Removing Chain Case Lid
Removing chain case lidTools
Preliminary work
Preliminary work for top chain case lid
1. Remove engine.
2. Remove cylinder head cover.
Preliminary work for bottom chain case lid
1. Remove manual transmission.
2. Remove flywheel or drive plate.
Information
Component overview
Top chain case lid
Chain case lid, bottom
Removing top chain case lid
ATTENTION Engine damage due to turning the crankshaft against the running direction (engine assembled)!
^ Never turn the engine against the running direction when the timing drive mechanism is fitted (timing chain may jump over).
^ Proceed carefully while working as otherwise engine damage may occur.
^ Only turn the engine on the crankshaft and never on the camshaft as the timing chain can jump over.
^ After working on the camshaft timing gears, the timing must be adjusted.
^ Please observe the general warning notes and working regulations
Note: Mark cable plugs of camshaft hall senders before removal.
1. Pull both cable plugs off camshaft hall senders -4 and 14-.
2. Pull off both cable plugs for the hydraulic valves for camshaft adjustment -15 and 16-.
3. Pull cable plug off valve for carbon canister -1-.
4. Remove coolant run-on pump -2- from the sheetmetal bracket. To do so, disconnect the cable plug and lever the coolant run-on pump out of the support using a screwdriver.
5. Pull cable plug of coolant temperature sensor off coolant temperature regulator housing -10-.
6. Lay the cables aside.
7. Release the aluminum water tube by removing the 2 fastening screws (M6 x 12).
8. Release the two spring-band clamps on the coolant hose -2- and set hose with water tube aside. Collect the draining coolant.
9. Remove black sheetmetal holder. To do this, remove the 3 fastening screws (M6 x 10) 1 -1-.
Note: The coolant temperature regulator housing must be removed because a hidden screw for the chain case lid is screwed in underneath.
10. Remove coolant temperature regulator housing. To do so, loosen 2 M6 x 120 and 1 M6 x 23 fastening screws -3- and pull off housing from water tube. Check sealing ring on water tube and replace if necessary.
11. Disassemble chain tensioner -1-.
12. Remove top chain case lid. To do so, undo 6 M6 x 70, 1 M6 x 20 and 2 M8 x 30 fastening screws -2- and loosen chain case lid by tapping it carefully with a plastic hammer.
13. Clean sealing surfaces on the cylinder block and chain case lid. Clean any sealant in the bores of the cylinder head gasket -arrows-. Check sealing rings in chain case lid and replace if necessary.
Removing bottom chain case lid
ATTENTION Engine damage due to turning the crankshaft against the running direction (engine assembled)!
^ Never turn the engine against the running direction when the timing drive mechanism is fitted (timing chain may jump over).
^ Proceed carefully while working as otherwise engine damage may occur.
^ Only turn the engine on the crankshaft and never on the camshaft as the timing chain can jump over.
^ After working on the camshaft timing gears, the timing must be adjusted.
^ Please observe the general warning notes and working regulations
1. Loosen all fastening screws, to do so, unscrew 2 M8 x 30 -1-, 14 M6 x 16, 2 M6 x 57 and 3 M6 x 18 screws (oil pan) -2-.
2. Tap the bottom chain case lid gently with a plastic hammer and remove it.
3. Clean all sealing surfaces on the chain case lid and cylinder block and clean off any residual sealant on the cylinder head gasket. To do this, remove any sealing paste from the bores on the cylinder head gasket -arrows-.