Remove/install timing case cover

AR01.40-P-8000TS

Remove/install timing case cover

18.02.2020

Engine

272, 273 in model 211, 219

Shown on engine 272.964

1

Intermediate flange

2

Guide pulley

3

Coolant hose

5

Segment disc

6

Central valves

7

Timing case cover

8

Power steering pump

9

Crankshaft radial sealing ring

12

Bolts

13

Screw

A9

Refrigerant compressor

MODEL 219.357

16

Coolant lines

16a

Electrical connector

16b

Bolts

17

Bracket

17a

Bolts

Y125

Low temperature cooling system shutoff valve

 

Remove/install

 Warning

Risk of injury caused by fingers being jammed or pinched when removing, installing or aligning hoods, doors, trunk lid/rear-end door or sliding roof.

No parts of the body or limbs should be within the operating area when the components are moving.

AS00.00-Z-0011-01A

 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

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

1

Turn key in ignition lock to position "0"

 Model 211, 219 with engine 272, 273
with code 889 (KEYLESS-GO)
Press Keyless Go start and stop button repeatedly until the ignition is switched off.

2

Remove air filter housing with engine air intake ducts

AR09.10-P-1150TS

3

Remove lower engine compartment paneling

Model 211 with engine 272, 273

AR61.20-P-1105T

Model 219 with engine 272, 273

AR61.20-P-1105TX

4

Drain engine oil



Model 211, 219 with engine 272

AP18.00-P-0101PIT



Model 211, 219 with engine 273

AP18.00-P-0101SX

 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

5

Drain coolant at radiator

AR20.00-P-1142TS

Topical note

Notes on coolant

AH20.00-N-2080-01A

6

Disconnect coolant hose on coolant temperature regulator housing

7

Disconnect coolant hose (3) at coolant pump

8

Remove fan shroud

AR20.40-P-6800TS

9

Attach guard plate for radiator/condenser



WF58.50-P-0110-01A

10

Remove poly-V belt, tensioning device and guide pulley (2)

AR13.20-P-0001TS

11.1

Remove air pump

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273

AR14.30-P-7251TS

11.2

Open hose clamps using hose clamp pliers and detach coolant lines (16)

Model 211.057/257, 219.357

 Hose clamp pliers

*003589033700

12

Remove coolant temperature control housing

AR20.10-P-2460TS

 Installation: Replace O-ring and seal.

13

Remove oil filter housing with oil-water heat exchanger

AR18.20-P-3471TS

14

Remove power steering expansion reservoir

Model 211 with engine 272, 273

AR46.25-P-1000TS

Model 219 with engine 272, 273

AR46.25-P-1000TX

15.1

Remove left and right air shutoff valve

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273

AR14.30-P-7200TS

15.2

Disconnect electrical connection (16a), remove screw/bolts (16b) and low-temperature cooling system shutoff valve (Y125)

Model 211.057/257, 219.357

 Screw/bolt, shutoff valve bracket to cylinder head

*BA01.30-P-1019-01O

16.1

Remove intermediate flange (1) of air shutoff valve

Model 211 (except 211.057/257), 219 (except 219.357) with engine 272, 273

 Screw/bolt, left air shutoff valve intermediate flange to cylinder head

*BA14.30-P-1004-02A

16.2

Remove screw/bolts (17a) and bracket (17)

Model 211.057/257, 219.357

 Screw/bolt, low temperature circuit coolant line bracket to cylinder head or cylinder head front cover

*BA01.30-P-1018-01O

17

Rotate engine at crankshaft center bolt in direction of engine rotation to a 40° crankshaft angle after top dead center (ignition TDC)

 Socket wrench bit

*001589650900

18

Install retaining lock for crankshaft/starter ring gear

AR03.30-P-5000TS

19

Remove belt pulley/vibration damper

AR03.30-P-1600TS

20

Remove front cover at left cylinder head

AR01.30-P-5700TS

 Installation: After installing the front cover, check that the camshafts are positioned at a 55° crank angle BTDC.

Refer to:



Check basic position of camshafts

AR05.20-P-6010TS

21

Remove front cover at the right cylinder head

AR01.30-P-5700TT

 Installation: After installing the front cover, check that the camshafts are positioned at a 55° crank angle BTDC.

Refer to:



Check basic position of camshafts

AR05.20-P-6010TS

22

Remove chain tensioner

Model 211, 219 with engine 272Chain tensioner with thread M241.5

AR05.10-P-7800TS

Model 211, 219 with engine 272, 273Chain tensioner with thread M221.5

AR05.10-P-7800VB

 Installation:
Replace chain tensioner with thread M221.5: The previously installed chain tensioner must not be reinstalled.
To remove the chain tensioner its thrust bolts are pressed into the end position and the lock on the thrust bolt prevents it moving back, whereby the timing chain would be overtensioned when being reinstalled.

 Model 211, 219 with engine 272
Both chain tensioners can be installed.

 Model 211, 219 with engine 273
Only the chain tensioner with thread M221.5 is installed.

23

Remove camshaft adjuster for exhaust camshafts

AR05.20-P-7201TT

24

Remove camshaft adjuster for intake camshafts

AR05.20-P-7201TS

25

Remove alternator

AR15.40-P-5032TS

26

Remove the oil dipstick guide tube

Model 211, 219 with engine 272, 273with rear sump

AR18.40-P-3510TS

Model 211 with engine 272, 273with front sump

AR18.40-P-3510TW

27

Remove power steering pump (8)

Model 211 with engine 272, 273

AR46.30-P-0500TS

Model 219 with engine 272, 273

AR46.30-P-0500TX

 Detach power steering pump (8) with expansion reservoir from front cover or from timing case cover (7) and place to one side with their connected lines.

28

Detach refrigerant compressor (A9) and put it on the side with connected lines

 Screw/bolt, refrigerant compressor to timing case/crankcase/engine support

*BA83.55-P-1001-01M

29

Remove oil pan

Model 211.052/054/056/057/072/252/254/256/257/272, 219.354/356/357with rear sump

AR01.45-P-7500TS

Model 211.087/090/092/287/290/292with front sump

AR01.45-P-7500TW

 If the oil pan cannot be released from the cylinder crankcase, warm oil pan in area of sealing surface with a hot air gun, then push assembly wedge between sealing surface to separate oil pan from the cylinder crankcase.

30

Remove bolts/screws (12, 13)

 Screw/bolt, cylinder head to timing case

*BA01.30-P-1003-01O

31

Detach timing case cover (7)

Notes on sealant path for timing case cover

AH01.40-P-1000-01VA

 Installation: Replace crankshaft radial sealing ring (9). Replace both sealing rings in timing case cover (7) and apply sealant to sealing surface of the timing case cover (7).

 Installation: Pay attention to different lengths and diameters of screw/bolts:



Bolt plan for timing case cover

AR01.40-P-8000-01VA

 Engine 272 in model 211, 219Screw/bolt, timing case cover to cylinder crankcase

*BA01.40-P-1001-01G

 Engine 273 in model 211, 219Bolt, timing case cover to cylinder crankcase

*BA01.40-P-1001-01T

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500



Clean

32

Clean oil pan sealing surfaces, oil pan bottom section and timing case cover (7)

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surface will be damaged otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

33

Install in the reverse order

34

Check engine oil level; correct if necessary



Model 211, 219 with engine 272

AP18.00-P-0101PIT



Model 211, 219 with engine 273

AP18.00-P-0101SX

 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

35

Carry out an engine test run and check engine for leak tightness

36

Check cooling system for leaktightness

AR20.00-P-1010TS

 Cylinder head

Number

Designation

Engine 272

Engine 273

BA01.30-P-1003-01O

Screw/bolt, cylinder head to timing case

M8

Nm

20

20

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1018-01O

Screw/bolt, low temperature circuit coolant line bracket to cylinder head or cylinder head front cover

Nm

9

 Cylinder head

Number

Designation

Engine 272

BA01.30-P-1019-01O

Screw/bolt, shutoff valve bracket to cylinder head

Nm

9

 Cylinder crankcase, timing case cover, end cover

Number

Designation

Engine 272

BA01.40-P-1001-01G

Screw/bolt, timing case cover to cylinder crankcase

M8

Nm

20

 Crankcase, timing case cover, end cover

Number

Designation

Engine 273

BA01.40-P-1001-01T

Bolt, timing case cover to cylinder crankcase

M8

Nm

20

 Air shutoff valve

Number

Designation

Engine 272

Engine 273

BA14.30-P-1004-02A

Screw/bolt, left air shutoff valve intermediate flange to cylinder head

Nm

14

14

 Refrigerant compressor

Number

Designation

Engine 272

Engine 273

BA83.55-P-1001-01M

Screw/bolt, refrigerant compressor to timing case/crankcase/engine support

Nm

20

20

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09