Page 644 of 2490
15. Di
sconnect the air cleaner cover.
R
e
lease the five clips which se
cure the air cleaner cover.
16. Disconnect the air flow meter multi-plug.
17 . R
emove the intake tube / air
flow meter / air cleaner cover
assembly.
1. Remove the intake tube / air flow meter / air cleaner
cover assembly.
2. Remove and discard the ru bber seal; air intake tube
to throttle body.
18. Remove the purge valve, fro m the evaporative control
system. Refer to Operation 17.45.01.
19. Remove the on-plug ignition coils. Refer to Operation
18.20.41 and 18.20.42.
20. Remove the camshaft covers. Refer to Operations 12.29.43
and 12.29.44.
21. Remove the variable valve ti ming solenoids. Refer to
Operation18.30.63.
22. Disconnect the engine harness retaining clips from the timing
cover.
Page 648 of 2490
8. Re
fit the variable valve timing
solenoids. Refer to Operation
18.30.63.
9. Refit the camshaft covers. Refer to Operations 12.29.43.and
12.29.44.
10. Refit the on-plug ignition coils and coil covers. Refer to
Operation 18.20.41 and 18.20.42.
11. Refit the purge valve. Refer to Operation 17.45.01.
12 . F
it the intake tube / air flow meter / air cleaner cover
assembly.
1. Fit a new rubber seal; air in take tube to throttle body.
2.
Fit the intake tube / air
flow meter / air cleaner cover
assembly.
13 . R
econnect the air cleaner cover.
F
it
the five clips which secu
re the air cleaner cover.
14. Co
nnect the intake tube to the throttle body.
1. Connect the intake tube to the throttle body.
2. Fit the two bolts which secure the intake tube to the throttle body.
Page 652 of 2490

8. Remove the drive belt
from
the generator and accessory
drive.
1. Use a spanner e.g. Churchill JD - 230 or Snap On XDHM 1415, on the centre bo lt of the belt tensioner
idler pulley, to turn the adju ster assembly to the left
against spring tension.
2. Whilst holding the tensioner against spring tension, remove the drive belt from the generator pulley.
Release the tensioner sl owly and remove the
spanner.
D i
sconnect the belt from the
other pulleys and remove it.
9. Remove t
he pulley from the water pump.
1. Remove the pulley securing screws.
2. Remove the pulley from the water pump.
10. Remove the belt tensione r assembly, from the Front
Accessory Drive. Refer to Operation 12.10.41.
11. Remove the idler pulley, from the Front Accessory Drive.
Refer to Operation 12.10.43.
12. Remove the crankshaft damper. Refer to Operation 12.21.09.
13. Carefully remove the engine covers, taking care not to
damage the plasti c fixings or the rubber inserts.
14. Disconnect the intake tube from the throttle body.
1. Remove the two bolts which secure the intake tube to the throttle body.
2. Disconnect the intake tube from the throttle body.
Page 653 of 2490
15
.
Disconnect the air cleaner cover.
R
elease the five clips which se
cure the air cleaner cover.
16. Disconnect the air flow meter multi-plug.
17
.
Remove the intake tube / air flow meter / air cleaner cover
assembly.
1. Remove the intake tube / air flow meter / air cleaner
cover assembly.
2. Remove and discard the ru bber seal; air intake tube
to throttle body.
18. Remove the purge valve, fro m the evaporative control
system. Refer to Operation 17.45.01.
19. Remove the on-plug ignition coils. Refer to Operation
18.20.41 and 18.20.42.
20. Remove the camshaft covers. Refer to Operations 12.29.43
and 12.29.44.
21. Remove the variable valve ti ming solenoids. Refer to
Operation18.30.63.
22. Disconnect the engine harness retaining clips from the timing
cover.
Page 657 of 2490
7. Reposition and secure the engine harness clips to the timing
cover.
8. Refit the variable valve timing solenoids. Refer to Operation
18.30.63.
9. Refit the camshaft covers. Refer to Operations 12.29.43.and
12.29.44.
10. Refit the on-plug ignition coils and coil covers. Refer to
Operation 18.20.41 and 18.20.42.
11. Refit the purge valve. Refer to Operation 17.45.01.
12. Fit the intake tube / air flow meter / air cleaner cover
assembly.
1. Fit a new rubber seal; air in take tube to throttle body.
2. Fit the intake tube / air flow meter / air cleaner cover
assembly.
Page 658 of 2490
13. Reconnect the air cleaner cover.
Fit the five clips which secu re the air cleaner cover.
14. Connect the intake tube to the throttle body.
1. Connect the intake tube to the throttle body.
2. Fit the two bolts which secure the intake tube to the throttle body.
15. Reconnect the air flow meter multi-plug.
16. Refit the engine covers.
17. Refit the crankshaft damper. Refer to Operation 12.21.09.
18. Refit the idler pulley, to the Front Accessory Drive. Refer to
Operation 12.10.43.
19. Refit the belt tensioner assembly, to the Front Accessory
Drive. Refer to Operation 12.10.41.
20. Refit the pulley to the water pump.
1. Refit the pulley to the water pump.
2. Fit the pulley securing screws. Tighten as far as
possible; then to the correct torque after the belt has
been fitted.
Page 666 of 2490

Installation
12. Remove the bolt which secures the sprocket to the exhaust
camshaft.
Move the sprocket forward from the camshaft boss.
Remove the sprocket and leav e the chain resting on the
cylinder head.
13. Clean and inspect all relevant components.
1. Push the tensioner piston into the body to provide clearance
for installing. Tensioner fitted to cylinder head.
1. Insert a thin rigid wire th rough the hole in the end of
the tensioner piston to displace the ball from the non-
return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
2. Install the sprocket to the secondary chain.
1. With the sprocket installe d to the chain, temporarily
position (do not install the securing bolt) the sprocket
onto the camshaft.
2. Adjust the position of the sprocket within the chain to
allow the chain tensioning tool 303-532 to be
approximately vertical, as shown.
3. Install the cams haft sprocket.
Apply force to the tool (303-532) in an anti-clockwise
direction to tension the chain on its drive side.
Whilst applying the opposing force to the sprocket and
chain, tighten the sprocket securing bolt to 115-125 Nm.
Remove the chain tensioning tool.
Page 670 of 2490

Installation
removing the bolt which secures the sprocket. 1. Place a flat piece of stee l strip along the timing cover
horizontal jointing face, adjacent to the exhaust
camshaft sprocket.
2. Secure the steel strip in place with adhesive tape.
11. A ball-ended hexagon drive bit is required to remove the
sprocket securing bolt. A suitable tool is available from Snap On as (FABLM10E) Long Series 10mm AF.
12. Remove the bolt which secures the sprocket to the exhaust
camshaft.
Move the sprocket forward from the camshaft boss.
Remove the sprocket and leav e the chain resting on the
cylinder head.
13. Clean and inspect all relevant components.
1. Push the tensioner piston into the body to provide clearance
for installing. Tensioner fitted to cylinder head.
1. Insert a thin rigid wire th rough the hole in the end of
the tensioner piston to displace the ball from the non-
return valve seat.
2. With the wire in position, press the piston fully into the tensioner body.
Remove the wire.
2. Install the sprocket to the secondary chain.
1. With the sprocket installe d to the chain, temporarily
position the sprocket onto the camshaft.
2. Adjust the position of the sprocket within the chain to
allow the chain tensioning tool 303-532 to be
approximately vertical, as shown.