01-210 Removing and installing timing case cover
Preceding work: Removing radiator (20-420). Removing power steering pump (46-710). Removing torsion bar (32-300). Removing oil sump (01-310). Removing V-belt tensioning device (13-345). Removing vibration damper or hub and belt pulley (03-342). Removing coolant pump (20-210). Removing air filter (09-400, or 09-410). Removing ignition distributor (15-535). Removing pressure oil pump for level control (32-640). | Operation No. of operation texts and operation values or standard texts and flat rates 01-8000 |
P01-0006-57
Cylinder head cover (81) | remove, install (01-406). |
Hexagon socket bolts (77) | unscrew, screw on (3 ea.), 25 Nm |
Strut (145) | unbolt, bolt on, 25 Nm (step 3). |
If AC fitted: AC compressor (425) | unbolt, bolt on and place to the side with lines connected, 25 Nm (step 4). |
Connector (327) | unplug at alternator, plug in (step 5). |
Alternator (G2) | unscrew, screw on, 30 Nm (step 6). |
Bracket (156) | for alternator, unscrew, screw on, 25 Nm |
TDC pulse generator cable (1) | unscrew, screw on (step 8). Note If timing case cover has been renewed, the TDC pulse generator bracket must be adjusted (03-345). |
Bracket (8) | for oil pump strainer basket, unscrew, screw on, 25 Nm, (step 9). |
Timing case cover | remove remaining bolts, take off timing case cover (steps 10 and 11). Do not damage cylinder head gasket; renew cylinder head gasket if damaged. |
Mating surfaces | clean (step 12). |
Timing case cover | coat with sealant 001 989 445 20 10 and install timing case cover (steps 13 and 14). Use |
Crankshaft radial seal | replace (step 15). |
Engine | rund and check for leaks. |
Special tools
001 589 72 21 00
001 589 66 21 00
116 589 03 07 00
102 589 01 14 00
Notes
The timing case cover is fixed in position with
2 straight pins 1014 and attached to the crankcase with 15 hexagon bolts. The timing case cover is sealed to the crankcase with the sealant part no. 001 989 45 20 10.
The timing case cover also acts as a support or housing for the following components or component parts:
Coolant pump
Ignition distributor
Oil pump
Oil overpressure valve
Radial seal for sealing crankshaft at front
Setting pointer
TDC pulse generator
Front side of timing case cover
45 Crankshaft radial seal
46 Setting pointer for TDC
e Coolant pump chamber with inlet
j Bracket for TDC pulse generator
P01-2070-13
To avoid any coolant flowing to the engine oil should a leak occur between crankcase and timing case cover, a groove (arrows) has been provided around the coolant inlet (h) to allow the coolant to flow to the outside.
Rear side of timing case cover
1 O-ring
23 Oil overpressure valve plug
38 Thrust piece
39 Bearing bush for intermediate gear shaft
f Oil pump
g Mount for ignition distributor
h Coolant inlet
P01-2006-13
The timing case cover is always supplied as a replacement part with the oil pump fitted, but without radial seal for the front of the crankshaft and without oil suction pipe with oil strainer.
A gasket for sealing the timing case must not be fitted to these engines (with single belt drive).
The timing case cover was modified effective 11/87.
The contours on the rear side have been lowered. This is detectible from the cast Part No. 102 015 11 01 on the front side of the cover.
This timing case cover can also be fitted to engines manufactured prior to this date.
A Previous version
B Present version
P01-2521-13
Removal
-------------------------------
1 Remove cylinder head cover (01-406).
2 Unscrew hexagon socket bolts (3 off M8,
arrows) in the chain box with a stud wrench
116 589 03 07 00. Tightening torque 25 Nm
(reference value).
P01-2033-13
3 Unscrew strut (145) for power steering pump and A/C compressor (arrows). Tightening torque 45 Nm.
P01-2022-13
4 On models fitted with A/C compressor: unscrew compressor. Unscrew bracket (b) to perform this step.
Place A/C compressor to the side with the pipe group connected.
P83-2072-13
5 Unplug connector (327) at the alternator, plug in.
P15-2013-13
6 Unscrew bolts (49 and 51), screw on; take
off alternator (G2), insert. Tightening torque
30 Nm.
7 Unscrew bracket (156), screw on. Tightening torque 25 Nm.
P01-2002-13
8 Unscrew TDC pulse generator cable (1) at the holder (2), screw on.
Note
If the timing case cover is replaced, the TDC
pulse generator bracket must be adjusted
(03-345).
P01-2001-13
9 Unscrew bracket (8) for oil pump strainer basket, screw on (arrows).
P18-2001-13
10 Remove remaining bolts (arrows) for timing case cover.
11 Take off timing case cover.
Do not damage cylinder head gasket. Renew cylinder head gasket if damaged.
P01-2021-13
Installation
-------------------------------
12 Clean sealing surfaces.
13 Coat contact surface of timing case cover with the sealant, part no. 001 989 45 20 10.
14 Carefully fit on timing case cover, paying attention to the cylinder head gasket, and bolt tight.
Pay attention to bolt lengths.
15 If the radial seal has been removed, insert
new radial seal with the sleeve
102 589 00 14 00.
Fit spacer ring (01) 102 589 01 14 00 for the
timing case cover with double roller chain.
P03-2057-13
16 The remaining parts are installed in the reverse order.
Note
If the timing case cover is replaced, adjust TDC pulse generator (03-345).
17 Run engine and check for leaks.