Front Covers at Top, Removal and Installation
Preceding work: Remove cylinder head covers. Service and Repair
Overview (For complete procedure, see below.)
- Bracket (10) of actuator detach, attach (21 Nm), (step 1).
- Shielding caps (1) and high voltage distributor (2) remove, install.
- Covers (1a) remove, install.
- Ignition cable holder, right side unbolt, bolt on.
- Power steering pump (11) (1st version)
with mounting plate remove, install (step 5).
- Poly V-belt slacken, tension.
- Bracket of poly V-belt tensioning device unbolt, bolt on (21 Nm).
- Power steering pump (11) with mounting plate and lines/wiring
connected unbolt, place to the side, bolt on (21 Nm), (step 7).
- Power steering pump (11) (2nd version)
with reservoir (13) remove, install, (step 8).
- Power steering pump (11), oil in
reservoir (13) extract, adjust oil to correct level, (step 9).
- Oil line (15) at reservoir (13) unbolt, bolt on, (step 10).
- Seal (14) replace according to condition.
- Filter (18) remove, install.
- Reservoir (13) unbolt, bolt on (8 Nm), (step 12).
- Gasket (12) replace according to condition.
- Distributor rotor (3) and follower (4) remove, install.
- Protective cover (5) and seals (6) take off, fit on.
- Connector of solenoid (8) of camshaft adjuster unplug, plug in.
- Front covers at top (30), (30a) remove.
- Sealing surfaces clean.
- Sealing surfaces coat with sealant 002 989 47 20 10.
- Front covers (30), (30a) install with insertion sleeve, 119 689 00 14 00.
- Leaks check with engine running.
Tightening Torques: Specifications
Procedure
1. Unscrew bolts from bracket of actuator.
Installation Note: Bolts should be coated with sealant 002 589 47 20 10 when installing.
2. Unbolt shielding caps and high voltage distributors and take off.
3. Unbolt coverings from front cover.
4. Unbolt right ignition cable holder at cylinder head.
5. If power steering fitted with non-removable reservoir (1st version) perform steps 8 to 9.
6. Slacken poly V-belt. Service and Repair
7. Unscrew bolts (arrows). Place mounting plate, with power steering pump (11) and lines/wiring connected, to the side. Tighten to 21 Nm on reassembly.
Installation Note: The power steering pump mounting plate bolt which is screwed into the cylinder head at the front must be coated with sealant when installed. Pay attention to angle bracket (1) of wiring harness.
8. If power steering pump with detachable reservoir (2nd version) is fitted perform steps 11 to 14.
9. Extract oil from the reservoir of the power steering pump with the hand pump, special tool 112 589 00 72 00 for extracting oil.
Installation Note: Fill power steering pump and bleed.
10. Unbolt oil line (15) at reservoir.
Installation Note: Replace seal according to condition.
11. Remove filter in reservoir of power steering pump.
12. Unscrew bolts (Torx) (arrows). Take off reservoir (13). Tighten to 8 Nm on reassembly.
Installation Note: Replace gasket of reservoir (13) according to condition.
13. Unbolt distributor rotor and follower.
Installation Note: The slot of the distributor follower must engage over the pin in the camshaft.
14. Unplug connector of solenoid of camshaft adjuster.
15. Unscrew bolts of covers at front, take off cover.
16. Clean sealing surfaces.
17. Coat front covers with sealant 002 989 47 20 10.
Fit insertion sleeve, special tool 119 589 00 14 00, onto exhaust camshaft sprockets and install front covers.
18. Coat front cover bolts with sealant. Tightening torque 21 Nm.
19. Install in reverse order, observing all installation notes and tightening specifications..
20. Run engine, check for leaks.