Right camshafts (Discovery 3)

Special tool

Position tool 303-645

Camshaft installation/locking tool 303-530

Tool for tensioning the timing chain 303-532

Removing

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

2. Remove the battery tray. For more information, refer to Battery Mounting Shelf (76.10.30)
3. Raise and support the vehicle.

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

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

6. Turn the crankshaft until the flat surfaces on the camshafts are parallel to the contact surfaces of the cylinder head.

7.

NOTE: The engine is now in the SAFE position.

Block the crankshaft.

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

8. Remove the valve timing control unit (VCT) right camshaft.

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

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



10. Remove the primary timing chain tensioner. Turn out two bolts.



11. Remove the primary timing chain tensioner guide. Turn out a bolt.




12. Remove the primary timing chain.



13. Remove the secondary timing chain tensioner and secondary timing chain. Remove the two remaining bolts.



14.

CAUTION: Discard bolts as they are no longer needed.

Remove the camshaft sprockets. Turn out 2 bolts.



15. Remove the special tool on a head of cylinders of the right number. Turn out 3 bolts.




16.

CAUTION: Loosen the camshaft bearing caps evenly and gradually.

NOTE: Remove the camshaft bearing caps. Note: note their position, direction and markings. Each lid is marked with its position (number) and directions (arrow).

Remove the camshaft bearing caps. Remove 20 bolts.



17. Remove camshafts.

Installation

1. Check up and adjust backlashes of pushers of valves.

2. Replace the valve shims with the thinner available shims. Apply a thin coat of clean engine oil to the new valve shims.

3. Install the camshafts.

• Clean the contact surfaces of the elements.
• Lubricate the journals and camshaft cams.

4. Install the camshaft bearing caps. Tighten the bolts evenly and progressively in the sequence shown (tightening torque 10 Nm).



5. Install the Torx head bolts to secure the sprocket to the camshafts.


6.

CAUTION: The camshaft lobes must be rotated 180 degrees from their respective valve lifters or the valve clearance will be incorrect.

Measure and record the valve clearances. Turn the sprockets on the Torx head bolts.



7.

CAUTION: Loosen the camshaft bearing caps evenly and gradually.

NOTE: Remove the camshaft bearing caps. Note: note their position, direction and markings. Each lid is marked with its position (number) and directions (arrow).

Remove the camshaft bearing caps. Remove 20 bolts.



8. Remove camshafts.

9. Remove the valve lifters, replace them with selected pushers.

10. Install camshafts.

• Lubricate the journals and camshaft cams.
• Clean the contact surfaces of the elements.

11. Install the camshaft bearing caps. Tighten the bolts evenly and progressively in the sequence shown (tightening torque 10 Nm).

12.

CAUTION: The camshaft lobes must be rotated 180 degrees from their respective valve lifters or the valve clearance will be incorrect.

Check if the valve clearances are adjusted correctly.

• Turn the sprockets on the Torx head bolts.
• Upon completion of the check, remove the Torx head bolts from the camshafts.

13. Establish the special tool on a head of cylinders of the right number. Screw in 3 bolts.

14. Hold the left secondary timing chain tensioner piston. Hold the chain tensioner piston with a metal pin with a diameter of 1 mm.



15. Install the secondary timing chain tensioner and chain onto the camshaft sprockets.

16.

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

Install the secondary timing chain and sprockets to the camshafts. Install the Torx head bolts to secure the sprocket to the camshafts.

17. Screw in the bolts of the tensioner of the secondary timing chain. Tighten the bolts (tightening torque 12 Nm).

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

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

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

21.

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 primary chain tensioner.

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

22.

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 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).

23. Remove the special tool on a head of cylinders of the right number.

24. Install the right variable valve timing control unit (VCT).

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

25. Remove the crankshaft locking tool. Remove the screw.

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

27.

NOTE: Check valve clearances before installing valve covers.

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

28. Install the battery tray. For more information, refer to Battery Mounting Shelf (76.10.30)