Lower Timing Chain Cover

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

Special tools and workshop equipment 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

Fig 1: Locating Fuel Supply Line

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-- 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.

Fig 2: EVAP Filter And Retainer

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NOTE:

Ignore -1-.

Free up the electrical wiring harness on the coolant reservoir.

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

Fig 3: Coolant Expansion Tank And Electrical Connector

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

-- Remove the noise insulation. Refer to Removal and Installation .

-- Remove the right noise insulation -arrows-.

Fig 4: Identifying Right Drive Axle Heat Shield

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-- Remove the frame for the noise insulation. Refer to Removal and Installation .

-- Remove the bolts -arrows-.

Fig 5: Air Guide Pipe And Bolts

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

CAUTION:

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-.

Fig 6: Rotating Tensioner

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-- 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-.

Fig 7: Identifying Vibration Damper Rotated Into "OT" Position Using Counter Hold Tool T10355

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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.

NOTE:

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

-- Install the vibration damper bolt and T10368 again.

Fig 8: Installing Vibration Damper Bolt And T10368 Again

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CAUTION:

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-.

Fig 9: Removing Engine Cover

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

Fig 10: Engine Support Bridge 10 - 222 Installed

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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.

Fig 11: Removing Bolts -1- And -2- And Connecting Brace

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-- 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-.

Fig 12: Identifying Ribbed Belt Tensioner Bolt And Locating Electrical Wiring Harness

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-- 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.

Fig 13: Identifying Oil Dipstick Guide Tube And Bolts

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

Fig 14: Identifying Turbocharger And Supports

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-- Remove the turbocharger support -1-.

-- Remove the bolts -1 through 15-.

Fig 15: Timing Chain Lower Cover Tightening Sequence

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-- Pry off the timing chain guard lower section

Installing

Tightening specifications, refer to TIMING CHAIN GUARD AND Camshaft Adjustment Valve 1 -N205- OVERVIEW and SUBFRAME ASSEMBLY OVERVIEW .

Silicone sealant.

NOTE:

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.

Fig 16: Centering Cover Alignment Bushings

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

Fig 17: Cut Tube Nozzle At Front Marking (Nozzle Diameter Approx. 3 Mm)

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

Fig 18: Identifying Silicone Sealant Application Area For Cover Sealing Surface

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Thickness of sealant bead: 2 to 3 mm.

NOTE:

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 Figure.

NOTE:

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 .

-- Install the ribbed belt. Refer to RIBBED BELT .

-- Adjust the subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .