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.
  CONSUMABLE SPECIFICATIONS
  
  

  Brake cleaner 2.0	500 ml, Spray can	83192365214
  	20, Canister	83192365215

  NOTE: RISK OF DAMAGE 
  Damage to the surface. 
  The use of metal-cutting tools (e.g., emery cloths) for cleaning surfaces can damage them and lead to leaks and/or engine damage. 

  • Do not use any metal-cutting tools.

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  NOTE: TECHNICAL INFORMATION 
  The sealing surfaces must be free of oil, grease and cleaning agents.
• Clean sealing surfaces (1) with special tool  0 495 102 (11 4 470)  . 
• Clean the sealing surface (1) with brake cleaner.
  CONSUMABLE SPECIFICATIONS
  
  

  Brake cleaner 2.0	500 ml, Spray can	83192365214
  	20, Canister	83192365215

• Position the timing case cover (1) underneath.
• Position the punch inside in the 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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  NOTE: TECHNICAL INFORMATION 
  For additional information see: OVERVIEW OF CONSUMABLES (APPLICABLE PARTS CATALOGUE) .
• Position the sealing compound (1) as shown on the special tool 2 469 803. 

  Parts:  Sealant

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  NOTE: TECHNICAL INFORMATION 
  The processing time of the liquid sealing compound can be at a maximum of 10 min.
  Commissioning of the assembly is not possible until 25 minutes after the processing time.
  Non-observance can lead to leaks in the assembly.

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• Apply the sealing compound in area (1) along the inner edge.
  SEALING COMPOUND SPECIFICATION
  
  

  Loctite 5970 liquid sealing compound Processing time <10 minutes at room temperature

  50 ml, Cartridge

  83190404517

  TECHNICAL DATA SPECIFICATIONS
  
  

  Height of the sealing bead

  2.0 mm... 2.5 mm

• 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). 
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Rear timing case cover on crankcase
  M6 x 31 Replace screws.	Joining torque	8 Nm
  	Angle of rotation	90°

  Fig 1: 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 

  NOTE: TECHNICAL INFORMATION 
  The radial shaft seal must be installed dry. Do not use motor oil or lubricant.
• 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.
• Guide the special tool 0 496 137 (11 8 815) out and remove.

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• 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 SEALING THE OIL DUCT .
• Refer to CLEANING SEALING SURFACES .
• Refer to INSTALLING THE CYLINDER HEAD GASKET .
• Refer to BLOCKING THE CRANKSHAFT IN THE TDC FIRING POSITION OF CYLINDER 1 .
• Refer to INSTALLING THE CYLINDER HEAD .
• Refer to ADJUSTING THE CAMSHAFTS WITH THE SPECIAL TOOL .
• Refer to INSTALLING THE INTAKE ADJUSTER .
• Refer to INSTALLING THE VANOS CENTRAL VALVE OF THE INTAKE ADJUSTER .
• Refer to INSTALLING EXHAUST CAMSHAFT 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 DISASSEMBLING ALL SPECIAL TOOLS .
• Refer to INSTALLING CHAIN TENSIONER .
• Refer to CHECKING THE TIMINGS OF THE CAMSHAFT .
• Refer to INSTALLING THE COOLANT LINE BETWEEN THE CYLINDER HEAD AND THE COOLANT PUMP .
• Refer to INSTALLING THE OIL RETURN LINE FOR THE EXHAUST TURBOCHARGER .
• Refer to INSTALLING CYLINDER HEAD COVER .
• Refer to INSTALLING BOTH ACTUATORS .
• 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 INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
• Refer to INSTALLING HIGH PRESSURE PUMP .
• Refer to INSTALLING ALL SPARK PLUGS .
• Refer to INSTALLING ALL IGNITION COILS .
• Refer to INSTALLING CATALYTIC CONVERTER .
• Refer to INSTALLING THE OXYGEN SENSOR MONITOR .
• Refer to INSTALLING LAMBDA OXYGEN SENSOR .
• Refer to INSTALLING THE INTAKE PLENUM .
• Refer to INSTALLING THE TANK VENT VALVE .
• Refer to INSTALLING CHARGE AIR LINE .
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to FILLING ENGINE OIL .
• Refer to CHECK/ADD FRONT AXLE TRANSMISSION OIL .
• 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 .