Installing Chain Housing Cover

Information 

• Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more sealant. 

Information 

Carefully apply Loctite 5900 sealant and make sure that no sealant gets into the bolt holes when joining the chain housing cover. Loctite 5900 can increase the friction coefficient of the aluminium screw. The sealant must not overflow.

1. Check that the -1-  control chain marking is still aligned with the crankshaft.

   The feather key must be -Arrow- at 1 o'clock position in TDC position. 

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   Marking TDC position of crankshaft/control chain

   Information 

   If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can occur because of condensed water forming or components distorting. Components must have a uniform temperature of at least 17°C.

2. Cleaning and degreasing the sealing faces of the engine and chain housing cover.
   1. 2.1 Clean sealing -Arrows-  faces with primer Loctite 7515.

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   Cleaning joint flange

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   Cleaning chain housing cover

   Information 

   If cold or excessively low-tempered components are sealed to each other by applying sealant, leaks can occur because of condensed water forming or components distorting. Components must have a uniform temperature of at least 17°C.

3. Fit the new metal seals -2, 3 and 4-  on the chain housing cover.

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   Chain housing cover

4. Fill the openings in the metal seals with sealant -1 and 2-  . Apply sealant at the specified markings on the engine. Apply the sealant in such a way that no excess sealant can expand into the engine when the chain housing cover is fitted (blocked oil ducts).

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   Applying sealant on chain housing cover

   1	Applying sealant on lower chain housing cover
   2	Applying sealant on connection point between chain housing cover and cylinder head, top
   3	Length of sealing compound application 20 mm

5. Apply sealant -1-  to the upper part of the oil pan -2-  .

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   Sealant on oil guide housing

6. Carefully position the chain housing cover.

   Information 

   When positioning the chain housing cover, a second person must ensure that no sealant is smeared.

   1. 6.1 The chain housing cover -1-  fits just past the narrow point between the coolant pipe and the hydraulic pump support -Arrows-  .

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   Narrow point between coolant pipe and power-steering pump support - Similar to illustration

7. Fit screws securing chain housing cover to oil guide housing -1-  by hand.

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   Chain housing cover on oil guide housing

8. Secure the chain housing cover.

   Information 

   The > 9768 - electronic torque wrench, 2 - 100 Nm (1.5 - 74 ftlb.) must be used when tightening the chain housing cover.

   The following parameters must be monitored for the M6 aluminium screws:

   • Torque limits: > Lower torque limit 5.2 Nm (3.8 ftlb.)   > Upper torque limit 9 Nm (6.6 ftlb.)
   • Rotation angle window: > Minimum torque angle + 50°  > Maximum torque angle + 95°  

   Example 1: The maximum torque of 9 Nm (6.5 ftlb.) is reached. The minimum torque angle is not below the 50° limit --> Installation is OK.

   Example 2: The maximum torque angle of 95° is reached. The minimum torque does not fall below the 5.2 Nm (3.8 ftlb.) limit -> Installation is OK.

   If the limits are exceeded when screwing in screws, the relevant screw must be replaced.

   Information 

   In case of repair, two aluminium screws must be changed to steel screws -15 and 30-  with aluminium washers -Arrows-  .

   > SY, 1533 ENGINE SYMPTOM - LOOSE/BROKEN SCREWS AND OIL LEAKS IN THE AREA OF THE CHAIN HOUSING COVER AND/OR CAMSHAFT PHASER (SY 210/21) 

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   Steel screw with aluminium washer

   1. 8.1 Tighten screws in the sequence -1 to 30-  .
   Fig 1: Chain Housing Cover Screws Tightening Sequence

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   Tightening sequence for chain housing cover

   1-30	Tightening sequence
   1-4	Aluminium screw M6 x 55
   5 + 6	Aluminium screw M8 x 55
   7-12	Aluminium screw M6 x 30
   13 + 14	Aluminium screw M6 x 55
   15	Steel screw M6 x 30 with aluminium washer 6.4 x 14 x 3 mm
   16-28	Aluminium screw M6 x 30
   29	Aluminium screw M6 x 55
   30	Steel screw M6 x 30 with aluminium washer 6.4 x 14 x 3 mm
   1-4 + 7-14, 16-29	Aluminium screw M6 > Initial tightening 4 Nm (3 ftlb.) > Final tightening + 90°
   5 + 6	Aluminium screw M8 > Initial tightening 10 Nm (7.4 ftlb.) > Final tightening + 90°
   15+30	Steel screw M6 x 30 > Tightening torque 10 Nm (7.4 ftlb.)

9. Secure screws on chain housing cover to the oil guide housing -1-  .

   > Initial tightening 4 Nm (3 ftlb.)

   > Final tightening + 90°

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   Chain housing cover on oil guide housing

10. Cut -Arrow-  the cord and pull it out.

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    Fixed control chain and tension rail

11. Position wiring harness and secure cable duct -1-  to the chain housing cover.
    1. 11.1 Plug in electric plug connection for oil pressure control valve and oil level sensor and clip in cable in the oil guide housing and oil pan area.
    2. 11.2 Position cable duct -1-  , fit and tighten screws -2-  .

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    Cable duct on chain housing cover

12. Secure lines -2-  on the chain housing cover.

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    Line for ATF cooling/crankcase ventilation line - Similar to illustration

13. Attach coolant hoses/lines -Blue-  , crankcase ventilation lines -Green-  and vacuum hoses -Orange-  .

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    Hoses and lines in front of the chain housing cover - exemplified on the V6 Biturbo

14. Install deflection rollers -1, 4-  and belt tensioner damper -2-  .
    1. 14.1 Fit the belt tensioner damper and deflection pulleys.
    2. 14.2 Tighten -3-  belt tensioner damper screws.

       > Tightening torque 32 (24 ftlb.) Nm

    3. 14.3 Secure deflection rollers.

       > Tightening torque 32 (24 ftlb.) Nm

    4. 14.4 Fit deflection roller covers.

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Belt drive