Lower Cover

REMOVING, INSTALLING LOWER TIMING CASE COVER

Part 1 Of 3:

Part 2 Of 3:

Part 3 Of 3:

TIGHTENING TORQUE





REPAIR PRODUCTS





SPECIAL TOOLS

Counterholder:

DETACHING AND ATTACHING TIMING CASE COVER





1 Unbolt belt pulley (10) of power steering pump and remove.
For this step, place poly V-belt (21) over belt pulley (10) of power steering pump (12), fit on holder (14) 603 589 00 40 00 and slacken bolts (arrows).
2 Unscrew bolts (arrows) of power steering pump and push power steering pump (12) to the side with oil lines connected.





3 On engines with TDC sensor: unbolt (L1/1) and (L1/2) at timing case cover (7).





4 Unscrew air cleaner (4) of air pump and remove.
5 Unscrew bolts (15, 16) and remove bracket (3) of air pump/generator.
Installation: pay attention to dowel sleeves at the bottom bolts (15, 16). Model 129: screw on bracket of generator wiring harness also at bottom bolt (16). Clip vacuum line of air shutoff valve into holder (3) (arrow).
6 Model 129: Remove secondary air injection line.
7 Remove chain tensioner.





8 Unscrew bolts (17, 18,19) and remove timing case cover (7).
Do not damage oil pan gasket (arrows).
9 Clean sealing surfaces at timing case cover (7) and at crankcase.
Model 129: remove bolts (arrows) with bottom oil pan removed,





10 Coat sealing surface (arrow) of oil gallery at timing case cover (7) with sealant.
Ensure that no sealant gets into the oil gallery (arrow).





11 Coat sealing surfaces at timing case cover with sealant 002 989 73 20 10.
Ensure that no sealant gets into the oil separator (arrow) of the crankcase ventilation otherwise proper operation of the crankcase ventilation is not assured,
12 Replace O-rings (8) for sealing the coolant passages.





13 Install timing case cover (7).
Do not damage oil pan gasket (arrows); pay attention to dowel sleeves.
14 Tighten front bolts (17,18) first.
if the timing case cover is removed. the TDC sensors (L1/1) and (L1/2) have to be set (up to 12/93).





15 Inspect colored marking (arrows) of the camshaft sprockets and timing chain.





16 Install chain tensioner.
17 Install in the reverse order.
18 Run engine and inspect for leaks.

TIGHTENING TORQUE






REPAIR PRODUCTS






CAUTIONS AND WARNINGS






POSSIBLE DANGERS
Risk of accident from vehicle starting off during starting operation (e.g. when testing compression pressure) as a result of gear engaged or when engine running and vehicles with automatic transmission as a result of selector lever position "P" or "N" not engaged (exception: some vehicles do not have a selector lever position "P").

RISK OF INJURY
Severe injuries may be caused by freely rotating parts in the area of the running engine. The heat produced by the engine when it is operating can result in severe burns if contact is made with individual, unshielded parts.

FIRST AID MEASURES IN THE EVENT OF BURNS
^ Do not rub the skin areas affected; flush with plenty of cold water and cover skin with sterile bandages.
^ Immediately consult a physician.

RULES OF CONDUCT / PROTECTIVE MEASURES
- As a general rule, carry out work an the running engine only if this is absolutely essential.
- Before starting the engine, apply parking brake. On models with manual transmission, move gearshift lever into Neutral position.
- On models with automatic transmission, move selector lever into position "P" or "N" (exception: some vehicles do not have a selector lever position "P").
- On models which do not have selector lever position "P", secure selector lever to prevent it from being operated unintentionally.
- Wear closed and close-fitting work clothes.
- Take off any jewelry, such as chains, rings etc.
- If you have long hair, wear a suitable head cover.
- Before commencing work on the running engine, check to obtain a general picture of the positioning of parts which may be hot.
- When carrying out work when starting the engine or when engine is running, do not touch any hot and rotating parts.


TIGHTENING TORQUE





REPAIR PRODUCTS