Lower Timing Chain Cover

Lower Timing Chain Cover

Special tools, testers and auxiliary items required

• Engine Support Bridge (10-222 A)

• Adapter (10-222 A/22)

• Engine Support Adapter (10-222 A/3) , (Qty. 2)

• Bracket with Spindle and Hook (10-222 A/10) , (Qty. 2)

• Locking Pin (T10060 A)

• Counter Hold Tool (T10355)

• Thrust Piece (T10368)

• Bits (T10099)

• Shackle (10-222 A/12)

• Lifting Eyebolt (3368) (for automatic transmissions only)

Removing

- Remove the noise insulation.

- Remove the front right wheel housing liner..

- Drain engine oil.

- Remove the bolts - arrows -.

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

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

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

- Remove the right charge air hose - arrows -.

- To release the tension on the ribbed belt, turn the tensioner in the - direction of the arrow - from underneath.

- Secure the tensioner using the locking pin (T10060 A).

- Remove the ribbed belt from the vibration damper.

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

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

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 vibration damper bolt using the counter hold tool (T10355).

- Remove the vibration damper.

To avoid damaging the splines, only use the thrust piece (T10368) to install the vibration damper bolt.

- Install the vibration damper bolt and the thrust piece (T10368).

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

- Remove the air filter housing. Refer to => [ Air Filter Housing ] Air Filter Housing.

Danger of causing damage to other electronic components when disconnecting the battery.

• Complete the steps for disconnecting the battery.

- With the ignition turned off, remove the ground wire - arrow - from the battery.

- Remove the battery.

- Remove the battery tray bolts - arrows - and tray.

with a Automatic Transmission

- Install the lifting eyebolt (3368) into the transmission mount bracket as shown.

- Install the engine support bridge (10-222 A) using the following special tools:

• Adapter (10-222 A/22) , (Qty. 2)

• Engine support adapter (10-222 A/3) , (Qty. 2)

• Bracket with spindle and hook (10-222 A/10) , (Qty; 2)

• Shackle (10-222 A/12)

with a Manual Transmission

- Remove the shift mechanism from the transmission.

• Adapter (10-222 A/22) , (Qty, 2)

• Engine support adapter (10-222 A/3) , (Qty. 2)

• Bracket with spindle and hook (10-222 A/10) , (Qty. 2)

• Shackle (10-222 A/12)

Continuation for All

- Tension the engine with the spindle.

- Remove the engine mount to engine mount bracket bolts - arrows -.

- Remove the engine mount. Refer to => [ Engine/Transmission Mount Overview ] Service and Repair.

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

- 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 bracket.

- Loosen the lower bolts on the engine mount bracket using the bits (T10099).

- Remove the engine mount bracket and the bolts.

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

- Remove the wastegate bypass regulator valve bolts - arrows - and valve from the turbocharger.

- Remove the connection bolts - 1 - and connection from the turbocharger.

- Remove the bolts - 1 through 15 -.

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

The lower timing chain cover could be damaged. To avoid deformation, do not hold between the bolting points.

- Pry the lower timing chain cover off, when doing this, begin at - 1 and 2 -.

Installing

• For the correct tightening specifications, refer to => [ Timing Chain Cover Overview ] Timing Chain Cover Overview.

• Sealant, use silicone sealant (D 174 003 A2).

• If the cover was bent while it was being removed, it must be replaced.

• Note the expiration date of the silicone sealant.

• The cover must be installed within 5 minutes after application of the silicone sealant.

• Replace the bolts which have been tightened to an additional torque angle

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

• Risk of contaminating the lubricating system. Cover open parts of engine.

• Wear protective eyewear.

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

- Seal off both sides of the seal with tape to prevent contamination.

- Use a rotating plastic brush to remove any remaining sealing on the cover.

- Clean the sealing surfaces, they must be free of oil and grease.

Checking the Cover for Distortion

- Install the cover using the old bolts and tighten them to 8 Nm.

- Check between the cover and housing using a feeler gauge, the gap must not exceed 0.2 mm.

• If the gap exceeds 0.2 mm, replace the cover.

• It is not possible to measure between the cover the upper oil pan, however check the sealing surface for evenness.

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

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

Cover with 15 Bolts

- Apply the silicone sealant (D 174 003 A2) on 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 application of the silicone sealant.

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

- Immediately install the cover and tighten the bolts:

• Cover with 15 bolts, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence, with 15 Bolts ] Timing Chain Cover Overview.

• Cover with 8 bolts, refer to => [ Lower Timing Chain Cover Bolt Tightening Sequence, with 8 Bolts ] Timing Chain Cover Overview.

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

- Fill the engine oil.

- Check the oil level.

Further installation is in the reverse order of removal.