Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Locking Pin (T10060 A)

• Counter Hold Tool (T10355)

• Engine Support Bridge (10 - 222 A) with Spindle (10 - 222 A /11)

• Bits (T10099)

• Thrust Piece (T10368)

Removing






- Remove the hose - 1 -.

- Release the EVAP canister - B arrow -, remove it upward - A arrow - and lay it aside.

- Remove the bolts - arrows - and the EVAP canister bracket.






• Ignore - 1 -.

• Free up the electrical wiring harness on the coolant reservoir.

• Disconnect the connector - 1 - from the engine coolant level warning switch (F66).






• Remove the bolts - arrows - and lay the coolant reservoir aside with the coolant hoses attached.

- Remove the noise insulation.

- Remove the right noise insulation - arrows -.






- Remove the frame for the noise insulation.

- Remove the bolts - arrows -.






- Lift the clamps - 1 and 2 - and remove the air guide pipe.

Risk of destroying due to reversed running direction on a used ribbed belt.

• Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

- To release ribbed belt tension, rotate tensioner in direction of - arrow -.






- Secure tensioner with (T10060 A).

- Remove the ribbed belt from the vibration damper ribbed belt pulley.

- Rotate the vibration damper using the (T10355) into the "TDC" position - arrow -.






• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

- Remove vibration damper bolt using the (T10355).

- Remove the vibration damper.

• To avoid damaging the splines, only install the vibration damper bolt with the (T10368).

- Install the vibration damper bolt and (T10368) again.






The engine could be destroyed.

• In order not to change the valve timing, the crankshaft must not be moved out of the "TDC" position when the vibration damper bolt is removed.

- Remove the idler roller - 1 -.

- Remove the engine cover - arrows -.






- Place the (10 - 222 A) on upper edge of web plates with the following tool parts:






• Engine brackets (10 - 222 A /1) , quantity: 2

• Spindle (10 - 222 A /11)

- Engage the spindle in the engine lifting eye and tension the engine.

- Remove the bolts - 1 and 2 - and the connecting brace.






- Remove the bolts - 3 to 6 - and the engine mount.

- Lift the engine approximately 50 mm and loosen the upper bolt for the engine support.

- Now lower the engine approximately 100 mm.

- Free up the electrical wiring harness - arrow -.






- Remove the bolt - 1 - and remove the ribbed belt tensioner from the accessory assembly bracket.

- Remove the lower bolts for the engine support using (T10099).

- Remove the engine support and the bolts.

- Remove the bolts - arrows - and remove the oil dipstick guide tube from the timing chain cover.






- Disconnect the wastegate bypass regulator valve (N75) from the turbocharger- arrows -.






- Remove the turbocharger support - 1 -.

- Remove the bolts - 1 through 15 -.






- Pry off the timing chain guard lower section

Installing

• Tightening specifications, refer to => [ Timing Chain Guard and Camshaft Adjustment Valve 1 (N205) Overview ] Timing Chain Guard and Camshaft Adjustment Valve 1 (N205) Overview and => [ Subframe Assembly Overview ] Subframe Assembly Overview.

• Silicone sealant, refer to the Electronic Parts Catalog (ETKA).

• Note the expiration date of the silicone sealant.

• The cover must be installed within 5 minutes after application of the silicone sealant.

• Replace the bolts which are being tightened with an additional turn.

• Replace sealing rings, seals and self-locking nuts.

- Remove any sealant residue on the cylinder block using a flat blade scraper.

- Make sure both alignment bushings for centering the cover - arrows - are present.






- Cut the tube nozzle at the front marking (nozzle diameter: approximately 3 mm).






- Apply the silicone sealant on the clean sealing surface of the new cover as shown in the illustration.






• Thickness of sealant bead: 2 to 3 mm.

• The cover must be installed within 5 minutes after application of silicone sealant.

• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

- Mount the cover immediately and tighten the bolts, tightening sequence. Refer to => [ Lower Timing Chain Cover Tightening Sequence ] Timing Chain Guard and Camshaft Adjustment Valve 1 (N205) Overview.

• After installing cover, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.

- Check oil level.

Installation is carried out in the reverse order while noting the following:

- Install the ribbed belt tensioning damper. Refer to => [ Ribbed Belt Tensioner ] Service and Repair.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Adjust the subframe mount. Refer to => [ Subframe Mount, Adjusting ] Adjustments.