AR01.40-D-8000NB | Remove/install timing case cover | 14.2.12 |
ENGINES 647.981 in MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada
ENGINES 647.981 in MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA
ENGINES 647.981 in MODELS 903.61 /62 /66 /67, 904.61 /62 /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 | ||
Danger! | Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries | No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. | |
1 | Disconnect ground lead from battery | ||
| Notes on battery | ||
2 | Unscrew cover at oil filter housing | Take out oil filter element so that engine oil flows off into oil pan. | |
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3 | Remove radiator unit | ||
4 | Drain engine oil | ||
Engine oil and filter change | |||
5 | Remove front cover at cylinder head | ||
6 | Remove poly-V belt | ||
7 | Remove belt pulley/vibration damper | ||
8 | Remove high-pressure pump | ||
9 | Remove coolant pump | ||
10 | Remove power steering pump | ||
11 | Remove refrigerant compressor and place with lines attached | ||
12 | Remove alternator and place with lines attached | ||
13 | Install lock cross member | ||
14 | Remove oil pan | ||
15 | Detach coolant hose (8) at oil-water heat exchanger (7) | Installation: Check condition of hose clamps and coolant hose (8); replace if necessary. | |
16 | Unscrew bolts (4) of cylinder head at timing case cover (1) | | |
17 | Unscrew bolts (3) and remove timing case cover (1) | Check cylinder head gasket; replace if there is damage to the cylinder head gasket, see: | |
Remove/install cylinder head | |||
Installation: Clean sealing surfaces and replace gasket (2). Pay attention to dowel sleeves (arrows). Apply a bead of sealant to the timing case cover (1). | |||
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Squeeze gun | |||
Loctite 5970 sealant | |||
| Notes on sealant path for timing case cover | ||
18 | Replace front crankshaft radial seal (5) | ||
19 | Fit on existing poly V-belt tensioning device (6) | Only when timing case cover (1) is replaced. | |
20 | Use existing oil-water heat exchanger (7) | Only when timing case cover (1) is replaced. | |
Installation: Replace seal (9). | |||
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21 | 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. | |
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. | |
22 | Allow engine to run until warm, switch the engine off and check the fuel system for oil leaks and leaktightness. | ||
23 | Encode radio, set clock |
Cylinder head tightening torques
Number | Designation | Engine | ||
BA01.30-P-1001-01I | Bolt, cylinder head to timing case cover | M8 | Nm | 20 |
Crankcase, timing case cover, end cover
Number | Designation | Engine | ||
BA01.40-N-1001-01B | Bolt, timing case cover to cylinder crankcase | M6 | Nm | 10 |
M8 | Nm | 20 | ||
Oil filter
Oil cooling system
Number | Designation | Engine 647.981 | |
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 5970 sealant | A 003 989 98 20 |
Referenced documents
- ah0140p100001e Notes on sealant path for timing case cover
- ah5410p000101a Notes on battery
- ah5410p000101a
- ap1800d0101a Engine oil and oil filter change
- ar0130d5700nb Remove/install front cover on cylinder head
- ar0130d5800nb Remove/install cylinder head
- ar0145d7500na Remove/install oil pan
- ar0320d3000na Replace front crankshaft radial seal
- ar0330d1600na Remove/install belt pulley/vibration damper
- ar0702d1020nb Removing/installing the high pressure pump
- ar1322d1202nb Remove/install poly V-belt
- ar1325d3200na Remove/install poly V-belt tensioning device
- ar1540d5032nb Remove and install generator
- ar2010d1271nb Remove/install coolant pump
- ar2020d3871na Remove/install radiator unit
- ar4630d0500na Removing and installing power steering pump
- ar8355d5300nb Remove/install refrigerant compressor
- 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
- as5410z000101a Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of