Contents: Crankshaft pulley ⬇ Timing chain cover ⬇
1. The installation details of the timing belt cover are shown in the accompanying illustration.
17.1 Timing drive installation details
1 Cylinder head, with camshaft housing
2 Cylinder block
3 Auxiliary units bracket
4 Lid
5 Crankshaft sprocket, bearing surfaces must not be lubricated
6 Bolt, to be replaced, 20 Nm, then tighten to an angle of 90°
7 Oil pump sprocket
8 Oil pump drive chain
9 Bolt, 25 Nm
10, 14 Bolt, 15 Nm
11 Chain tensioner 8
12 Tensioner spring 11
13 Oil pan, installed with sealant D176 404A2
15 Piston
16 Spring
17 Chain tensioner 31
18 Bolt, 9 Nm
19 Chain cover 31
20 Bolt, 10 Nm
21 Crankshaft pulley, bearing surfaces must not be lubricated
22 Pulley bolt 21, must be replaced, 150 Nm, then tighten to an angle of 180°, when tightening the thread must be lubricated, but the supporting surface must not
23 Bushing
24 Sealing ring, must be replaced
25 Bolt, 50 Nm
26 Gasket
27 Left-hand thread bolt, to be replaced, 40 Nm, then tighten to 90°
28 Bolt, to be replaced, 50 Nm, then tighten to an angle of 90°
29 Chain tension bar 31
30 Timing phase regulator
31 Timing chain
32 Exhaust shaft sprocket
33 Chain guide bar 31
34 Guide bolt stud, 20 Nm
35 Bushing
Crankshaft pulley
2. Remove the drive belt (see Section 16).
3. Holding the pulley from turning with the T30004 tool and the T30004/1 bolt, unscrew the pulley mounting bolt and remove the pulley (see accompanying illustration).
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Caution: After removing the pulley, do not turn the crankshaft to prevent the chain from slipping off.
17.3 Right engine support mounting bolts
4. Install the pulley and tighten the new bolt by hand. The bearing surfaces of the bolt, pulley and bushing must not be lubricated.
5. Turn the crankshaft to the TDC position of piston No.1 (see Section 19).
6. Remove the bolts (1 and 3 in the accompanying illustration) and remove the bracket (2) of the right coolant pipe.
17.6 Bracket mounting bolts
Note: When installing, tighten bolt (1) to 8 Nm and bolt (3) to 40 Nm.
7. Unscrew the service hole plug in the cylinder block and screw the T10340 lock bolt into it until it stops, with a force of 30 Nm (see accompanying illustration). This bolt prevents the crankshaft from turning past TDC when the pulley mounting bolt is tightened.
17.7 Device T10340
8. Holding the pulley from turning with the T30004 tool and the T30004/1 bolt, tighten the pulley mounting bolt with a force of 150 Nm, and then tighten it to an angle of 90°.
9. Unscrew the lock bolt T10340 and tighten the service hole plug with a force of 30 Nm.
10. Further installation is carried out in reverse order.
Timing chain cover
11. Remove the top engine cover. To do this, unscrew the bolts (1 in illustration 15.2), unhook the coolant hoses (2) and pull the cover up.
Note: When installing, tighten the bolts to 8 Nm.
12. Unscrew the bolt (1 on the accompanying illustration) coolant pipes and remove the PCV hose (2) from the timing chain cover.
17.12 Coolant line (1) and PCV hose
13. Disconnect the ventilation line (1 on the accompanying illustration), by pressing on the retaining ring.
17.13 Ventilation line (1)
14. Disconnect the hose from the adsorber (1 on the accompanying illustration), leading to the intake manifold. Release the canister in the direction of the arrow (B) and remove it from the bracket in the direction of the arrow (A).
17.14 Removing the EVAP canister
15. Remove the bracket fasteners (3 on the accompanying illustration) adsorber, unscrew the filler neck bolt (2), disconnect the low coolant level sensor connector and pull the wiring out of the expansion tank. Unscrew the expansion tank mounting bolts (1) and set it aside without disconnecting the coolant hoses.
17.15 Providing access to the casing
16. Remove the drive belt (see Section 16).
17. Remove the water pump pulley (see Chapter 3).
18. Disconnect the connector (1 in illustration 5.13a) compressor magnetic clutch and unscrew the bolts (arrows). Remove the air conditioning compressor without disconnecting the refrigerant lines from it and secure it to the hood lock holder with wire so that the refrigerant lines are not stretched or kinked.
19. Remove the accessory bracket (see Section 16).
20. Unscrew the hollow bolt (2 on the accompanying illustration) supply oil line (1) of the turbocharger from the timing chain casing (3).
17.20 Oil Line Hollow Bolt
21. Remove the generator and idler roller (2 on the accompanying illustration), turn the crankshaft to TDC. Remove the crankshaft pulley (see subsection above) and the engine oil pan (see Section 21).
17.21 Fastening the generator and intermediate roller
22. Remove the front bonnet bumpers from the top sides of both front fenders. Insert the T10311 plates on the right (And in illustration 5.47) and left (B) sides in the direction of the arrows until they stop so that the arrows "R" and "L" on the plates point backwards. These plates are needed to avoid damaging the wings. Install the MP9-200 support, hook its spindle onto the right lifting eye and unload the right support (see accompanying illustration).
17.22 Unloading the right engine support
23. Remove the bolts (1-6 on the accompanying illustration) and remove the engine support.
17.23 Engine support fasteners
24. Remove the bolts (1-6 and arrows in the accompanying illustration) and remove the casing. If necessary, slightly raise the engine. The crankshaft bushing should remain in the casing. Remove the front crankshaft oil seal from the casing.
17.24 Timing chain cover fastener
25. Remove any sealant residue from the mating surfaces using a suitable chemical and degrease them. Insert new sealing rings into the rear side of the casing (see accompanying illustration).
17.25 Sealing rings on the back of the casing
26. Apply 10 mm diameter and 1 mm thick spots of D176 501A1 sealant to the places shown in the accompanying illustration (1 and 2) to prevent leaks between the casing and the joints of the cylinder head with its cover and the cylinder block.
17.26 Places to apply sealant
27. Install a new gasket on the centering sleeves. To facilitate centering, screw two M6x80 studs into the cylinder head and block. Slide the timing chain cover together with the crankshaft sleeve onto the studs and centering sleeves.
28. Tighten the casing mounting bolts evenly and diagonally: M6 bolts with 10 Nm and M10 bolts with 50 Nm.
29. Adjust the position of the engine support (see Section 15).
30. Install the front crankshaft oil seal (see Section 18).
31. Install the crankshaft pulley (see subsection above).
32. Secure the turbocharger oil feed pipe.
33. Further installation is carried out in reverse order.