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Timing cover cap

Timing cover cap

To remove



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

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

3. Raise the car, remove the lower engine cover, the cover in the right-hand wheel housing and the front right wheel.


4. Relieve the tension on the belt tensioner by turning it anticlockwise (towards the rear of the car) with a 19 mm spanner and lift off the belt.

5. Remove the belt tensioner.

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


7. 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.

8. Remove the right-hand engine mounting from the engine and the body and raise the engine higher.


Important

Make sure nothing is damaged when the engine is moved.


9. Remove the bolts on the cover, carefully insert a spatula behind the cover and prise it off.

Important

Take care, otherwise the cover can be distorted, which result in leaks.



To fit



1. Cover the opening in the timing cover with a lint-free cloth and remove any remains from the old gasket from the sealing surface. Clean also the sealing surface on the cap.

2. Apply a string of silicone sealant about 2 mm thick on the cap, remove the cloth from the timing cover and fit the cap.

Tightening torque: 6 Nm (4.5 lbf ft).

3. Fit the right-hand engine mounting to the engine.

Tightening torque: 47 Nm (35 lbf ft).

Carefully lower the engine and remove the jack.

4. Make sure the engine is suspended evenly and tighten the right-hand engine mounting.

Tightening torque: 47 Nm (35 lbf ft).

5. Apply Molycote 1000 on the turbocharger studs.

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


7. 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).

8. Fit the belt tensioner, tightening the top bolt first.


Tightening torque: 42 Nm (31 lbf ft).

Tighten the bottom bolt.

Tightening torque: 23 Nm (17 lbf ft).

9. Fit the multigroove V-belt on all the pulleys. Relieve the tension on the belt tensioner by turning it anticlockwise (towards the rear of the car) with a 19 mm spanner and fit the belt on its pulley. Make sure the belt is positioned correctly on all the pulleys.

10. Refit the lower engine cover, the cover in the right-hand wheel housing and the wheel.

Tightening torque, wheel 110 Nm (81 lbf ft).

Lower the car to the floor.

11. Tighten the last nut between the turbocharger and the front exhaust pipe.


Tightening torque: 25 Nm (18.5 lbf ft).

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