Removal

Timing Cover

To remove (Engine removed)






NOTE: Step numbers below refer to numbers used in the illustrations.


1. Drain the oil, disconnect the leads for the starter motor, alternator, oil pressure sensor and oil level sensor.

2. Remove the oil filler pipe arid remove the intake manifold steady bar.

3. Remove the crankcase breather pipe with inlet pipe and undo the turbocharger nuts (turbo)nuts.

4. Slacken the bolts securing the turbocharger steady bar and remove the water pipe for the turbocharger from the thermostat housing (turbo).

5. Disconnect the throttle body preheating hose and remove the bolts from the thermostat housing cover.

6. Unplug the ignition discharge module connector (turbo) and disconnect the crankcase breather and vacuum hoses from the camshaft cover.

7. Remove the cover plate and ignition calbes or ignition discharge module and move the module aside. Remove the spark plugs.






8. Remove the camshaft cover, line up the 0° mark on the flywheel with the timing mark and check that the timing marks on the camshafts are also in line.

9. Remove the chain tensioner.
After removing the plug a 27 mm socket can be used.

10. Remove the camshaft sprockets and position the chain so that it will not obstruct removal of the cylinder head.

11. Remove the cylinder head. Start with the timing cover bolts and continue in reverse assembly order. Use protective collar tool No. 75 19 531 to collect the bolts.

12. Wipe up any oil that has run out. Make sure that the timing chain does not obstruct its removal and then lift off the cylinder head.

13. Unplug the oil level sensor connector and pull the cable out of its clamps.

14. Remove the protective plate and oil pan. Do not remove the guide sleeve from the cylinder block. Wipe off all surplus oil.

15. Remove the crankshaft pulley. Use flywheel locking segment tool No. 83 94 868.

16. Remove the water pump and sleeve with O-rings.

17. Remove the belt tensioner, alternator and the bolt for the support bearing bracket in the timing cover.

18. Remove all the timing cover bolts, carefully tap the cover out of the guides and lift it away.