Engine With HFM-SFI
Replacement
1. Remove guide rail at top (42).
NOTE: If the top cued guide rail (42) is taken out of its mounting, the pressure pin in the chain tensioner is moved one detent in the pressure direction. The chain tensioner must be removed to avoid the timing chain being over-tensioned.
2. Unbolt heating water return pipe (25) at fan bearing bracket and coolant pump.
3. Replace seal (26).
4. Unplug connectors (L5/1) of camshaft position sensor and (Y49) camshaft adjustment actuator.
5. If secondary air injection fitted, disconnect vacuum pipes and connector at switchover valve (Y27).
6. If 1st version tensioning device fitted, unbolt and push down shock absorber of tensioning device (34) at front cover (38).
Installation Hint: Tightening torque: 21 Nm.
7. Unscrew screw plug (35) with seal (36).
8. Use impact extractor (02) 116 589 20 33 00 on top guide rail pin (37) and threaded insert (03) 116 889 01 34 00 in order to pull off.
9. Unscrew bolts (3) and (4) at front cover (30).
Installation Hint: Tightening torque: 21 Nm.
10. Remove front cover with bottom right bolt (arrow).
NOTE: Do not apply pressure to front cover (30) when removing.
11. Reverse procedure to install, noting the following:
- Replace seal (30c) and shaped rubber gasket (24).
- Apply sealant 002 989 45 20 on left and right at joint (arrows) to cylinder head in the form of a dot.
- Insert new (dry) shaped rubber gasket (24) (without sealant) into the oil-free groove.
- Coat top side of shaped rubber gasket with a little engine oil.
- Coat front cover (30) at contact surfaces to cylinder head with sealant 002 989 45 20.
- Fit front cover on, first of all, tighten bottom bolts (4).
CAUTION:
^ When installing the front cover (30), ensure that the shaped rubber gasket (24) is not shifted; chamfer edge on cover (30) at bottom for this purpose.
^ Tightening torque: 21 Nm).
NOTE: If the front cover is replaced, the camshaft position sensor must be adjusted with a clearance of: 0.2 - 0.6 mm.
- Run engine and check for leaks.