Note. When installing, you will need: new cover gaskets, crankshaft seal and PTU sealant - see text.
Withdrawal
1. Drain the coolant (see chapter 1).
2. Remove the cylinder head cover (see paragraph 4).
3. Remove accessory drive belts (see chapter 1).
4. Remove the thermostat (see chapter 3).
5. Remove the damper pulley and crankshaft hub (see paragraph 5).
6. Remove the oil pan (see paragraph 12).
7. Remove the accessory drive belt tensioner (pic. 6.7).
8. Now you need to remove the water pump pulley. To prevent the pump pulley from turning when the bolts are loosened, screw the old belt onto the pulley and hold it firmly. Turn away bolts and remove a pulley.
9. Remove the two pins from the top of the cover. Beat them with a beard (less than 5 mm in diameter) towards the rear of the engine (pic. 6.9).
10. To access the bolts of the chain cover to the cylinder head, remove the phase regulator (see paragraph 9).
11. Turn out three bolts of fastening of a cover to a head of cylinders (pic. 6.11). Note that one of the bolts also secures the chain guide.
12. Turn out bolts of fastening of a cover of a chain to the block of cylinders and remove a cover (pic. 6.12, a, b). Remove the pads.
Installation
13. Remove the crankshaft cuff from the chain cover.
14. Thoroughly clean the mating surfaces of the cover with the cylinder block and block head.
15. Insert a new cuff into the bore of the cover. Press it into the bore using a pipe with an outer diameter slightly smaller than the diameter of the cuff or a wooden block (pic. 6.15).
16. Drive in the dowel pins of the upper part of the cover so that they protrude 2-3 mm above the surface of the cylinder block.
17. Place new gaskets on the cover. To keep them from falling "glue" them with a small amount of grease.
18. Apply a bead of Drei Bond 1209 to the top side of the cover where it contacts the head/block gasket (pic. 6.18).
19. Place the cover on the cylinder block, making sure that the gaskets do not move. Make sure the dowel pins fit into the corresponding holes in the cover. Screw in the cover fixing bolts and tighten them until hand-tight.
20. Drive in the cover dowel pins until they are flush with the outside of the cover.
21. Gradually tighten the cover bolts until the required torque is reached. Don't forget the three bolts securing the cover to the cylinder head.
22. Replace the phase regulator (see paragraph 9).
23. Install the pulley with damper and hub on the crankshaft.
24. The rest of the installation is carried out in the reverse order of removal, taking into account the following remarks.
- A) Install the accessory drive belt tensioner strut with the TOP/OBEN arrow pointing up,
- b) Install accessory drive belts (see chapter 1).
- V) Install thermostat (see chapter 3)
- G) Install the cylinder head cover (see paragraph 4).
- d) Install pallet (see paragraph 12).
- e) Finally, fill the cooling system.