Remove/install timing case cover

AR01.40-P-8000L

Remove/install timing case cover

02.05.2017

Engine

137.970 in model 215.378, 220.178/878

1

Fan shroud with suction fan

7

Left cylinder head cover

15

Coolant pump

2

Poly-V-belt

8

Right cylinder head cover

17

Coolant pump guide pulley

3

Poly-V belt tensioning device

9

Thermostat housing

18

Power steering pump

4/1

Screw

10

Oil pump for cylinder shutoff

19

Cylinder head bolts on left on timing case cover

4/2

Screw

11

Right front cover

20

Cylinder head bolts on right on timing case cover

5/1

Washer

12

Belt pulley/vibration damper

21

Timing case cover

5/2

Washer

12a

Screw

A9

Refrigerant compressor

6/1

Guide pulley

13

Left cylinder head

6/2

Guide pulley

14

Right cylinder head

 

Remove/install

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Topical note

Notes on sealant path for timing case cover

AH01.40-P-1000-01A

 Danger

Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect/connect battery ground line

AR54.10-P-0003I

Topical note

Notes on battery

AH54.10-P-0001-01A

 Installation:
After connecting, read fault memory, encode radio and normalize power windows.
Vehicles with stationary heater: adjust time display on stationary heater.

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

2

Remove engine compartment paneling

AR61.20-P-1105M

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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

3

Drain coolant at radiator

AR20.00-P-1142HA

4

Remove air filter

AR09.10-P-1050L

5

Remove fan shroud with suction fan (1)

AR20.40-P-6800AC

6

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

7

Remove poly-V belt (2)

AR13.22-P-1202L

8

Remove poly-V belt tensioning device (3)

AR13.25-P-3200L

9

Remove thermostat housing (9)

Remove/install coolant thermostat

AR20.10-P-2460L

10

Remove coolant pump (15)

AR20.10-P-1271L

Bolt plan for coolant pump

AR20.10-P-1271-03L

 Only on a defective coolant pump. The timing case cover can be removed with coolant pump attached; the connecting bolts between the timing case cover and coolant pump are not removed in the process. Remove connecting bolts according to the bolt plan.

11

Remove air pump

AR14.30-P-7251L

12

Remove alternator

AR15.40-P-5032N

13

Remove oil pump for cylinder shutoff (10)

AR01.30-P-5704L

 Secondary-oil pump for cylinder shutoff on left cylinder head

*BA01.30-P-1003-01G

14

Remove front cover on right (11)

AR01.30-P-5700L

 Right front cover on cylinder head

*BA01.30-P-1001-01G

 Bolt, guide pulley to front cover on right

*BA01.30-P-1002-01G

15

Remove cylinder heads (13, 14)

AR01.30-P-5800L

 Internal Torx bolt, cylinder head to crankcase

*BA01.30-P-1004-01G

16

Position crankshaft at a 30° crank angle after ignition TDC of cylinder 1


Engine must not be cranked back.
The dimensional accuracy will not be ensured otherwise.

 Crank engine at crankshaft in direction of rotation of engine until 30° marking on belt pulley/vibration damper is aligned with marking on timing case cover.

17

Remove belt pulley/vibration damper (12)

AR03.30-P-1600L

 Center bolt to vibration damper

*BA03.30-P-1001-01D

18

Remove power steering pump (18)

AR46.30-P-0500N

 Model 215.378 with engine 137.970
Model 220.178/878 with engine 137.970
with code 487 (Active Body Control (ABC))Self-tapping bolt, power steering pump to timing case

*BA46.30-P-1010-01C

19

Detach A/C compressor (A9) from cylinder crankcase

AR83.55-P-5300M

 Place to the side with lines still connected.

 Screw/bolt, A/C compressor to bracket

*BA83.55-P-1001-01A

20

Remove screw/bolts for timing case cover (21)

Bolt plan for timing case cover with removed coolant pump

AR01.40-P-8000-01L

Bolt plan for timing case cover with mounted coolant pump

AR01.40-P-8000-01LA

 Installation: Observe bolt plan for timing case cover.

 Timing case cover to cylinder crankcase

*BA01.40-P-1001-01C

21

Remove timing case cover (21)

AR03.20-P-3000-01B

Topical note

Notes on sealant path for timing case cover

AH01.40-P-1000-01A

 Installation:
Ensure that no sealant gets into the oil ducts.
Blocking of the oil duct can occur otherwise.

 Installation:
The front crankshaft radial sealing ring must be installed new.
Leaks can occur otherwise.

 Installation: Replace timing case cover sealing rings and observe application of sealant.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

 Torx bit set

*000589011000

22

Install in the reverse order

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

23

Check for leaktightness with engine running

24

Check cooling system for leaktightness

 Warm up engine to operating temperature and then inspect cooling system or leaks.

25

Read out fault memory and clear



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

 Cylinder head

Number

Designation

Engine 137

BA01.30-P-1001-01G

Right front cover on cylinder head

M6

Nm

8

 Cylinder head

Number

Designation

Engine 137

BA01.30-P-1002-01G

Bolt, guide pulley to front cover on right

M8

Nm

30

 Cylinder head

Number

Designation

Engine 137

BA01.30-P-1003-01G

Secondary-oil pump for cylinder shutoff on left cylinder head

M6

Nm

8

 Cylinder head

Number

Designation

Engine 137

BA01.30-P-1004-01G

Internal Torx bolt, cylinder head to crankcase

Stage 1

Nm

20

Stage 2

° 

90

Stage 3

° 

90

 Cylinder crankcase, timing case cover, end cover

Number

Designation

Engine 137

BA01.40-P-1001-01C

Timing case cover to cylinder crankcase

Nm

14

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

Number

Designation

Engine 137

BA03.30-P-1001-01D

Center bolt to vibration damper

Stage 1

Nm

200

Stage 2

°

90

 Power steering pump

Number

Designation

Model 215.375/378

MODEL 220.178/878 with CODE 487

BA46.30-P-1010-01C

Self-tapping bolt, power steering pump to timing case

Thread not pre-tapped

Nm

35

35

Thread pre-tapped

Nm

20

20

 Refrigerant compressor

Number

Designation

Engine 137 in model 215, 220

BA83.55-P-1001-01A

Screw/bolt, A/C compressor to bracket

Nm

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10