Catenary rule, upper timing chain

Catenary rule, upper timing chain

1.	Place the car on a lift, put covers over the wings and detach the negative cable from the battery.

2.	Remove the air cleaner with mass air flow sensor and hoses from the turbocharger and camshaft cover.

3.	Remove the engine cover.

4.	Remove the turbo delivery pipe (2 bolts under the wiring harness).

5.	Remove the wiring harness channel from the cylinder head and disconnect the fuel lines from the camshaft cover.

6.	Remove the rear centre nut securing the front exhaust pipe to the turbocharger.

7.	Raise the car, remove the lower engine cover and the front right wheel.

8.	Remove the front part of the exhaust pipe from the turbocharger and lower the car.

9.	Place a jack with a wooden block on top under the oil sump and carefully lift the engine to take the weight off the right-hand engine mounting.

10.	Dismantle the right-hand engine mounting from the engine and the body.

11.	Remove the engine anchorage (the bottom bolt does not need to be removed completely) and raised the engine it bit higher. Important Make sure nothing is damaged when the engine is moved.

12.	Remove the camshaft cover.

13.	Dismantle the upper timing chain tensioner.

14.	Heat both the catenary rule bolts and remove them.

15.	Pull the catenary rule upwards and remove it. Important Note its position.

To fit

1.	Position the new catenary rule, apply sealant 74 96 284 to the bolts and tighten them. Tightening torque: 8 Nm (6 lbf ft).

2.	Fit the chain tensioner for the upper timing chain with a new gasket. Tightening torque: 60 Nm (44 lbf ft).

3.	Fit the right-hand engine mounting bracket on the engine. Tightening torque: 47 Nm (35 lbf ft).

4.	Fit the right-hand engine mounting to the engine. Tightening torque: 47 Nm (35 lbf ft). Carefully lower the engine and remove the jack.

5.	Make sure the engine is suspended freely and tighten the right-hand engine bracket to the body. Tightening torque: 47 Nm (35 lbf ft).

6.	Apply Molycote 1000 on the turbocharger studs.

7.	Raise the car and position the front part of the exhaust pipe with a new gasket and mount new nuts.

8.	Tighten the joints in the front exhaust pipe loosely making sure the exhaust pipe is not under strain at any point and then tighten it to the turbocharger. Tightening torque: 25 Nm (18.5 lbf ft).

9.	Refit the lower engine cover and the wheel. Tightening torque, wheel 110 Nm (81 lbf ft). Lower the car to the floor.

10.	Clean any gasket remains from the sealing surfaces on the camshaft cover.

11.	Position a new gasket on the camshaft cover. There are sleeves on the bolts on which the gasket fits.

12.	Apply sealing compound 87 81 841 to the sealing surface, see illustration.

13.	Position the transmission cover on the cylinder head and tighten the bolts. Tightening torque: 8 Nm (6 lbf ft).

14.	Tighten the remaining nuts between the turbocharger and the front exhaust pipe. Tightening torque: 25 Nm (18.5 lbf ft).

15.	Press the fuel lines back into their fastenings and fit the wiring harness channel on the cylinder head.

16.	Refit the turbo delivery pipe.

17.	Refit the air cleaner with mass air flow sensor and hoses.

18.	Connect the crankcase ventilation hose to the camshaft cover and refit the engine cover.

19.	Connect the negative cable to the battery.

20.	Restore the engine bay to its original condition.

21.	Adjust the clock in the car and press 5 times on the remote control lock/unlock button.