Left Timing Chain Cover, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Hand drill with plastic brush attachment
Protective eyewear
Sealant.

Removal

Fig 1: Identifying Hose Clamps -1 & 2-, EGR Cooler Switch-Over Valve -3- And Bolts -Arrows-

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-- Remove the left intermediate pipe. Refer to LEFT INTERMEDIATE PIPE, REMOVING AND INSTALLING .

-- Remove the EGR Cooler Switch-Over Valve 2 -N381- -3-.

-- Remove the bolts -arrows-.

-- Push the left rear coolant pipe to the side and remove the coolant hose -2-.

NOTE:

Ignore -item 1-.

-- Remove the bolts -3- and -4- and remove the exhaust gas recirculation pipes.

Fig 2: Exhaust Gas Recirculation Pipes And Bolts

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NOTE:

Ignore -items 1 and 2-.

-- Remove the bolts -1 through 4- and remove the left timing chain cover.

Fig 3: Identifying Bolts -1 Through 4- And Left Timing Chain Cover

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Installation

Tightening specifications, refer to TURBOCHARGER OVERVIEW and EXHAUST GAS RECIRCULATION OVERVIEW .

NOTE:

Replace the bolts for the left timing chain cover.

-- Remove old sealant form the grooves in the timing chain cover as well as from the sealing surfaces.

CAUTION:

Risk of contaminating lubricating system.

Cover open parts of engine.

Fig 4: Cleaning Remaining Sealant With Rotating Plastic Brush

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WARNING:

Danger of eye injury.

Wear protective eyewear.

-- Remove the sealant residue on the cover for the timing chain, cylinder block and cylinder head, for example using a rotating plastic brush.

-- Clean the sealing surfaces; they must be free of oil and grease.

NOTE:

Note the expiration date of the sealing compound.

-- Cut the tube nozzle at the front marking (nozzle diameter: approximately 1.5 mm).

Fig 5: Cut Tube Nozzle At Front Marking

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than specified.

-- Apply a sealant bead to the clean sealing surface of the left timing chain cover as shown in the illustration.

Fig 6: Appling Sealant Bead To Timing Chain Cover -1-

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The groove -1- of sealing surface must be completely filled with sealant.
The sealant bead must be 1.5 to 2.0 mm above the sealing surface.

-- Install the seal -2-.

NOTE:

Note the expiration date of the sealing compound.

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

Fig 7: Cut Tube Nozzle At Front Marking

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-- Apply a sealant bead with a 3 mm diameter to the transitions between the cylinder head and lower timing chain cover -arrows- as illustrated.

Fig 8: Applying Sealant Bead At -Arrow-

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CAUTION:

The lubrication system could be plugged with excess sealant.

Do not apply sealant bead thicker than specified.

NOTE:

The timing chain cover must be installed within 5 minutes after applying the sealant

-- Position the left timing chain cover and tighten the bolts, refer to Fig 9.

Fig 9: Left Timing Chain Cover Bolts

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Install in reverse order of removal. Note the following:

-- Install the left rear coolant pipes, refer to LEFT REAR COOLANT PIPE, REMOVING AND INSTALLING .

-- Install the left intermediate pipe, refer to LEFT INTERMEDIATE PIPE, REMOVING AND INSTALLING .