Table of contents: Left upper timing chain cover ↓ Right upper timing chain cover ↓ Lower timing chain cover ↓
1. Timing chain cover installation details are shown in the illustrations.
19.1a. Timing chain cover installation details (models before 05.2010.):
1 - Rear crankshaft oil seal;
2 - Lower timing chain cover;
3, 18 - Centering bushings, 2 pcs.;
4, 8, 11, 17 - Bolts subject to replacement, tightened in several approaches, with a final force of 9 Nm;
5 - Bolt, 9 Nm;
6 - Sealing cover;
7, 14 - Sealing ring, subject to replacement;
9 - Left upper timing chain cover;
10, 16 - Gasket, subject to replacement;
12 - Torx bolt 30, 9 Nm;
13 - Vacuum pump;
15 - Right upper timing chain cover;
19 - Sealing element, 2 pcs.;
20 - Cover fastening bolts 2.
19.1b. Timing chain cover installation details (models from 06.2010.):
1 - Cover mounting bolts 4;
2 - Rotor of the CKP sensor;
3 - Rear crankshaft oil seal;
4 - Lower timing chain cover;
5, 20 - Centering bushings, 2 pcs.;
6, 10, 13, 19 - Bolts subject to replacement, tightened in several approaches, with a final force of 9 Nm;
7 - Bolt, 9 Nm;
8 - Sealing cover;
9, 16 - Sealing ring, subject to replacement;
11 - Left upper timing chain cover;
12, 18 - Gasket, subject to replacement;
14 - Torx bolt 30, 9 Nm;
15 - Vacuum pump;
17 - Right upper timing chain cover;
21 - Sealing element, 2 pcs.;
22 - Starter housing;
23 - CKP sensor housing;
24 - Crankshaft position sensor mounting bolt;
25 - SKR sensor;
The timing chains are located on the rear of the engine.
Left upper timing chain cover
2. Remove the left intermediate pipe of the exhaust system (see Chapter 4).
3. Remove EGR cooler switching valve No. 2 "N381" from the bracket (3 in the illustration), unscrew the bolts (arrows), disconnect the coolant hose (2) and push the rear left coolant pipe to the side.
19.3. Valve "N381" (3) and fastening of coolant lines (1, 2, arrows).
4. Remove the bolts (3 and 4 in the illustration) and remove the EGR pipes.
19.4. Bolts (3 and 4) of EGR pipes.
5. Remove the bolts (1-3 in illustration 8.11c) and remove the left upper timing chain cover.
6. Follow the steps described in paragraphs 9 and 11 Section 8.
7. Install the remaining removed parts.
Right upper timing chain cover
8. Remove the vacuum pump (see Chapter 8).
9. Cut the ties (arrows in the illustration) and move the electrical wiring aside.
19.9. Removing the wiring bracket.
Unscrew the bolt (1) and remove the bracket (2).
10. Remove the bolts (1-3 in illustration 19.12) and remove the right upper timing chain cover.
11. Follow the steps described in paragraph 9 Section 8.
12. Apply a bead of sealant into the groove (1 in illustration 8.11a) covers of the right upper chain. The sealant should completely fill the groove and protrude from it by 1.5-2.0 mm. Place the gasket (2). Apply beads of sealant with a diameter of 3 mm to the joints of the right cylinder head with the lower timing chain cover (by analogy with illustration 8.11b), install the right upper chain cover and tighten its bolts in the following order. Tighten the bolt first (1 in the illustration) - with a force of 3 Nm, and then tighten the bolts in sequence (2-1-3) with a force of 9 Nm.
19.12. Sequence of tightening the fasteners of the right upper chain cover.
Note: Tighten the bolts (3) in a diagonal order.
13. Install the remaining removed parts.
Lower timing chain cover
14. Remove the drive disc (see section 18). Drain the engine oil (see Section 6 of Chapter 1).
15. Remove the left and right intermediate exhaust pipes together with the intermediate flanges (see Chapter 4).
16. Remove the left and right upper timing chain covers (see subsections above).
17. If present, unscrew the nuts (see illustration) and remove the wiring connector bracket from the left engine mount bracket.
19.17. Electrical wiring bracket nuts.
18. Remove the bolts (arrows in the illustration) and separate the return oil pipe (1) from the cylinder block.
19.18. Bolts (arrows) for fastening the return oil pipe (1).
19. Follow the steps described in paragraphs 8-9 Section 8.
20. Install the sealing elements into the lower chain cover (2 and 5 in the illustration) and apply beads of sealant into the grooves (1 and 4).
19.20. Lower timing chain cover seal parts.
The sealant should completely fill the grooves and protrude 1.5-2.0 mm. Apply 1.5-2.0 mm diameter beads of sealant around holes (3 and 6). Make sure there are two centering bushings for the lower chain cover in the cylinder block. Install the cover and tighten its fasteners in the following order. First tighten all the bolts (1-9 in illustration 8.8) with a force of 5 Nm in a diagonal order, starting from the inside and moving outwards. Then, also in a diagonal order, tighten bolts (1-7) to 9 Nm. Finally, tighten bolts (8 and 9) to 23 Nm.
21. Install the new rear crankshaft oil seal and drive plate (see Section 18).
22. Install the remaining removed parts. Fill the engine oil and check the coolant level (see Chapter 1).