Remove/install timing case cover

AR01.40-D-8000R

Remove/install timing case cover

26.10.09

 

Remove, Install

1

Disconnect ground cable from battery

2

Drain engine oil

 Installation: Check oil level, correct

3

Remove radiator

Engine 601.943

AR20.20-D-3865B

Engine 602.980

AR20.20-D-3865A

4

Remove fan

AR20.40-D-5660A

5

Remove poly-V belt

AR13.22-D-1202B

6

Remove poly-V-belt tensioning device

 Only when replacing timing case cover

AR13.25-D-3200A

7

Remove upper guide pulley (28)

Engine 602.980 without AC compressor

8

Remove guide pulley bracket (29)

Engine 602.980 without AC compressor

9

Remove vacuum pump

AR43.05-D-1320A

10

Remove vibration damper

Engine 602.980

AR03.30-D-1600A

Engine 601.943

AR03.30-D-1600B

11

Unscrew bolt (21) on oil dipstick guide tube from cylinder head

12

Unscrew belt pulley from coolant pump (27), remove

13

Unscrew hexagon head bolt (15) and remove power steering pump belt pulley (14)

14

Unscrew power steering pump (12)

Lay power steering pump down to side with lines connected and fasten

15

Remove alternator

AR15.40-D-5032A

16

Unscrew generator support (22)

Engine 601.943

*BA15.40-N-1005-01I

Engine 602.980

*BA15.40-N-1005-01I

17

Remove cylinder head cover (4)

AR01.20-D-5014A

18

Unscrew hexagon head bolts (7) and remove fuel filter with bracket (8)

 Attach with connected lines at side of engine compartment.

19

Unscrew hexagon socket head bolt (6) on cylinder head to timing case cover



*BA01.30-N-1003-01B



*116589030700

20

Unscrew bolts (17) with square nuts (9) to injection pump or intermediate flange

Engine 601.943

*BA07.11-N-1007-01A

Engine 602.980

*BA07.13-N-1003-01A

21

Unscrew hexagon head bolt (11) from oil pan (10) in area of timing case cover (16)

 Only loosen all other hexagon head bolts on oil pan.

 Installation: 

*BA01.45-N-1001-01H

Engine 601.943 bolt plan, oil pan

AR01.45-D-7500-06B

Engine 602.980 bolt plan, oil pan

AR01.45-D-7500-06A

22

Unscrew TDC sensor bracket (25)

Engine 601.943



 Installation: Screw on bracket so that the TDC position of the indicator on the 1st cylinder coincides with the TDC marking on the vibration damper

*BA03.30-N-1003-01B

23

Unscrew hexagon head bolt (20) on timing case cover to cylinder crankcase

 Installation: Observe bolt plan

Bolt plan for timing case cover

AR01.40-D-8000-01A



*BA01.40-N-1001-01B

24

Take off timing case cover (16)

 Do not damage oil pan gasket, replace if necessary

Installation: Clean sealing surfaces and apply sealant.

*BR00.45-Z-1017-01A

25

Replace O-ring (26)

On engines with vane-type vacuum pump (Barluk)

26

Install in the reverse order

Number

Designation

Engine 601.943

Engine 602.980

BA01.30-N-1003-01B

Cylinder head on timing case cover

M8

Nm

23

23

Number

Designation

Engine
601.943

Engine
602.980

BA01.40-N-1001-01B

Bolt, timing case cover to cylinder crankcase

M6

Nm

9

9

M8

Nm

-

-

Number

Designation

Engine
601.943

Engine
602.980

BA01.45-N-1001-01H

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

23

23

M10

Nm

-

-

Number

Designation

Engine
601.943

BA03.30-N-1003-01B

Bolt, TDC sensor bracket on timing case cover

Nm

9

Number

Designation

Engine 601.943

BA07.11-N-1007-01A

Injection pump on crankcase

Nm

23

Number

Designation

Engine 602.980

BA07.13-N-1003-01A

Bolts, intermediate flange to crankcase

Nm

23

Number

Designation

Engine 601.943

Engine 602.982

BA15.40-N-1003-01I

Bolt connecting alternator to carrier

Nm

45

45

BA15.40-N-1005-01I

Bolt, generator support on cylinder crankcase

Nm

23

25

Number

Designation

Order number

BR00.45-Z-1017-01A

Sealant, SV flame starting system replaced with: A001 989 25 20

A 000 989 54 20