Upper Cover

REMOVING, INSTALLING UPPER TIMING CASE COVERS

Part 1 Of 2:

Part 2 Of 2:

TIGHTENING TORQUE











REPAIR PRODUCTS





SPECIAL TOOLS

Torx Bit Set:

DETACHING AND ATTACHING TIMING CASE COVER





1 Engine 120.980/981: Remove distributor rotor arm and driver (4).
Installation: The slot of the driver (4) should engage in the locating pin (arrow) in the camshaft.
2 Engine 120.980/981: Remove protective cover and seal.
3 Lift power steering pump reservoir up and out together with hoses.





4 Unbolt bracket (11) and remove.





5 Unbolt connection fitting (12a) at power steering pump (12).
Installation: Replace seal.





6 Unscrew bolts (arrows) and take off front covers.
7 Replace shaped rubber gasket and O-ring of coolant passage in front cover.
8 Clean sealing surfaces of front cover of cylinder head and groove of timing case cover.





9 Inspect shaped gaskets (arrows) of cover guide rail bridge (13)for signs of damage and replace if necessary.





10 Apply spots of sealant 002 9897320 10 into the oil-free groove of the timing case cover at the joint to the left and right cylinder head (arrows).
11 Insert new shaped gasket dry (without sealant) into oil-free groove. Coat the top side of the shaped rubber gasket with a little engine oil.
12 Coat front cover with sealant 002 989 73 20 10 at contact surfaces to cylinder head.





13 Engine 120.980/981: Fit insertion sleeve (1) 103 589 01 14 00 onto the exhaust camshaft. Coat sealing lip of radial seal (2) with engine oil,
14 install front covers.
When installing front covers, ensure that the shaped rubber gasket is not shifted at the bottom (arrows); chamfer edge at bottom of cover for this step.
At left-hand cover, remove screw plug (31), remove guide rail pin and re-install after installation.








15 Install bolts according to bolt diagram; tighten the bottom bolts first.
Install left front cover with bottom bolt (2).

WARNINGS AND CAUTIONS






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 on 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