Installing the rear timing case cover

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• Clean sealing surfaces (1) with special tool  0 495 102 (11 4 470)  .
• Clean the sealing surface (1)  with brake cleaner.

• Clean sealing surfaces (1) with special tool  0 495 102 (11 4 470)  .
• Clean the sealing surface (1)  with brake cleaner.

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• Position the timing case cover (1)  underneath.
• Position punch on inner side of crankshaft sealing ring (2)  .
• Remove the crankshaft sealing ring (2)  outwards in arrow direction.

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• Check the fitting sleeves (1)  for damage, replace if necessary.
• Check for correct fit of fitting sleeves (1)  .

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• Have the special tool 2 469 803 ready.

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• Position the sealing compound (1)  as shown on the special tool 2 469 803 .

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• Apply the sealant in areas (1)  along the inner edge.

• Replace screws (1)  to (11)  .

  Parts:  Screws

• Carefully mount the timing case cover (A)  .
• Tighten the screws in the sequence (1)  to (11)  with the special tool 0 490 504 (00 9 120) .

Fig 1: Rear Timing Case Cover Screws Tightening Sequence

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• Connect connectors (1)  and lock.

  The connector (1)  must engage audibly.

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Installing the rear crankshaft seal 

• Install special tool 0 496 137 (11 8 815)  on the crankshaft.
• Pull off crankshaft sealing ring (1)  in the arrow direction using special tool 0 496 137 (11 8 815) so that crankshaft sealing ring (1) rests  all around the timing case cover.

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• Guide the special tool 0 496 137 (11 8 815)  out and remove.
• Secure special tool 0 494 029 (11 9 182)  to the crankshaft using special tool 0 494 031 (11 9 184)  .

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• Connect special tool 2 360 215 to special tool 0 494 028 (11 9 181) in the arrow direction  .

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• Position special tools 0 494 028 (11 9 181) and 2 360 215 and bring into contact with the crankshaft seal in connection with special tool 0 494 030 (11 9 183)  .
• Check the freedom of movement between the special tool 2 360 215  and the crankshaft sensor during installation.
• Screw in the crankshaft sealing ring up to the stop of the timing case cover using special tool 2 360 215  .

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Follow-up work 

• Refer to REFITTING OIL PAN .
• Refer to INSTALLING BEARING BRACKET .
• Refer to INSTALLING FRONT AXLE DIFFERENTIAL .
• Refer to INSTALLING THE FLYWHEEL .
• Refer to BLOCKING THE CRANKSHAFT IN THE TDC FIRING POSITION OF CYLINDER 1 .
• Refer to SEALING THE OIL DUCT .
• Refer to CLEANING SEALING SURFACES .
• Refer to INSTALLING THE CYLINDER HEAD GASKET .
• Refer to INSTALLING THE CYLINDER HEAD .
• Refer to INSTALLING THE OIL RETURN LINE IN THE CYLINDER HEAD .
• Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
• Refer to INSTALLING THE INTAKE ADJUSTER .
• Refer to INSTALLING EXHAUST CAMSHAFT ADJUSTER .
• Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
• Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
• Refer to PRE-TENSIONING THE TIMING CHAIN WITH THE SPECIAL TOOL .
• Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE EXHAUST CAMSHAFT ADJUSTER .
• Refer to TIGHTENING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
• Refer to REMOVING ALL SPECIAL TOOLS .
• Refer to INSTALLING CHAIN TENSIONER .
• Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
• Refer to INSTALLING THE INTAKE PLENUM .
• Refer to INSTALLING CYLINDER HEAD COVER .
• Refer to INSTALLING BOTH ACTUATORS .
• Refer to INSTALLING THE TWO HIGH PRESSURE PUMPS .
• Refer to PREPARING THE INJECTORS FOR INSTALLATION .
• Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
• Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 1 TO 3 .
• Refer to REMOVING THE HIGH PRESSURE LINE BETWEEN THE HIGH PRESSURE PUMP AND THE RAIL FOR CYLINDERS 1 TO 6 .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING ALL SPARK PLUGS .
• Refer to INSTALLING ALL IGNITION COILS .
• Refer to INSTALLING THE HOLDER OF THE POSITIVE BATTERY CABLE .
• Refer to INSTALLING THE COOLANT RETURN LINE BETWEEN THE EXHAUST TURBOCHARGER AND THERMOSTAT .
• Refer to INSTALLING THE COOLANT FEED LINE PART 2 BETWEEN THE AUXILIARY COOLANT PUMP AND EXHAUST TURBOCHARGER .
• Refer to INSTALLING THE OIL FEED LINE FOR CYLINDERS 1 TO 3 .
• Refer to FASTENING THE AUXILIARY COOLANT PUMP FOR THE EXHAUST TURBOCHARGER .
• Refer to INSTALLING THE EXHAUST TURBOCHARGER HEAT SHIELD FOR CYLINDERS 1 TO 3 .
• Refer to INSTALLING THE CONNECTING BRACKET ON THE EXHAUST TURBOCHARGER FOR CYLINDERS 4 TO 6 .
• Refer to INSTALLING THE OIL RETURN LINE FOR CYLINDERS 1 TO 3 .
• Refer to INSTALLING THE OIL RETURN LINE FOR CYLINDERS 4 TO 6 .
• Refer to INSTALLING THE OIL FEED LINE FOR CYLINDERS 4 TO 6 .
• Refer to INSTALLING THE CLEAN AIR PIPE FOR CYLINDERS 4-6 .
• Refer to INSTALLING THE IDLER PULLEY .
• Refer to INSTALLING THE DRIVE BELT FOR ALTERNATOR .
• Refer to TOPPING UP THE MOTOR OIL .
• Refer to INSTALLING THE OIL FILLER CAP .
• Refer to REMOVING THE ENGINE FROM THE ASSEMBLY JIG .
• Refer to MOUNTING THE ENGINE ON THE FRONT AXLE .
• Refer to INSTALLING THE COMPLETE FRONT AXLE WITH THE ENGINE AND TRANSMISSION .