Installing Chain Housing Cover

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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.

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

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Cleaning joint flange

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Cleaning chain housing "over"

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

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Chain housing cover

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

Apply sealant -3- to the upper part of the oil pan

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Applying sealant on oil guide housing
Carefully position the chain housing cover.
Information

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

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

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Narrow point between coolant pipe and power-steering pump support
Fit screws securing chain housing cover to oil guide housing by hand.
Only for V6 biturbo engines: Position support -3- and fit screws -1- .

Fit screws -2- .

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Chain housing cover on oil guide housing

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

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

> Refer to 153300 Symptom Engine - Loose/Broken Screws and/or Oil Leaks in the Timing Case Cover and/or Camshaft Adjuster Cover Area (SY 210/21) in the appropriate service information.

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Steel screw with aluminium washer

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.)

Secure chain housing cover to the oil guide housing.
Only for V6 biturbo engines: Tighten screws -1- .

> Tightening torque 23 Nm (17 ftlb.)

Tighten screws -2- .

> Initial tightening 4 Nm (3 ftlb.) Final tightening + 90°

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Chain housing cover on oil guide housing
Cut -Arrow- the cord and pull it out.

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Fixed control chain and tension rail
Position wiring harness and secure cable duct to the chain housing cover.
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.

Position cable duct -1- , fit and tighten screws -2- .

> Initial tightening 4 Nm

> Final tightening + 90°

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Cable duct on chain housing cover
Secure ATF lines -2- on the chain housing cover.
Fit and tighten screw

Tighten screw -1- to Initial tightening 4 Nm (3 ftlb.) Final tightening + 90°

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ATF lines
Secure coolant hoses/lines -blue- , positive crankcase ventilation line -green- and vacuum hoses -orange- .
Secure positive crankcase ventilation line Initial tightening 4 (3 ftlb.) Nm Final tightening + 90° .

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Hoses and lines in front of the chain housing cover - shown on the V6 biturbo as an example
Install deflection rollers -1. 4- and belt tensioner damper -2- .
Fit the belt tensioner damper and deflection rollers.

Tighten screws -3- for the belt tensioner damper.

> Tightening torque 32 (24 ftlb.) Nm

Secure deflection rollers

> Tightening torque 32 (24 ftlb.) Nm

Fit deflection roller covers.

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Belt drive

Information

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

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.

Check that the -1- control chain marking is still aligned with the crankshaft.
The feather key must be at 1 o'clock position -Arrow- in TDC position.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Cleaning joint flange

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Cleaning chain housing cover Information

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

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Chain housing cover

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).

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

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

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

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Sealant on oil guide housing
Carefully position the chain housing cover.
Information

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

The chain housing cover -3- 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
Fit screws securing chain housing cover to oil guide housing -3- by hand.

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Chain housing cover on oil guide housing

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

Information

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

> Refer to 153300 Symptom Engine - Loose/Broken Screws and/or Oil Leaks in the Timing Case Cover and/or Camshaft Adjuster Cover Area (SY 210/21) in the appropriate service information.

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Steel screw with aluminium washer

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.)

Secure 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
Cut -Arrow- the cord and pull It out.

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Fixed control chain and tension rail
Position wiring harness and secure cable duct -1- to the chain housing cover.
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.

Position cable duct -1- fit and tighten screws -2- .

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Cable duct on chain housing cover
Secure ATF lines on the chain housing cover.
Fit and tighten screw

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ATF lines
Secure coolant hoses/lines -Blue- , positive crankcase ventilation line -Green- and vacuum hoses -Orange- .

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Hoses and lines in front of the chain housing cover - exemplified on the V6 Biturbo
Install deflection rollers -1. 4- and belt tensioner damper -2- .
Fit the belt tensioner damper and deflection pulleys.

Tighten -3- belt tensioner damper screws.

> Tightening torque 32 (24 ftlb.) Nm

Secure deflection rollers

> Tightening torque 32 (24 ftlb.) Nm

Fit deflection roller covers.

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Belt drive