1 - timing block cover, lower; 2 - hairpin (4 things.); 3 - cylindrical pin (2 pcs.); 4 - stuffing box; 5, 6 - sealing gaskets; 7, 8 - bolts (M6)
Replacing the lower timing cover must be carried out in the following order. Remove D-VANOS adjustment unit and thermostat.
Remove the alternator drive belt and its tensioner. While holding the water pump pulley from turning with the drive belt, remove the pulley mounting bolts.
Remove vibration damper. If the vibration damper is designed with a separate hub, the vibration damper hub must be removed. Remove the oil pan.
Use a mandrel with a diameter of less than 5.0 mm, press out the centering pins (3) on the timing cover, moving backwards. Loosen the top screws (arrows, fig. 3.78) fastening the timing cover to the cylinder head.
Remove bolts (arrows, fig. 3.79) fastening the timing cover to the cylinder block and remove it from the end of the engine.
Attention! Check the cylinder head gasket for damage. If necessary, remove the cylinder head and replace its seal.
Clean the sealing surfaces on the timing cover, cylinder head using a hardwood scraper.
Drive roll pins (3, fig. 3.77) into the timing case cover so that they protrude approximately 2-3 mm.
Attach new gaskets (5 and 6) on the timing case cover with a small amount of grease. Apply a bead of sealant «Drei Bond 1209» to the junction of the gaskets of the timing cover and the cylinder head.
Install the timing cover and screw in all the bolts (arrows, fig. 3.79) its attachment to the cylinder block. Bolts pre-tighten to 5 Nm (0.5 kgf·m).
Insert the centering pins at the same time (3. see fig. 3.77).
Tighten all bolts (M8, fig. 3.79) fastening the timing cover to the cylinder block in a checkerboard pattern with a torque of 10 Nm (1.0 kgf·m).
Attention! When all the bolts are tightened, for control, go through them again in a checkerboard pattern with a tightening torque of 10 Nm (1.0 kgf·m).
Screw in the bolts (arrows, see fig. 3.78) fastening the timing cover to the cylinder head and tighten them with a torque of 10 Nm (1.0 kgf·m).
Replace front crankshaft oil seal and assemble engine.