Lower Timing Chain Guard Section

Lower Timing Chain Guard Section

Special tools, testers and auxiliary items required

• Locking Pin (T10060 A)

• Counter Hold Tool (T10355)

• Engine Support Bridge (10 - 222 A) with Spindle (10 - 222 A /11)

• Engine Sling (2024 A)

• Lifting Eye (2024 A /2)

• Bits (T10099)

• Thrust Piece (T10368)

Removing

- Remove the noise insulation in the center by loosening the fasteners - 1 and 2 -.

- Loosen the fasteners - 1, 2 and 3 - and remove the right noise insulation.

- Remove the bolts - arrows -.

- Lift the clamps - 1 and 2 - and remove the air guide pipe.

Risk of destroying due to reversed running direction on a used ribbed belt.

• Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

- To release ribbed belt tension, rotate tensioner in direction of - arrow -.

- Secure tensioner with (T10060 A).

- Remove ribbed belt from vibration damper ribbed belt pulley.

- Rotate the vibration damper using the (T10355) into the Top Dead Center (TDC) position - arrow -.

• The notch on the vibration damper must line up with the arrow marking on the timing chain lower cover.

- Remove vibration damper bolt using (T10355).

- Remove the vibration damper.

• To avoid damaging the splines, only install the vibration damper bolt with the (T10368).

- Install the vibration damper bolt and (T10368) again.

Danger of causing damage to the engine.

• In order not to change the valve timing, the crankshaft must not be moved out of the TDC position when the vibration damper bolt is removed.

- Remove the idler roller - 1 -.

- Tighten the (2024 A /2) on the engine lifting eye using a collar nut - arrow -.

- Place (10 - 222 A) on upper edge of web plates with the following tool parts:

• Engine brackets (10 - 222 A /1) , quantity: 2

• Spindle (10 - 222 A /11)

- Tension the engine with the spindle.

- Remove the subframe bolts - arrows - on the engine.

- Lift the engine approximately 50 mm and loosen the upper bolt for the engine support.

- Now lower the engine approximately 100 mm.

- Free up the wiring harness - arrow -.

- Remove the bolt - 1 - and remove the ribbed belt tensioner from the accessory assembly bracket.

- Remove the lower bolts for the engine support using (T10099).

- Remove the engine support and the bolts.

- Remove the bolts - arrows - and remove the oil dipstick guide tube from the timing chain cover.

- Disconnect the wastegate bypass regulator valve (N75) from the turbocharger - arrows -.

- Remove the turbocharger support - 1 -.

- Remove the bolts - 1 through 15 -.

• There may be 8 bolts installed, depending on the version.

- Pry off the timing chain guard lower section

Installing

• Tightening specifications, refer to => [ Timing Chains Guard, Camshaft Adjustment Valve 1 (N205) Overview ] Timing Chains Guard, Camshaft Adjustment Valve 1 (N205) Overview => [ Subframe Overview ] Subframe Overview

• Silicon sealant, refer to the Parts Catalog.

• Note the expiration date of the silicone sealant.

• The cover must be installed within 5 minutes after the silicone sealant has been applied.

• Replace the bolts which are being tightened with an additional turn.

• Replace sealing rings, seals and self-locking nuts.

Risk of contaminating lubricating system.

• Cover open parts of the engine.

- Remove any sealant residue on the cylinder block using a flat blade scraper.

- Clean any oil or grease off the sealing surfaces.

- Remove any sealant residue on the cylinder block using a flat blade scraper.

- Make sure both alignment bushings for centering the cover - arrows - are present.

- Cut the tube nozzle at the front marking (nozzle diameter: approximately 2 mm).

Cover with 15 Bolts

- Apply the silicon sealing compound to the clean sealing surface - arrow 1 - and on the edges - arrows 2 - of the new cover as shown in the illustration.

• Thickness of sealant bead: 2 to 3 mm

• The cover must be installed within 5 minutes after the silicone sealant has been applied.

• The sealant bead may not be thicker than specified, otherwise excess sealant could enter the oil pan and clog the oil intake tube.

- Immediately attach the cover and tighten the bolts:

• Cover with 15 bolts, refer to => [ Timing Chain Guard Lower Section - Tightening Sequence for 15 Bolts ] Timing Chains Guard, Camshaft Adjustment Valve 1 (N205) Overview

• Cover with 8 bolts, refer to => [ Timing Chain Guard Lower Section - Tightening Sequence for 8 Bolts ] Timing Chains Guard, Camshaft Adjustment Valve 1 (N205) Overview

• After installing cover, allow sealant to dry for approximately 30 minutes. Only after then may the engine oil be replenished.

- Check oil level.

Further installation is performed in reverse order of removal, noting the following:

- Install the ribbed belt tensioning damper. Refer to => [ Ribbed Belt Tensioning Damper ] Ribbed Belt Tensioning Damper.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Adjust the subframe mount. Refer to => [ Subframe Mount, Adjusting ] Adjustments.