Remove/install timing case cover

AR01.40-P-8000VA

Remove/install timing case cover

29.11.11

9.11.11

Operation sequence adapted according to the change in repair method

 

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

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

AS00.00-Z-0010-01A



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"

 Vehicles with code (889) Keyless-Go: Press Keyless-Go start/stop button repeatedly until ignition is switched off.

2

Remove air filter housing with engine air intake ducts

AR09.10-P-1150VA

3

Remove lower engine compartment paneling

AR61.20-P-1105V

4

Drain engine oil

AP18.00-P-0101VA

 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

5

Drain coolant at radiator

AR20.00-P-1142VA



Notes on coolant

AH20.00-N-2080-01A

6

Disconnect coolant hose on coolant temperature regulator housing

7

Detach coolant hose (3) at coolant pump

8

Remove fan shroud

AR20.40-P-6800VA

9

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

10

Remove poly-V belt tensioning device

AR13.25-P-3200VA

11

Detach guide pulley (2)

AR13.21-P-3350VA

12

Remove air pump

AR14.30-P-7251VA

13

Remove coolant temperature control housing

 Installation: Install new O-ring and seal.

AR20.10-P-2460VA

14

Remove oil filter housing with oil-water heat exchanger

AR18.20-P-3471VA

15

Remove power steering expansion reservoir

See remove and install power steering pump.

AR46.30-P-0500VA

16

Remove left and right air shutoff valve

Left air shutoff valve

AR14.30-P-7200VB

Right air shutoff valve

AR14.30-P-7200VA

17

Remove intermediate flange (1) of air shutoff valve



*BA14.30-P-1004-02A

18

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



*001589650900

19

Install retaining lock for crankshaft/starter ring gear

AR03.30-P-5000VA

20

Remove belt pulley/vibration damper

AR03.30-P-1600VA

21

Remove front cover at left cylinder head

 Installation: after installing the front cover, check that the camshafts are positioned at 55° crank angle BTDC:


AR01.30-P-5700VB

Check basic position of camshafts.

AR05.20-P-6010VA

22

Remove front cover at the right cylinder head

 Installation: after installing the front cover, check that the camshafts are positioned at 55° crank angle BTDC:


AR01.30-P-5700VA

Check basic position of camshafts.

AR05.20-P-6010VA

23

Remove chain tensioner

M241.5

AR05.10-P-7800VA

M221.5

AR05.10-P-7800VB

 Installation: Install new chain tensioner with thread of M221.5. The previously installed chain tensioner must not be reinstalled because during removal, its pressure pin is pressed into the end position. The thrust pin latch prevents this return stroke. This would overstretch the timing chain on reinstalling.

24

Remove camshaft adjuster for exhaust camshafts.

AR05.20-P-7201VB

25

Remove camshaft adjuster for intake camshafts.

AR05.20-P-7201VA

26

Remove alternator

AR15.40-P-5032VA

27

Remove the oil dipstick guide tube

AR18.40-P-3510VA

28

Detach power steering pump (8) from timing case cover (7) and put it on the side with connected line

AR46.30-P-0500VA

29

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



*BA83.55-P-1001-01M

30

Remove complete exhaust system

AR49.10-P-7000VA

31

Mount engine hoist

AR33.10-P-0100-01VA



*240589006100

32

Remove both the Screw/bolts of both the front engine mounts

AR22.10-P-1100VA

33

Raise engine

34

Remove bottom part of oil pan

AR01.45-P-7555VB

35

Remove oil pan

AR01.45-P-7500VA

36

Lower the engine and detach it

from the engine support frame

37

Remove Screw/bolts (12, 13)



*BA01.30-P-1003-01O

38

Detach timing case cover (7)

 Installation: Observe different bolt lengths and diameters: 

Bolt plan for timing case cover:

AR01.40-P-8000-01VA



*BA01.40-P-1001-01G

 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):





Notes on sealant path for timing case cover

AH01.40-P-1000-01VA



*112589002500

Loctite 5970 sealant

*BR00.45-Z-1013-01A



Clean

39

Clean sealing surfaces

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

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

40

Install in the reverse order

41

Check engine oil level; correct if necessary

AP18.00-P-0101VA

 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

42

Conduct engine test run and check engine for leaks

43

Inspect cooling system for leaks

AR20.00-P-1010V

Number

Designation

Engine
272

BA14.30-P-1004-02A

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

Nm

14

Number

Designation

Engine
272

BA01.30-P-1003-01O

Cylinder head bolt on timing case

M8

Nm

20

Number

Designation

Engine
272

BA01.40-P-1001-01G

Screw/bolt, timing case cover to cylinder crankcase

M8

Nm

20

Number

Designation

Engine 272

BA83.55-P-1001-01M

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

Nm

20

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite 5970 sealant

A 003 989 98 20

BR00.45-Z-1038-04A

Loctite 7200

Henkel Loctite Deutschland GmbH
Arabellastrasse 17
81925 München
Germany
Tel. +49 899268-0
Fax + 49 899101978
www.Loctite.de

BR00.45-Z-1046-04A

Loctite 7063 cleaning spray (150 ml)

A 001 986 71 71 10