Timing cover, VIN 12020001-
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Timing cover, VIN 12020001-
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(in-car)
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Important
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The cylinder head must be removed only if the engine is at room temperature.
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1.
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Make a note of any radio code.
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2.
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Position the car on a lift, put covers over the wings, detach the cables from the battery, remove the battery and open the expansion tank cap.
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3.
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Raise the car, remove the lower engine cover, the belt circuit cover and the front right wheel.
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4.
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Place a receptacle under the car and open the radiator drain plug.
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5.
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Unplug the oil level sensor and oil temperature sensor connectors. Cut the cable tie.
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7.
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Remove the air cleaner with mass air flow sensor and hoses.
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8.
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Remove the upper engine cover.
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9.
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Remove the charge air pipe (2 bolts under the wiring harness) and seal the openings of the hose and the turbocharger. Disconnect the hose from the throttle body.
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10.
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Unplug the atmospheric pressure sensor, coolant temperature sensor, control module (2 connectors), EGR valve, timing sensor and pressure sensor. Cut the lower cable tie.
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Important
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Take care not to damage the pins when removing the fitting the connector to the control module.
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11.
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Remove the wiring duct from the cylinder head and remove the fuel lines from the camshaft cover.
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12.
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Unplug the glow plugs.
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13.
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Detach the wiring harness from the rear bracket and remove the wiring harness and bracket from the engine mountings.
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14.
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Detach the vent hose from the thermostat housing and put it on one side.
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15.
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Remove the throttle body. Remove and move aside the EGR valve.
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16.
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Remove the fuel return hoses.
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17.
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Remove the hoses from the thermostat housing.
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18.
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Disconnect the fuel lines from the fuel distribution pump.
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19.
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Mark the position of the fuel rails and their clamps, and remove the rails.
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20.
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Remove the vacuum hose from the swirl throttle control valve.
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21.
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Detach the hook for the coolant hose from the rear lifting eye.
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22.
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Remove the heat shields from over the turbocharger, starter motor and the exhaust manifold, and undo the nut on the rear engine mounting.
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23.
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Remove the vacuum hose from the wastegate.
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24.
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Remove the front exhaust pipe from the turbocharger.
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25.
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Cover the generator to protect it against coolant spill and detach the coolant hose from the generator bracket.
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26.
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Detach the vacuum hose from the brake servo and the vacuum hose connected to the bottom of the vacuum pump.
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27.
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Remove the vacuum pump and adapter.
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Important
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Note the position of the vacuum pump and dismantle it carefully.
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28.
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Remove the top bolt on the exhaust manifold support and loosen the bottom one so that the support can be rotated out of the way.
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29.
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Raise the car and detach both the turbocharger oil pipes from the cylinder block and seal the pipes.
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30.
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Relieve the tension of the belt tensioner by turning it anticlockwise with a 19 mm wrench. Lift off the belt.
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31.
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Remove the belt tensioner.
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32.
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Remove the crankshaft position sensor with O-ring and lower the car.
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33.
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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.
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Important
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Make sure nothing is damaged when the engine is moved.
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34.
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Remove the right-hand engine mounting and bracket from the engine and the body.
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35.
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Remove the camshaft cover.
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36.
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Remove the bolts securing the pump drive cover, carefully insert a spatula behind the cover and prise it off.
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Important
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Take care, otherwise the cover can be distorted, which result in leaks.
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37.
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Turn the crankshaft with the centre bolt on the pulley two revolutions until it reaches the mark for top dead centre in cylinder 1. Make sure both cams for cylinder 1 point upwards.
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38.
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Insert
Adjustment tool, crankshaft
83 95 352 into the hole for the crankshaft position sensor. Push the tool somewhat inward at the same time as turning the crankshaft to its zero point. The tool will then go into a recess in the crankshaft and lock it.
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39.
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Make sure the marks on the crankshaft pulley and the timing cover are aligned. The arrow on the single cam chain sprocket on the fuel distribution pump must also be aligned with the recess in the pump. Fit
83 95 337 Adjustment tool, fuel pump
into the hole.
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40.
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Remove all the inspection gauges.
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41.
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Attach a hose to the cylinder block drain plug. Place a receptacle under the car and drain the coolant. Use an 8 mm hex key. Close the drain plug.
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42.
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Remove the coolant pump pulley and the coolant pump.
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43.
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Dismantle the upper timing chain tensioner.
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44.
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Attach a long cable tie to the timing chain. This is to be used as a handle.
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45.
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Remove the camshaft sprocket. Use an open wrench to hold the sprocket steady using the hexagonal recess on the camshaft.
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46.
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Carefully place the chain on one side.
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47.
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Remove the top generator bolt and loosen the bottom one so that the generator can be rotated downwards
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48.
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Place wedges
83 95 238 Wedge
between the oil sump and the subframe to support the engine properly. Lower the engine and remove the jack.
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49.
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Undo the four bolts securing the cylinder head to the timing cover.
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Important
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Note the length of the bolts and their location.
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50.
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Dismantle the cylinder head by undoing the bolts in the illustrated order. Lift the cylinder head
straight up
and lay it in such a way as the fuel injectors, glow plugs or valves are not damaged.
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51.
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Raise the car, place a receptacle under the engine, undo the oil drain plug and drain the engine oil.
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53.
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Dismantle the lower timing chain tensioner.
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54.
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Dismantle the oil sump. Clean away dropping oil.
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Important
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Take note of the length and position of the bolts.
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55.
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Undo all the bolts on the timing cover.
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Important
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Note how the bolts are fitted, as they are of varying lengths.
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56.
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Undo the four bolts on the upper timing chain gear and remove the chain and gear.
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Important
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The centre nut must
absolutely not
be undone.
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57.
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Carefully remove the lower timing chain together with the gears and store them suspended without changing their relative positions.
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58.
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Dismantle all the catenary rules.
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59.
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Remove the timing cover gasket.
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60.
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Remove the front crankshaft seal from the timing cover.
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1.
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Clean the sealing surfaces, check all the parts and replace as necessary.
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2.
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Fit a new gasket on the cylinder block.
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3.
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Refit all the catenary rules.
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5.
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Refit the gears on the crankshaft and fuel distribution pump together with the lower timing chain. Make sure the recess in the fuel distribution pump flange is aligned with the hole in the pump and that they are visible through the hole in the gear. The lower part of the timing chain must be taut.
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7.
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Fit the upper timing chain and fasten the gear on the fuel pump shaft without tightening the bolts.
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9.
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Fit the timing cover with the bolts in their original positions.
Tightening torque: 20 Nm (15 lbf ft).
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11.
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Position the sealing ring with protective sleeve and tool 83 95 410 (KM-935-2) on the crankshaft. Press in the sealing ring using the bolt for the crankshaft belt pulley until it is flush with the timing cover.
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12.
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Check that there are no impurities or other foreign matter in the sump and clean the sealing surfaces with benzene.
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13.
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Apply sealing compound 87 81 841 to the mating surfaces, see illustration.
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14.
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Position the oil sump against the gearbox and fit it with new gaskets. If the gearbox has been dismantled, a steel rule must be put against the sealing surface to the gearbox to guide the position of the oil sump.
Tightening order:
1 Tighten all bolts by hand.
2 Tighten the bolts in the cylinder block and timing cover: 20 Nm (15 lbf ft)
3 Tighten the bolts on the gearbox: M8, 20 Nm (15 lbf ft); M10, 40 Nm (30 lbf ft)
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15.
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Refit the oil plug with a new seal.
Tightening torque 18 Nm (13 lbf ft)
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16.
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Fit the chain tensioner for the lower timing chain with a new gasket. Do not confuse the lower and upper chain tensioners. See Lower timing chain tensioner.
Tightening torque 60 Nm (44 lbf ft)
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17.
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Remove tools 83 95 352 and 83 95 337.
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18.
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Fit the crankshaft pulley with a new bolt. Use
Holding tool, diesel
83 95 360.
Tightening torque 150 Nm (111 lbf ft) + 45°
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19.
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Refit
Adjustment tool, crankshaft
83 95 352 and make sure the marks on the crankshaft belt pulley and the timing cover are aligned.
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21.
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Remove adjustment tool 83 95 337 and tighten the bolts securing the timing chain gears to the fuel distribution pump.
Tightening torque 20 Nm (15 lbf ft)
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22.
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Check that adjustment tool 83 95 337 can be fitted and removed with ease.
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23.
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Use compressed air to blow clean the bolt holes in the cylinder block.
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24.
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Clean any gasket remains from the sealing surfaces of the cylinder head and cylinder block.
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25.
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Sparingly apply flange sealant 87 81 841 to the areas shown in the illustration.
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26.
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Check with a steel rule that the sealing surfaces on the cylinder head and cylinder block are plane and not damaged.
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27.
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Place a new gasket of the same thickness as that removed onto the cylinder block (1 notch = 1.3 mm, 2 notches = 1.4 mm).
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28.
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Fit
Adjustment tool, camshaft
83 95 386 to the camshaft and cylinder head. The camshaft can be turned slightly if necessary with an open spanner in the hexagonal recess on the camshaft at the same time as the gauge is put into the correct position.
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29.
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Position the cylinder head on the cylinder block while pulling the timing chain up to its correct position.
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30.
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Tighten the cylinder head with new bolts in the order shown in the illustration.
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Important
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The order of each stage must be followed.
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Tightening torques
Stage I: 25 Nm (18.5 lbf ft)
Stage II: 65°
Stage III: 65°
Stage IV: 65°
Stage V: 65°
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31.
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Tighten the bolts on the timing cover as previously fitted.
Tightening torque: 20 Nm (15 lbf ft).
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32.
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Place a jack with wood block under the oil sump, carefully raise the engine and remove the wedges between the engine and the subframe.
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33.
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Fit the generator.
Tightening torque: 35 Nm (26 lbf ft).
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34.
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Lift up the timing chain and position the camshaft gear so that it runs freely on the camshaft, and fit it with a new bolt. Tighten by hand.
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Important
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The crankshaft must not be turned in the reverse direction.
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36.
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Mount the adapter for the
Adjustment tool, timing chain
83 95 394 on the camshaft sprocket and mount the adjustment tool on the cylinder head.
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37.
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Secure the position of the adapter on the camshaft gear by turning it slightly anticlockwise with a ratchet handle. Tighten the adjuster screw on the tool.
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Important
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Inspection gauge 83 95 337 must be easy to remove and fit the whole time. If this is not the case, the tool's adjuster screw can be loosened slightly.
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38.
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Using a new bolt to secure the camshaft sprocket, tighten the bolt while holing the camshaft steady with an open wrench in the hexagonal recess on the camshaft.
Tightening torque 90 Nm (67 lbf ft) + 60°
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39.
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Fit the chain tensioner for the upper timing chain with a new gasket.
Tightening torque 60 Nm (44 lbf ft)
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40.
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Remove all tools and gauges.
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41.
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Turn the crankshaft two revolutions until it is just before the mark for top dead centre in cylinder 1. Check that both cams for cylinder 1 point diagonally upwards.
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42.
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Insert
Adjustment tool, crankshaft
83 95 352 into the hole for the crankshaft position sensor. Push the tool somewhat inward at the same time as turning the crankshaft to its zero point. The tool will then go into a recess in the crankshaft and lock it.
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43.
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Make sure the marks on the crankshaft pulley and the timing cover are aligned. The arrow on the single cam chain sprocket on the fuel distribution pump must also be aligned with the recess in the pump.
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45.
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Fit adjustment tool 83 95 386 to the camshaft and cylinder head. If the gauge does not fit, the engine valve timing must be adjusted. See
Adjusting valve timing
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46.
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Fit the coolant pump and its belt. Use a new O-ring.
Tightening torque: 20 Nm (15 lbf ft).
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47.
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Remove all special tools.
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48.
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Clean any gasket remains from the sealing surfaces on the camshaft cover.
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49.
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Position a new gasket on the camshaft cover. There are sleeves on the bolts on which the gasket fits.
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50.
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Apply sealing compound 87 81 841 to the sealing surface, see illustration.
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51.
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Position the transmission cover on the cylinder head and tighten the bolts.
Tightening torque: 8 Nm (6 lbf ft).
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52.
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Lay the engine wiring harness over the engine.
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53.
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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 pump cover.
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54.
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Apply a 2 mm bead of flange sealant 87 81 841 to the pump cover, remove the cloth from the timing cover and fit the pump cover.
Tightening torque 6 Nm (5 lbf ft).
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55.
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Fit the right-hand engine mounting and bracket to the engine.
Tightening torque: 47 Nm (35 lbf ft).
Carefully lower the engine and remove the jack.
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56.
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Make sure the engine is suspended evenly and tighten the right-hand engine mounting.
Tightening torque: 47 Nm (35 lbf ft).
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57.
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Raise the car and fit the crankshaft position sensor with a new O-ring.
Tightening torque: 8 Nm (6 lbf ft).
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58.
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Plug in the oil level sensor and oil temperature sensor. Secure the cables to the coolant pipe using a cable tie.
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59.
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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).
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60.
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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.
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61.
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Connect the turbocharger oil return pipe to the cylinder block.
Tightening torque: 30 Nm (22 lbf ft).
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62.
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Connect the turbocharger oil delivery pipe to the cylinder block.
Tightening torque: 20 Nm (15 lbf ft).
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63.
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Lower the car and lower the exhaust manifold support back into place and tighten the bolts.
Tightening torque 25 Nm (19 lbf ft)
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64.
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Fit the exhaust pipe and a new gasket and fit new nuts. Tighten.
Tightening torque 25 Nm (19 lbf ft)
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65.
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Clean the sealing surfaces on the vacuum pump.
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66.
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Fit a new gasket on the vacuum pump and fit the pump together with the adapter.
Tightening torque: 8 Nm (6 lbf ft).
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Important
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The vacuum pump must be fitted in the same position as it was previously.
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67.
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Connect the vacuum hose for the brake servo to the vacuum pump.
Tightening torque: 18 Nm (13 lbf ft).
Connect the vacuum hose to the bottom of the vacuum pump.
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68.
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Connect the vacuum hose to the wastegate vacuum unit.
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69.
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Attach the coolant hose to the generator bracket.
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70.
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Refit the heat shields over the starter motor, exhaust manifold and turbocharger.
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71.
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Tighten the nut on the rear engine mounting.
Tightening torque: 47 Nm (35 lbf ft).
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72.
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Fit the hook for the coolant hose on the rear lifting eye.
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73.
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Connect the vacuum hose to the swirl throttle control valve.
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74.
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Attach the fuel rails with clamps in their original positions.
Tightening torque 25 Nm (19 lbf ft)
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75.
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Connect the fuel lines to the fuel distribution pump with new seals.
Tightening torque 25 Nm (19 lbf ft)
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76.
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Connect the hoses to the thermostat housing.
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77.
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Connect new fuel return hoses to the fuel bridges. Pull off the connection on the fuel pump and connect
30 14 883 pressure/vacuum pump
. Create a vacuum of 750 mbar and wait for 1 minute. Make sure the dial on the tool has not moved.
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78.
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Connect the vent hose to the thermostat housing.
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79.
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Fit the EGR valve with a new O-ring and the throttle body. Plug in the connector.
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80.
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Fit the wiring harness bracket to the engine mounting and press the fuel lines on the bracket.
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81.
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Fit the wiring harness duct to the cylinder head, plug in all the connectors including the control module and glow plugs and secure the wiring harness.
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Important
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Take care not to damage the pins when removing the fitting the connector to the control module.
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82.
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Fit the cable duct to the throttle body and camshaft cover
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83.
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Connect the hose to the throttle body.
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84.
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Refit the charge air pipe.
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85.
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Refit the air cleaner with mass air flow sensor and hoses.
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86.
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Connect the fuel lines.
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88.
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Remove the end cap and connect the nipple to the service outlet on the fuel pump feed line.
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89.
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Suck until a constant flow of fuel is seen in the suction line to the brake bleeding tool.
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90.
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Remove the bleed nipple from the service outlet while it is still sucking (to avoid fuel spillage and air entering the system).
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91.
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Put on the end cap for the service outlet.
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92.
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Refit the engine cover.
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93.
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Fit the battery and connect the cables.
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95.
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Fill with coolant, check the integrity of the system and bleed it as follows:
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•
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Connect exhaust hoses to both the engine exhaust system and the auxiliary heater exhaust system and start the engine.
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•
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Check that there is a constant flow of coolant through the hose from the thermostat housing to the expansion tank. NOTE: vital.
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Start the parking heater with the diagnostic tool (Body, SID, Activate, Heater). The parking heater stops when the engine temperature has reached 80°C or on exiting the parking heater menu.
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Run the engine until the thermostat has opened. Top up as necessary.
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96.
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Restore the engine bay to its original condition.
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97.
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Adjust the clock in the car and press 5 times on the remote control lock/unlock button.
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98.
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Raise the car. Fit the lower engine cover and belt circuit cover. Fit the wheel.
Tightening torque 110 Nm (81 lbf ft)
Lower the car to the floor.
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