Remove/install timing case cover · ar0140p8000hb · Mercedes-Benz WIS

AR01.40-P-8000HB

Remove/install timing case cover

2.3.10

ENGINE 611.960 in MODEL 202.133 /134 /193 /194

ENGINE 611.961 in MODEL 210.006 /007 /206 /606

ENGINE 612.961 in MODEL 210.016 /216 /616

ENGINE 612.963 in MODEL 163.113

ENGINE 613.961 in MODEL 210.026 /226

ENGINE 613.960 in MODEL 220.026

P01.40-0331-09

Shown on engine 611.960

03 Retaining lock for crankshaft/starter ring gear

1 Bottom part of front soundproofing

2 bottom part of rear soundproofing

3 Cylinder head cover trim panel

11 Poly-V belt

30 Coolant hose

31 Coolant hose

110/6 Charge air pipe

4 Cylinder head cover trim panel

4/2 Air intake hose

9 Charge air hose

10 Electric fan

P01.40-0332-09

Shown on engine 611.960

5 Cylinder head cover

6 Vacuum pump

7 Front cover

8 Dowel pin

15 Power steering pump

22 Chain tensioner

24 Bolts

12 AC compressor

13 Predelivery pump

14 Belt pulley

P01.40-0333-09

Shown on engine 611.960

17 Coolant hose

18 Coolant hose

19 Coolant pump

20 Charge air hose

27 Fitting sleeves

28 Rubber seal

32 Return flow check valve

G2 Alternator

21 Charge air pipe

23 Belt pulley/vibration damper

25 M8 Cylinder head bolts

26 Timing case cover

 	Remove/install
 Danger!	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
Danger!	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
1	Open engine hood and raise to vertical position	Model 163	AR88.40-P-1000GI
		Model 202	AR88.40-P-1000E
		Model 210	AR88.40-P-1000F
		Model 220	AR88.40-P-1000M
		 Have assistant secure hood.
2	Disconnect battery ground line	Model 163, 202, 210	AR54.10-P-0003A
		Model 220	AR54.10-P-0003I
3	Remove bottom parts of soundproofing (1, 2)	Model 163	AR94.30-P-5400GH
		Model 202.1	AR94.30-P-5300A
		Model 210	AR94.30-P-5300AB
		Model 220	AR94.30-P-5300M
4	Drain coolant	Engine 611.960/961, 612.961, 613.960/961  At radiator and crankcase.	AR20.00-P-1142HB
			*BF20.00-P-1001-02E
		Engine 612.963 At radiator.	AR20.00-P-1142M
5	Drain engine oil		*BF18.00-P-1001-01A
			*BA01.45-P-1003-01A
6	Remove trim panels of the cylinder head cover (3, 4)	Engine 611	AR01.20-P-5014-02A
		Engine 612	AR01.20-P-5014-02B
		Engine 613	AR01.20-P-5014-02C
			*BA01.20-P-1002-01A
			*BA01.20-P-1003-01A
7	Detach coolant hoses (30, 31) at coolant thermostat housing	 Inspect condition of hose clamps and hoses, replace if damaged.
		6 mm socket hexagon on flexible shaft for hose clamps with worm drive
		7 mm socket hexagon on flexible shaft for hose clamps with worm drive
8	Remove air intake hose (4/2)
9	Remove charge air pipe (110/6) together with charge air hose (9)	Engine 611.960, 611.961 up to 30.6.99	AR09.41-P-1311HB
		Engine 611.961 as of 1.7.99, 612.961, 613.961	AR09.41-P-1311HC
		Engine 613.960	AR09.41-P-1311M
10.1	Remove electric fan (10)	Engine 611.960/961, 612.961	AR20.40-P-5000B
		Engine 612.963	AR20.40-P-5000M
10.2	Remove viscous-drive fan.	Engine 613.961	AR20.40-P-5660HC
10.3	Remove fan shroud together with suction fan	Engine 613.960	AR20.40-P-6800M
Danger!	Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.	No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
11	Remove fuel injectors (Y76)		AR07.16-P-1000HB
12	Clean fuel injectors (Y76)	 Seal injector recesses with pin before cleaning. Clean injector stems and injector recesses with fleece cloth. Clean nozzle tips only with non-woven cloth. Clean injector recesses with round and cylinder brush, blow out, clean with fleece cloth and cover up. Clean injector stems with a wire brush and non-woven cloth and grease with special grease.
		 Replace injector seal and screws of tensioning clamps.
	Notes on injectors		AH07.16-P-1000-01A
		Round brush	*611589006800
		Cylinder brush	*668589006800
		 Brake caliper brush	*000589266800
		Special grease	*BR00.45-Z-1036-06A
13	Remove cylinder head cover (5)		AR01.20-P-5014HB
14	Position piston of cylinder 1 to ignition TDC	Rotate engine at crankshaft. Do not rotate engine at the camshaft sprocket bolt. Do not crank engine back.  Markings on camshaft and camshaft bearing cap (arrows) must be aligned.
15	Install retaining lock for the crankshaft/starter ring gear (03)		AR03.30-P-5000HB
16	Remove chain tensioner (22)	 Replace seal of chain tensioner (22).	AR05.10-P-7800HB
17.1	Release rail on bracket	Engine 611.961 from 7/99, 612, 613
18.1	Remove coolant thermostat	Engine 611.961 from 7/99, 612, 613
19	Remove front cover (7) at cylinder head		AR01.30-P-5700B
20	Remove poly-V belt (11)		AR13.22-P-1202HB
21.1	Remove belt pulley (14) of the power steering pump (15)	Engine 611
			*BA46.30-P-1001-01A
		 Counterholder	*603589004000
22.1	Unbolt power steering pump (15) on timing case cover	Engine 613.960/961. Attach power steering pump with piping connected at the side at top of engine compartment.
			*BA46.30-P-1009-01A
23.1	Detach electrical connector at the AC compressor (12)	For automatic air conditioning code (580a), Comfort automatic air conditioning, code (581b).
24.1	Unbolt AC compressor (12)	For automatic air conditioning code (580a), Comfort automatic air conditioning, code (581b).  Attach AC compressor (12) with the connected pipe system at the bottom of the engine compartment on the side.
			*BA83.55-P-1001-01C
25	Detach coolant hose to oil-water heat exchanger	 Inspect condition of hose clamps and hoses, replace if necessary. Detach at crankcase.
26.1	Detach ATF lines to oil-water heat exchanger	Engine 612.961, 613.961
27	Detach coolant hoses (17, 18) on coolant pump (19)
28	Remove coolant pump (19)		AR20.10-P-1271HB
29.1	Remove charge air hose (20) together with charge air pipe (21)	Engine 611
29.2	Remove charge air pipe (21)	Engine 612, 613
30	Remove alternator (G2)	Engine 611.961 from 1.6.99, 612.961, 613.961 in model 210	AR15.40-P-5032EC
		Engine 611.960 in model 202	AR15.40-P-5032EA
		Engine 612.963 in model 163.113	AR15.40-P-5032GI
		Engine 613.960 in model 220.026 as of 1.6.00	AR15.40-P-5032IB
		 Water-cooled generator.
31	Remove belt pulley/vibration damper (23)		AR03.30-P-1600HB
			*BA03.30-P-1001-01A
32.1	Unbolt side of oil pan	Engine 613.960
			*BA01.45-P-1008-01A
33	Remove bolts (24) of oil pan	 Unscrew bolts in area of timing case cover. Only slacken all other bolts of the oil pan.
			*BA01.45-P-1001-01A
			*BA01.45-P-1004-01A
34	Unscrew bolts M8 of cylinder head (25) at timing case cover (26)	 Engine 611.960/961, 613.960/961	*BA01.30-P-1005-01A
		 Engine 612.961/963	*BA01.30-P-1001-01M
35	Remove timing case cover (26)	 Installation: Clean sealing surfaces. Install new rubber gasket (28). Observe fitting sleeves (27). Coat sealing surface of front cover with sealant. See: 
	Notes on sealant path for timing case cover		AH01.40-P-1000-01E
		Loctite sealant 5970	*BR00.45-Z-1013-01A
		 Squeeze gun	*112589002500
		 Do not damage cylinder head gasket and oil pan gasket. Replace the damaged gasket if required! See: 
		Remove/install cylinder head Engine 611.960/961	AR01.30-P-5800HB
		Remove/install cylinder head Engine 612.961/963	AR01.30-P-5800HC
		Remove/install cylinder head Engine 613.960/961	AR01.30-P-5800HD
		Remove/install oil pan Engine 611.960/961	AR01.45-P-7500HB
		Remove/install oil pan Engine 612.961	AR01.45-P-7500HC
		Remove/install oil pan Engine 612.963	AR01.45-P-7500M
		Remove/install oil pan Engine 613.961	AR01.45-P-7500HD
		Remove/install oil pan Engine 613.960	AR01.45-P-7500MA
		 Check front crankshaft radial sealing ring and replace it if required. See: 
		Replace front crankshaft radial seal.	AR03.20-P-3000HB
		 Installation: Observe installation position of return flow check valve (32).
		Bolt plan of timing case cover (26)	AR01.40-P-8000-01HB
			*BA01.40-P-1001-01A
36.1	Remove poly-V belt tensioning device	Engine 611.960 /961, 612.961, 613.960 /961.  Only when timing case cover (26) is replaced.	AR13.25-P-3200HB
37.1	Remove oil-water heat exchanger	 Only when timing case cover (26) is replaced.
		Engine 611	AR18.30-P-3481HB
		Engine 612, 613	AR18.30-P-3481HC
38	Install in the reverse order
39	Inspect cooling system for leaks	 Engine with new cylinder head gasket: Do not pressure-test cooling system until engine has reached operating temperature.	AR20.00-P-1010HA
 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
40	Check for oil leaks with engine running
 Danger!	Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure.	Keep all ignition sources out of hazard area. Do not carry out any work on system when it is pressurized.	AS07.16-Z-0001-01A
41	Check fuel system for leaks with engine running
42	Read out fault memory and erase	Stored faults, which may result from wires being disconnected or from simulation during assembly or testing, have to be processed and erased in the fault memories after completing the work.
	Connect hand-held tester (HHT), read out diagnostic trouble code memory	Engine 611.960 Engine 611.961 up to 6.99 See: 	AD00.00-P-2000-03A
		Diagnosis manual for diesel engine, Volume 1.2
		Engine 611.961 from 7.99, engine 612, 613 See: 
		STAR DIAGNOSIS

 Crankcase ventilation, cylinder head cover

Number	Designation		Engine 611.960/ 961/962	Engine 612.961/ 962/967	Engine 612.963	Engine 613.960/ 961


BA01.20-P-1002-01A	Bolt, trim panel of cylinder head cover to cylinder head cover	Nm	10	10	10	10
BA01.20-P-1003-01A	Bolt, charge air distribution pipe cover to charge air manifold	Nm	10	10	10	10

 Cylinder head tightening torques

Number	Designation			Engine 611.960/ 961	Engine 613.960/ 961


BA01.30-P-1005-01A	Bolt, cylinder head to timing case cover	M8	Nm	20	20

 Cylinder head tightening torques

Number	Designation			Engine 612.961/962/963/965/966/967/981


BA01.30-P-1001-01M	Bolt, cylinder head to timing case cover	M8	Nm	20

 Crankcase, timing case cover, end cover

Number	Designation			Engine 611.960/ 961	Engine 612.961/ 963	Engine 613.960/ 961


BA01.40-P-1001-01A	Bolt, timing case cover to cylinder crankcase	M6	Nm	-	-	-
		M8	Nm	20	20	20

 Oil pan

Number	Designation			Engine 611.960/ 961/962	Engine 612.961/962/ 963/965/966, 613.961	Engine 613.960


BA01.45-P-1001-01A	Bolt, oil pan to cylinder crankcase	M6	Nm	9	9	9
		M8	Nm	20	20	20
		M10	Nm	-	-	-
BA01.45-P-1003-01A	Oil drain screw on oil pan	M12	Nm	-	-	-
		M14	Nm	30	30	30
BA01.45-P-1004-01A	Bolt, oil pan to timing case cover	M6	Nm	9	9	9
BA01.45-P-1008-01A	Bolt for side part of oil pan		Nm	-	-	9

 Flywheel, driven plate, vibration damper, starter ring gear

Number	Designation				Engine 611.960/ 961	Engine 612.961/ 963/965/ 966	Engine 613.960/ 961


BA03.30-P-1001-01A	Central bolt for vibration damper	8.8	Stage 1	Nm	200	200	200
			Stage 2	 °	90	90	90
		10.9	Stage 1	Nm	325	325	325
			Stage 2	 °	90	90	90

 Power steering pump

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
BA46.30-P-1009-01A	Bolt, power steering pump to timing case cover	Nm	20

 Power steering pump

Number	Designation		Model 210.006/007/ 016/026/206/ 216/226/606/616


BA46.30-P-1001-01A	Bolt on belt pulley	Nm	30
BA46.30-P-1009-01A	Bolt, power steering pump to timing case cover	Nm	20

 Refrigerant compressor

Number	Designation		Engine 611.960	Engine 611.961	Engine 612.961/ 963	Engine 613.960/ 961


BA83.55-P-1001-01C	Bolt, refrigerant compressor to timing case cover	Nm	20	20	20	20

 Engine lubrication system

Number	Designation			Engine 611.960/961 with ASSYST	Engine 612.961	Engine 612.963


BF18.00-P-1001-01A	Engine oil	Filling capacity (oil and filter change)	Liters	6.0	7.0	7.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-01A	BB00.40-P-0228-01A	BB00.40-P-0228-01A
			Sheet	BB00.40-P-0228-03A	BB00.40-P-0228-03A	BB00.40-P-0228-03A
			Sheet	BB00.40-P-0228-05A	BB00.40-P-0228-05A	BB00.40-P-0228-05A
			Sheet	BB00.40-P-0229-01A	BB00.40-P-0229-01A	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A	BB00.40-P-0229-03A	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A	BB00.40-P-0229-05A
			Sheet	BB00.40-P-0229-31A	BB00.40-P-0229-31A	BB00.40-P-0229-31A

 Engine lubrication system

Number	Designation			Engine 613.960	Engine 613.961


BF18.00-P-1001-01A	Engine oil	Filling capacity (oil and filter change)	Liters	8.5	7.5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0228-01A	BB00.40-P-0228-01A
			Sheet	BB00.40-P-0228-03A	BB00.40-P-0228-03A
			Sheet	BB00.40-P-0228-05A	BB00.40-P-0228-05A
			Sheet	BB00.40-P-0229-01A	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A
			Sheet	BB00.40-P-0229-31A	BB00.40-P-0229-31A

 Cooling system

Number	Designation			Engine 611.960	Engine 611.961	Engine 612.961


BF20.00-P-1001-02E	Cooling system	Total filling capacity	Liters	8.0	10.3	10.6
		Filling capacity of anticorrosion/ antifreeze down to -37°C	Liters	4.0	5.2	5.3
		Filling capacity of anticorrosion/ antifreeze down to -45°C	Liters	4.5	5.7	5.8
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A	BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Sheet	BB00.40-P-0325-00A	BB00.40-P-0325-00A	BB00.40-P-0325-00A

 Cooling system

Number	Designation			Engine 612.963	Engine 613.960	Engine 613.961


BF20.00-P-1001-02E	Cooling system	Total filling capacity	Liters	11.0	15.5	11.2
		Filling capacity of anticorrosion/ antifreeze down to -37°C	Liters	5.5	7.75	5.6
		Filling capacity of anticorrosion/ antifreeze down to -45°C	Liters	6.25	8.0	6.2
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A	BB00.40-P-0310-01A	BB00.40-P-0310-01A
			Sheet	BB00.40-P-0325-00A	BB00.40-P-0325-00A	BB00.40-P-0325-00A

112 589 00 25 00

Round brush

Squeeze gun

Counterholder

Cylinder brush

603 589 00 40 00

611 589 00 68 00

668 589 00 68 00

Brake caliper brush

000 589 26 68 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite sealant 5970	A 003 989 98 20
BR00.45-Z-1036-06A	Special grease	A 001 989 42 51 10

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