Remove/install timing case cover

AR01.40-P-8000HW

Remove/install timing case cover

15.2.12

 

Remove/install

1.1

Remove lower engine compartment paneling

Engine 602.982 in model 210

AR94.30-P-5300AB

1.2

Remove underride guard

Engine 602.983 in model 461

2

Drain engine oil

3.1

Remove charge air pipe above at the front

Engine 602.982 in model 210

AR09.41-P-1311H

4

Remove viscous fan clutch with fan shroud

Engine 602.982 in model 210

AR20.40-P-5660HB

Viscous fan clutch for engine 602.983 in model 461

AR20.40-P-5660GV

Fan shroud for engine 602.983 in
model 461

AR20.40-P-6800GV

5.1

Detach ground line (W10)

Engine 602.982 in model 210

AR54.10-P-0003A

5.2

Disconnect battery ground line

Engine 602.983 in model 461

AR54.10-P-0003G

6

Remove alternator

7

Mount guard plate for radiator

8

Remove top charge air pipe (1)

9.1

Remove engine cover (2)

Engine 602.982 in model 210

10

Install retaining lock (3)

AR03.30-P-5000HA

11

Remove cylinder head cover (4)

12

Detach bolts for coolant pump (8), power steering pump (9) belt pulley



*603589004000



*BA46.30-P-1007-01A



*BA20.10-N-1001-01B

13

Remove tensioning device (7) on poly-V-belt

Model 210

AR13.25-P-3200HA

Model 461

AR13.25-P-3200GG

14

Remove belt pulley (8) for coolant pump, power steering pump (10)

15

Remove poly-V belt (22) guide pulley

16

Unscrew power steering pump (10) with attached lines, place to one side and fasten to side of the engine compartment



*BA46.30-P-1008-01A

17

Detach fuel filter with bracket and connected lines, place to the side.

18

Take off vacuum connections at vacuum pump (11)

 Engine 602.982

*BA43.05-N-1002-01A

 Engine 602.983

*BA43.05-P-1004-01B

19

Remove vacuum pump (11)

 Engine 602.982

*BA43.05-N-1001-01A

 Engine 602.983

*BA43.05-P-1001-01B

20

Unbolt bracket (12) for oil dipstick guide tube

21

Remove vibration damper (13)

AR03.30-P-1600HA

22

Unscrew hexagonal bolts (14) on alternator carrier (15)



*BA01.40-N-1005-01B

23

Remove alternator carrier (15)

24

Unscrew hexagon bolt (16) of the oil pan in the area of the timing case cover



 Slacken other hexagon bolts of oil pan, tighten.

 Do not damage oil pan gasket

*BA01.45-N-1001-01H

25

Unscrew injection pump bolts (arrows) on timing case cover



*BA07.13-P-1001-01B

26

Remove top guide rail pins (17)

AR01.30-D-5800-04B



*116589203300



*116589013400



*605589003300

27

Unscrew hexagon socket bolts (18) in the chain housing



*BA01.30-N-1003-01B

28

Unbolt timing case cover (19), remove

 Installation: Clean sealing surfaces and coat with sealant

*BR00.45-Z-1012-01A

Replace radial seal (20)

AR03.20-P-3000HA

29

Replace O-ring (21) at oil spray nozzle (oil supply of vacuum pump)

 Only for Barluk vacuum pump
installed until 08/96 and from 07/97

Refer to 

GF01.40-P-8000-01A

Structure of the vacuum pump/timing case cover/oil nozzle

GF01.40-P-8000-01A

30

Install in the reverse order

 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

31

Check for leaks with engine running

Number

Designation

Engine
602.982/
983

BA01.40-N-1005-01B

Carrier, alternator to crankcase

Nm

25

Number

Designation

Engine 602.982/
983

BA01.30-N-1003-01B

Cylinder head on timing case cover

M8

Nm

25

Number

Designation

Engines 601, 602 except 602.982, 603 except 603.913/963

BA01.45-P-1001-01A

Screw/bolt, oil pan to cylinder crankcase

M6

Nm

10

M8

Nm

25

M10

Nm

40

Number

Designation

Engine
602.982

BA01.45-N-1001-01H

Screw/bolt, oil pan to cylinder crankcase

M6

Nm

10

M8

Nm

25

M10

Nm

-

Number

Designation

Engine 602.982/
983

BA07.13-P-1001-01B

Screw/bolts, intermediate flange to crankcase

Nm

23

Number

Designation

Engine 602.982/
983

BA20.10-N-1001-01B

Screw/bolts, belt pulley to coolant pump

Nm

15

Number

Designation

Engine 602.982

BA43.05-N-1001-01A

Vacuum pump on timing case cover

Nm

10

BA43.05-N-1002-01A

Vacuum line on vacuum pump

Nm

30

Number

Designation

Model 461, 463

BA43.05-P-1001-01B

Screw/bolt, vacuum pump to timing case cover

Nm

10

BA43.05-P-1004-01B

Vacuum line on vacuum pump

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

Model 210.061/062/063/
065/070/074/
081/082/083/
261/262/263/
265/270/274/
281/282/283/
663

BA46.30-P-1007-01A

Screw/bolt, belt pulley to power steering pump

Nm

30

-

BA46.30-P-1008-01A

Screw/bolt, power steering pump to support

Nm

25

25

Number

Designation

Order number

BR00.45-Z-1012-01A

Sealant, Omnifit FD 3041

A 002 989 47 20 10