Installing Chain Case Lid

Installing chain case lid

Component overview

Installation Location:

Component Overview:

Installing chain case lid

Note: Acetone can be used to clean the sealing faces. Ventilate this for 5 minutes before applying more sealant.

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

Lid Seals:

2. Attach the four seals -1, 2, 3 and 4- to the chain case lid.
3. Apply a silicone sealing bead to the contact points of the 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.

Additional Silicone:

Note: In the case of the M48/50 (turbo) engine, sealant must also be applied to the metal seal in the chain tensioner area.

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

Threaded Joint And Dimension:

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

Tightening Sequence:

5. Push the chain case lid upwards slightly and tighten the fastening screws -7, 8, 9 and 10- (about 1 - 2 Nm (0.5 - 1.5 ft. lbs.) in such a way that the lid is slightly jammed. Then align the lid. --> '153123 Installing chain case lid - chapter on "Adjusting"'

Aligning the chain case lid with a dial gauge

Adjusting The Preload:

ATTENTION: Danger of leaks!
^ If the chain case lid is not aligned properly, this component or the oil pan may start to leak during operation.
--> The chain case lid must not project over 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 in such a way that the dial gauge has a preload of about 1 mm.

Resetting Dial Gauge Scale:

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 at 0.

Measuring The Setback Distance:

3. Measure the offset. 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. It must not project out.

Aligning The Chain Case Lid:

4. Align the chain case lid by tapping lightly with a rubber hammer.

Checking The Position:

5. Once the chain case lid has been aligned, tighten two fastening screws on the left and right of the chain case lid base to 10 Nm (7.5 ft. lbs.). Then, check the position of the chain case lid again using the dial gauge.
6. Tighten the remaining fastening screws to the appropriate torque in the sequence shown.

Note: See figure! --> Tightening sequence
^ The quality of the exterior fastening screws must be 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 (M6/10.9) to 13 Nm (9.5 ft. lbs.).
^ Then check all screws again (second time round).

Tightening Sequence:

Subsequent work

Oil Pan Tightening Sequence:

1. Install oil pan.

Fastening Screws:

Fastening Screws On Engine Mounts:

2. Install engine carrier.

Radial Shaft Seal:

3. Fit front radial shaft seal.

Crankshaft Belt Pulley:

4. Fit crankshaft pulley. Fastening screw tightening torque: 250 Nm (185 ft. lbs.) + 90° torque angle.

Oil-Water Heat Exchanger:

5. Install bracket for oil-water heat exchanger.

Deflection Roller:

6. Fit deflection roller of cylinder row 1-4. Tightening torque 24 ft. lbs.. Then clip on cap.

Coolant Pump Pulley:

7. Tighten coolant pump pulley.

Belt Tensioner:

8. Install belt tensioner. Install holder with tensioning element. Tighten the top fastening screw Tightening torque 24 ft. lbs.. Tighten the bottom fastening screw Tightening torque 24 ft. lbs..

Drive Belt:

9. Fit and tension the drive belt.

Chain Tensioner:

10. Install chain tensioner with new sealing ring.
11. Install oil dipstick.

Camshaft Guide:

12. Check timing and adjust if necessary.
13. Install cover for camshaft housing (valve cover).
14. Install engine.