Remove/install timing case cover · ar0140d8000na · Mercedes-Benz WIS

AR01.40-D-8000NA

Remove/install timing case cover

2.3.10

ENGINES 612.981
in model WD1XD141, WD1XD241, WD1XD341, WD1XD441, WD1XD541, WD1XD641, WD1XD741,
WD2YD141, WD2YD241, WD2YD341, WD2YD441, WD2YD541, WD2YD641, WD2YD741,
WD5WD141, WD5WD241, WD5WD341, WD5WD641, WD5WD741

ENGINES 612.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada

ENGINES 612.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

ENGINES 612.981 in MODEL 903.61 /66 /67, 904.61 /66 with CODE (ZU9) National version for Mexico

D01.40-1102-06

1 Timing case cover

2 Gasket

3 Screw

4 Screw

5 Crankshaft radial seal

6 Poly-V belt tensioning device

7 Oil/water heat exchanger

8 Coolant hose

9 Gasket

 	Remove/install
1	Disconnect ground cable at battery
2	Remove complete radiator unit		AR20.20-D-3865NA
3	Drain engine oil
			AP18.00-D-0101A
4	Unscrew cover at oil filter housing		*103589020900
		 Take out oil filter element so that engine oil flows off into oil pan.
			*BA18.20-P-1002-01G
5	Remove front cover at cylinder head		AR01.30-D-5700NA
6	Remove poly-V belt		AR13.22-D-1202NA
7	Remove/install high-pressure pump		AR07.02-D-1020NA
8	Remove coolant pump		AR20.10-D-1271NA
9	Remove belt pulley/vibration damper		AR03.30-D-1600NA
10	Remove power steering pump		AR46.30-D-0500NA
11	Take off refrigerant compressor at timing case cover and place to the side with refrigerant lines connected
12	Detach generator at timing case cover and place to the side with cables connected		AR15.40-D-5032NA
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		AR01.45-D-7500NA
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)		*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.
			*BA01.40-N-1001-01B
		Application of sealant, 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-5800NA
18	Replace front crankshaft radial seal (5)		AR03.20-D-3000NA
19	Fit on existing poly V-belt tensioning device (6)	 Only if timing case cover is replaced.
			*BA13.25-P-1001-01G
20	Use existing oil-water heat exchanger (7)	 Only if timing case cover is replaced. Install new gasket (9).
			*BA18.30-P-1001-01C
21	Install in the reverse order
22	Bleed low pressure fuel circuit		AR07.16-D-0100A
23	Inspecting cooling system for leaks	 Engine with new cylinder head gasket:	AR20.00-D-1010C
		Do not pressure-test cooling system until engine has reached operating temperature.
 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
24	Inspect for oil leaks	 Run engine until warm, switch off and inspect 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
25	Inspect fuel system for leaks	 Run engine, switch off and inspect for leaks.
26	Encode radio, set clock

 Cylinder head tightening torques

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

 Crankcase, timing case cover, end cover

Number	Designation			Engine 612.981


BA01.40-N-1001-01B	Bolt, timing case cover to cylinder crankcase	M6	Nm	-
		M8	Nm	20

 Belt tensioning device

Number	Designation		Engine 612.981


BA13.25-P-1001-01G	Bolt from poly-V belt tensioning device to timing case cover	Nm	30
BA13.25-P-1002-01G	Bolt connecting tensioner pulley to poly-V belt tensioning device	Nm	36

 Engine lubrication, oil filter

Number	Designation		Engine 612.981


BA18.20-P-1002-01G	Threaded cap to oil filter	Nm	25

 Oil cooling system

Number	Designation		Engine 612.981


BA18.30-P-1001-01C	Bolt, oil-water heat exchanger to timing case cover	Nm	14

103 589 02 09 00

Wrench socket

Squeeze gun

112 589 00 25 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite sealant 5970	A 003 989 98 20

Referenced documents

ah0140p100001e Notes on sealant path for timing case cover
ap1800d0101a Engine oil and oil filter change
ar0130d5700na Remove/install front cover on cylinder head
ar0130d5800na Remove/install cylinder head
ar0145d7500na Remove/install oil pan
ar0320d3000na Replace front crankshaft radial seal
ar0330d1600na Remove/install belt pulley/vibration damper
ar0702d1020na Remove high pressure pump, install
ar0716d0100a Bleed low pressure fuel circuit
ar1322d1202na Remove/install poly-V belt
ar1540d5032na Remove/install alternator
ar2000d1010c Inspect cooling system for leaks
ar2010d1271na Remove/install coolant pump
ar2020d3865na Removing and installing radiator
ar4630d0500na Removing and installing power steering pump
as0000z000501a 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.
as0716z000101a Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure