Installing Chain Case Lid

Installing chain case lid








Component overview

Installing chain case lid

Note: To clean the sealing surfaces, acetone can be used. Ventilate this for 5 minutes before applying more sealant.

1. Clean and degrease the sealing surfaces of the engine and housing lid.





2. Place the 4 seals -1, 2, 3 and 4- on the chain case lid.





3. Apply a silicone sealing bead onto the contact points camshaft housing/cylinder head, cylinder head/crankcase and crankcase upper section/crankcase lower section. The sealing bead should protrude about 20 mm above the contact points.





Note: In the case of the M48150 engine, sealant must also be applied to the metal seal in the chain tensioner area.

4. Screw down all fastening screws manually. At this stage, the screw heads should not be all the way down.





Note:
^ The chain case lid must be aligned using a dial gauge.
^ The chain case lid must not project over the lower section of the crankcase.
^ It (-dimension A- ) cannot go under 1/10 mm (-dimension A < 1/10 mm-).





5. Push the chain case lid upwards slightly and position the fastening screws -7, 8, 9 and 10- (about 1 - 2 Nm (0.5 - 2.5 ft. lbs.) in such a way that the lid is slightly jammed. Then align the lid.

Aligning the chain case lid with a dial gauge

Caution: Danger of leakage!
^ If the chain case lid is not aligned properly, this component or the oil pan may become leaky during operation.
^ The chain case lid must not project over the lower section of the crankcase.
^ It cannot go under 0.1 mm (dimension A 0.1 mm).





1. Insert the dial gauge into the universal gauge holder and position it such that the dial gauge has a preload of about 1 mm.





2. Set dial gauge scale to 0. To do this, place the dial gauge holder on a completely flat surface (e.g. crankcase flange) and turn the dial gauge scale until the pointer is on 0.





3. Measure offset. In order to do this, push with the holder starting from the lower section of the crankcase towards the chain case lid (the foot of the dial gauge holder is not located on the same component as the dial gauge probe) and measure the offset. The chain case lid must not be set back any more than 0.1 mm. A projection is not permissible.





4. Align the chain case lids by knocking lightly with a rubber hammer.





5. When the chain case lid has been aligned, tighten 2 fastening screws on the left and right of the chain case lid foot to 10 Nm (7.5 ft. lbs.). Subsequently, check the position of the chain case lid again with the dial gauge.
6. Tighten the remaining fastening screws to the appropriate torque in the order shown.





Note:
^ The exterior fastening screws must have a quality of 10.9.
^ If the quality is 8.8, the screws must be replaced.
^ Tighten screws 1 to 4 (M6 / 8.8) to 10 Nm (7.5 ft. lbs.).
^ Tighten screws 5 to 6 (M8 / 8.8) to 23 Nm (17 ft. lbs.).
^ Tighten screws 7 to 32 (M8 / 10.9) to 13 Nm (9.5 ft. lbs.).
^ Subsequently, check all screws again (second time round).

Remaining work





1. Install oil pans.





2. Install engine carrier.





3. Install front radial shaft sealing ring.





4. Install crankshaft belt pulley. Fastening screw tightening torque: 250 Nm + 90° torque angle.





5. Install bracket for oil-water heat exchanger.





6. Install deflection roller of cylinder bank 1-4. Tightening torque of the fastening screws: 23 Nm (17 ft. lbs.). Then clip on cap.





7. Tighten the coolant pump belt pulley to 23 Nm (17 ft. lbs.).





8. Install belt tensioner. Install holder with tensioning element. Tighten the upper fastening screw (M8 x 100) to 32 Nm (24 ft. lbs.). Tighten the lower fastening screw (M8 x 33) to 23 Nm (17 ft. lbs.).





9. Install and tighten drive belt.





10. Install chain tensioner with new sealing ring. Tightening torque: 60 Nm (44 ft. lbs.).





11. Check timing and adjust if necessary.
12. Install valve cover.
13. Install engine.

Tightening torques











Note:
^ The exterior fastening screws must have a quality of 10.9.
^ If the quality is 8.8, the screws must be replaced.
^ Tighten screws 1 to 4 (M6/ 8.8) to 10 Nm (7.5 ft. lbs.).
^ Tighten screws 5 to 6 (M8/ 8.8) to 23 Nm (17 ft. lbs.).
^ Tighten screws 7 to 32 (M8 I 10.9) to 13 Nm (9.5 ft. lbs.).
^ Subsequently, check all screws again (second time round).