Securing 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 

The tightening specifications for the basic engine are stored centrally.

> Refer to 1X001N Technical values in the appropriate service information. 

> Refer to 2X001N Technical values in the appropriate service information. 

or

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

1. Tighten the fastening screws to the relevant parameters in the sequence shown.
   Fig 1: Chain Housing Cover Screws Tightening Sequence

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   Tightening specifications 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	> Initial tightening 4 Nm (3 ftlb.) Final tightening + 90°
   5 + 6	> Initial tightening 10 Nm (7.4 ftlb.) Final tightening + 90°
   15 + 30	> Tightening torque 10 Nm (7.4 ftlb.)

   Carry out further assembly work => 

2. Secure cable duct at the front right.

   Route cable duct on the chain housing cover and fit the screw.

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   Securing cable duct

3. Clip vacuum lines on cable duct -Arrows-  .

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   Clipping in vacuum lines at the cable duct

4. Fit belt tensioner and deflection rollers on the chain housing cover. Also fit screws and cover. Beit drive 
   Fig 2: Belt Drive Components Location

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   Belt drive

   1	Deflection roller
   2	Hydraulic belt tensioner; tensioner to lever, tensioning roller to tensioning lever
   3	Screw, M8 x 96; complete lever on chain housing cover and cylinder head; belt tensioner and chain housing cover at the console
   4	Deflection roller
   5	Dual poly-V-belt

5. On turbo engines, fit positive crankcase ventilation completely in front of the chain housing cover One-way couplings for ventilation on turbo engines. 
   Fig 3: One-Way Couplings For Ventilation On Turbo Engines Components Location

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   One-way couplings for ventilation on turbo engines

   1	Turbocharger/manifold module
   2	Check valve on vent line for oil mist separator and intake-air distributor
   3	Full-throttle ventilation one-way coupling => Cannot be refitted. When mounting for the first time, ensure that the markings are in the correct position relative to each other.
   4	Full-throttle ventilation one-way coupling to intake manifold => Cannot be refitted. When mounting for the first time, ensure that the markings are in the correct position relative to each other.