Removal and Installation of Timing Case Cover
Preceding Work:
- Tensioning (drive belt) device removed. Service and Repair
- Cylinder head covers removed. Service and Repair
Procedure:
- Position cylinder 1 to 45° before ignition TDC (arrow).
- Fix camshafts in position with pins (01), special tool 111 689 03 15 00.
- Unscrew left cylinder head: bolts (1), (1a) and (2). Tightening torque on reassembly: (21 Nm).
- Place mounting plate with power steering pump (11) to the side with oil lines connected.
Installation Note: Coat bolt (2) with sealant 002 989 47 20 10.
On engine 119.97: install bolt (1a) with retaining bracket (4) of wiring harness.
- Remove front covers at top (30) and (30a).
- Mark timing chain relative to camshaft sprockets (31), (32), (33) and (34) with colored marking (arrows).
- Remove chain tensioner (6). Service and Repair
- Remove camshaft adjusters (32) and (33) and exhaust camshaft sprockets (31) and (34).
- Remove vibration damper. Service and Repair
- Detach and lower oil pan. Service and Repair
CAUTION: Do not damage oil pan gasket; remove oil sump, if necessary, and replace gasket.
- Remove coolant pump (3). Water Pump
- Unscrew screw plug (35) with seal (36). Tighten to 15 Nm on reassembly.
Installation Note: Replace seal (36) according to condition.
- Remove tensioning rail pin (37) with impact puller (02) and threaded insert (03), special tools 116 589 20 33 00 and 116 589 01 34 00.
- Remove tensioning rail (38).
- Unscrew fit collar bolts; (a) and (b) and bolts (d) and (e) of timing case cover. Tighten to 21 Nm on reassembly.
NOTE:
- When performing repairs, fit collar bolts or the bolts + washers should be installed depending on the bolts fitted previously.
- On engines 119.98, the center bolts (b and e) are discontinued; if the timing case cover is replaced on engines 119.97, it should be bolted on to the left and right cylinder head with two bolts each.
- Remove front crankshaft radial seal (15). Service and Repair
- Remove oil pump (25). Service and Repair
- Unscrew bolts (f), (g) and (h) at front of timing case cover (9). Tighten to 21 Nm on reassembly
- Remove timing case cover (9).
NOTE:
- Use a bent piece of metal to detach oil pump chain (26) at the crankshaft sprocket (27) and attach.
- Replace front crankshaft radial seal.
CAUTION: Do not damage cylinder head gaskets (arrows).
- Replace O-rings (23) and (24) for sealing the coolant ducts.
- Clean sealing surfaces.
- Coat sealing surfaces with sealant 002 989 47 20 10.
- Coat cylinder head gaskets (arrows) with engine oil.
- Installation is reverse of removal procedure, observing all installation notes and tightening specifications. Note dowel sleeve (29) and dowel pin (29a).
- Check for leaks with engine running.