tightened up to the exhaust camshaft sprocket bolt. Failure to follow this procedure will result in engine damage.

CAUTION: Apply counterclockwise force to the special tool to tighten the primary timing chain from its working side.

CAUTION: Use new bolts.

Install the special tool on the right side exhaust camshaft sprocket.

• Bolt of fastening of an asterisk of an inlet camshaft (tightening torque 120 Nm).
• Bolt of fastening of an asterisk of a final camshaft (tightening torque 120 Nm).

20. Install the valve timing solenoid housing (VCT) right camshaft.

• Install new o-rings.
• Tighten new bolts (tightening torque 22 Nm).

21. Remove the special tool from a head of cylinders of the right number.

22. Remove the special tool from a head of cylinders of the left number.

23. Install the engine front cover. For more information refer to Engine front cover (12.65.01)

24. Remove the crankshaft locking tool. Remove the screw.

25. Install the SKR sensor. For more information refer to Crankshaft Position Sensor (TFR) (18.30.12)

26. Connect the wire "masses" to the battery.