Remove/install timing case cover

AR01.40-D-8000D

Remove/install timing case cover

2.3.10

 

Remove/install

1

Disconnect ground cable at battery

2

Remove complete radiator unit

AR20.20-D-3865F

3

Drain engine oil



Engine oil and filter change

AP18.00-D-0101A

4

Unscrew cover at oil filter housing



 Take out oil filter element so that engine oil flows off into oil pan.

*103589020900



*BA18.20-P-1002-01G

5

Remove front cover at cylinder head

AR01.30-D-5700D

6

Remove poly-V belt

AR13.22-D-1202E

7

Remove/install high-pressure pump

AR07.02-D-1020A

8

Remove coolant pump

AR20.10-D-1271E

9

Remove belt pulley/vibration damper

AR03.30-D-1600G

10

Remove power steering pump

AR46.30-D-0500E

11

Take off refrigerant compressor at timing case cover and place to the side with refrigerant lines connected

 On vehicles fitted with air conditioning
(code HH6, HH9).

AR83.55-D-5300B

12

Detach generator at timing case cover and place to the side with cables connected

AR15.40-D-5032E

13

Insert front end crossmember and attach with screws

 If required for attaching the engine lifting device for removing the oil pan.

14

Remove oil pan

Engine 611.981/983/987

AR01.45-D-7500F

Engine 612.981

AR01.45-D-7500G

15

Detach coolant hose (8) at oil-water heat exchanger

 Inspect condition of hose clamps and hoses, replace if necessary.

16

Unscrew bolts (4) of cylinder head at timing case cover (1)

 Engine 611.981/983/987

*BA01.30-P-1005-01A

 Engine 612.981

*BA01.30-P-1001-01M

17

Unscrew bolts (3) and remove timing case cover (1)



 Installation: Clean sealing surfaces. Replace rubber gasket (2). Pay attention to dowel sleeves (arrows). Coat sealing surface of timing case cover with sealant. Refer to:

*BA01.40-N-1001-01B



Notes on sealant path for timing case cover

AH01.40-P-1000-01E

Loctite sealant 5970

*BR00.45-Z-1013-01A

 Squeeze gun

*112589002500

 Inspect cylinder gasket, replace if damaged 

Remove/install cylinder head

AR01.30-D-5800E

19

Replace front crankshaft radial seal (5)

AR03.20-D-3000D

20

Fit on existing poly V-belt tensioning device (6)

 Only if timing case cover replaced



*BA13.25-P-1001-01G

21

Use existing oil-water heat exchanger (7)

 Only if timing case cover is replaced.
Install new gasket (9).



*BA18.30-P-1001-01C

22

Install in the reverse order

23

Bleed low pressure fuel circuit

AR07.16-D-0100A

24

Inspecting cooling system for leaks

 Engine with new cylinder head gasket:

Do not pressure-test cooling system until engine has reached operating temperature.

AR20.00-P-1010HA

 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

25

Inspect for oil leaks

 Allow engine to run until warm, then turn off engine and check for leaks

 Danger!

Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure.

Keep all ignition sources out of hazard area.

Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

26

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

27

Encode radio, set clock

Number

Designation

Engine 611.981/
983/987

BA01.30-P-1005-01A

Bolt, cylinder head to timing case cover

M8

Nm

20

Number

Designation

Engine
612.961/962/963/965/966/967/981

BA01.30-P-1001-01M

Bolt, cylinder head to timing case cover

M8

Nm

20

Number

Designation

Engine
611.981/
983/ 987

Engine
612.981

BA01.40-N-1001-01B

Bolt, timing case cover to cylinder crankcase

M6

Nm

-

-

M8

Nm

20

20

Number

Designation

Engine 611.981/
983/987

Engine 612.981

BA13.25-P-1001-01G

Bolt from poly-V belt tensioning device to timing case cover

Nm

30

30

BA13.25-P-1002-01G

Bolt connecting tensioner pulley to poly-V belt tensioning device

Nm

36

36

Number

Designation

Engine 611.981/
983/987

Engine 612.981

BA18.20-P-1002-01G

Threaded cap to oil filter

Nm

25

25

Number

Designation

Engine 611.981/
983/987

Engine 612.981

BA18.30-P-1001-01C

Bolt, oil-water heat exchanger to timing case cover

Nm

14

14

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite sealant 5970

A 003 989 98 20