Remove/install timing case cover

AR01.40-P-8000HA

Remove/install timing case cover

12.4.10

 

Remove/install

1

Disconnect battery ground line

AR54.10-P-0003A

2

Remove charge air pipe (3)

Engine 605.960 in model 202

Engine 605.962 in model 210

AR09.41-P-1311H

3

Remove viscous fan clutch

Engines 605, 606

AR20.40-P-5660HB

Engine 604

AR20.40-P-5660HA

4

Remove poly-V belt

AR13.22-P-1202HA

5

Remove radiator (14)

Model 124 with engine 606.910

Model 210 with engine 606.912

AR20.20-P-3865HA

Model 210 with engine 606.962

AR20.20-P-3865HB

6

Remove pulleys of coolant pump (5) and power steering pump (6)

 except VDA pump:

To loosen bolts, place poly-V belt on pulleys and attach counterholder.



*603589004000



*BA20.10-P-1001-01A



*BA46.30-P-1001-01A

7

Remove cylinder head cover

AR01.20-P-5014HA

8

Remove vacuum pump (9)

 Installation of vane-model delivery pump (Barluk):

Replace O-ring (21) at oil spray nozzle.

AR43.05-P-1320A

9

Turn cylinder 1 to TDC

 so that bracket for TDC sensor can be adjusted during assembly.

10

Install retaining lock (03) for crankshaft/ring gear

 Use M690 bolts otherwise thread in rear end cover will be damaged.

AR03.30-P-5000HA

11

Remove oil-water heat exchanger (17) at oil pan

On vehicles with oil/water heat exchanger at oil pan.

AR18.30-P-3480HA

12

Remove vibration damper (77)

AR03.30-P-1600HA

13

Remove alternator

Model 202

AR15.40-P-5032EA

Model 210

AR15.40-P-5032F

14

Remove generator carrier (2)



*001589760900

15

Unscrew bolts for oil pan (8)



 Unscrew bolts near timing case cover, only loosen all other bolts of oil pan.

*BA01.45-P-1001-01A



*BA01.45-P-1002-01A



*001589760900

16

Remove coolant hoses (1, 4) at front cylinder head

 Inspect condition of coolant hoses and hose clamps, replace if necessary.

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

17

Unscrew power steering pump (30)

 Attach with connected lines at side of engine compartment.

AR46.30-P-0500A

18

Unbolt fuel filter (70/2)

 Unbolt fuel filter with connected lines and lay to one side.

19

Remove guide rail pins (32) at cylinder head

AR01.30-P-5800-04A



*116589203300



*116589013400



*605589003300

 Installation: Coat top slide rail pin with sealant and knock into the cylinder head as far as the stop.

Ensure the guide rail is correctly installed in the cylinder head

*BR00.45-Z-1012-01A

 Sealant optional.

*BR00.45-Z-1009-01A

20

Remove poly-V-belt tensioning device (33)

 Only if timing case cover is replaced.

AR13.25-P-3200HA

21

Unscrew injection pump (35) bolts on timing case cover



*BA07.02-P-1001-01A

 Installation: Check start of delivery,

AD07.00-P-1464B

22

Unscrew bracket for TDC sensor (36)

 Installation: Screw on bracket in such a way that the pointer is aligned with TDC marking on the vibration damper (77),
if necessary: 

Check setting of bracket of TDC sensor and correct

AR03.00-P-1101HA

23

Unscrew bolts, cylinder head to timing case cover (34)



*116589030700



*BA01.40-P-1002-01A

24

Remove timing case cover (40)

  Installation: Observe bolt length!

*BA01.40-P-1001-01A

 Do not damage cylinder head gasket and oil pan gasket. If necessary, replace damaged gasket:

Remove/install cylinder head

AR01.30-P-5800HA

Remove oil pan.

Remove oil pan, engine 604, 605 in
model 202, engine 605, 606 in model 124.

AR01.45-P-7500HA

Remove oil pan, engine 605, 606 in
model 210, engine 606.961 in model 140.

AR01.45-P-7500C

Remove oil pan, engine 604 in model 210.

AR01.45-P-7500D

 Check front crankshaft radial seal, if necessary according to condition:

Replace front crankshaft radial seal.

Observe fitted sleeves (6).

AR03.20-P-3000HA

25

Clean sealing surfaces at timing case cover and at crankcase

 Coat with sealant.

*BR00.45-Z-1012-01A

 Sealant optional.

*BR00.45-Z-1009-01A

26

Install in the reverse order

27

Fill cooling system

AR20.00-P-1142HW

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

28

Check for leaks with engine running

Number

Designation

Engine
604, 605, 606

BA01.40-P-1001-01A

Bolt, timing case cover to cylinder crankcase

M6

Nm

10

M8

Nm

-

BA01.40-P-1002-01A

Bolt, cylinder head to timing case cover

Nm

25

Number

Designation

Engine 604, 605, 606

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

10

M8

Nm

25

M10

Nm

-

BA01.45-P-1002-01A

Bolt, transmission bell housing to oil pan

Nm

40

Number

Designation

Engine
603.971

Engine
604

Engine
605
except
605.911

Engine 606 except 606.910

BA07.02-P-1001-01A

Injection pump flange

Nm

20

20

20

20

Number

Designation

Engine
604, 605, 606

BA20.10-P-1001-01A

Bolt, pulley to coolant pump

Nm

10

Number

Designation

Model 124

Model 140

BA46.30-P-1001-01A

Bolt on belt pulley

Nm

30

30

Number

Designation

Model 202.018/020/022/
023/024/025/028/078/
080/082/083/085/120/
121/122/125/128/180/
182/188

BA46.30-P-1001-01A

Bolt on belt pulley

Nm

30

Number

Designation

Model 210.003/004/010/
015/017/020/025/035/
037/045/053/055/072/
210/215/217/225/235/
237/245/272/610/617

BA46.30-P-1001-01A

Bolt on belt pulley

Nm

30

Number

Designation

Order number

BR00.45-Z-1009-01A

Sealing compound Loctite 574, 50 ml

A 001 989 89 20 10

BR00.45-Z-1012-01A

Omnifit FD 3041 sealant

A 002 989 47 20 10