Remove/install timing case cover

AR01.40-P-8000PP

Remove/install timing case cover

2.3.10

14.10.04

Ventilating the low-temperature circuit not applicable owing to a changed ventilating method for the cooling system

 

Remove/install

1

Disconnect battery ground line

 Do not connect quiescent current retention unit.

Model 203

AR54.10-P-0003P

Model 209

AR54.10-P-0003Q

2.1

Remove bottom section of soundproofing

Engine 611.962, 612.962/967

AR94.30-P-5300P

2.2

Remove lower engine compartment paneling

Engine 612.990

AR61.20-P-1105P

3

Drain coolant

AR20.00-P-1142HB

4

Drain/collect engine oil

 Installation: Replace gasket of oil drain screw, in order to avoid engine oil leakage.



*BA01.45-P-1003-01A



*BF18.00-P-1001-01A

5

Remove trim panels of the cylinder head cover (1, 2)

Engine 611

AR01.20-P-5014-02A



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

Engine 612

AR01.20-P-5014-02B



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

6

Detach coolant hoses (17, 18) at the thermostat housing (9)

 Check the condition of hose clamps and coolant hoses (17, 18). Replace if damaged, in order to avoid engine leakage.

6 mm socket hexagon

7 mm socket hexagon

7

Remove air filter

AR09.10-P-1050C

8.1

Remove the charge air hose (15) at the mixing chamber (35)

Engine 611.962, 612.962/967

 Installation: Replace seal (16).

 Ensure that the catch springs are exactly located. The charge air hose (15) must be fitted tightly on the mixing chamber (35) to prevent leaks.

9

Remove fuel injectors (Y76)

AR07.16-P-1000HB

10

Remove cylinder head cover (6)

AR01.20-P-5014HB

11.1

Remove electric fan

Engine 612.962/967/990

AR20.40-P-5000PP

12

Attach guard plate for radiator/condenser

Engine 611.962, 612.962/967



Guard plate for radiator/condenser

WF58.50-P-0110-01A

13

Set piston of cylinder 1 to ignition TDC.

 Rotate the engine at the crankshaft only in the direction of engine rotation. Do not rotate the engine at the Bolt, the camshaft sprocket.
The markings on the camshaft and camshaft bearing caps must align.

14.1

Detach fixture of ATF line at left engine mount

Engine 612.962/967/990 with transmission 722.6

15

Remove starter

AR15.30-P-7100PD

16

Install retaining lock for starter ring gear



*602589004000

17

Remove chain tensioner (4)

 Installation: Install new sealing ring (5).

AR05.10-P-7800HB

18

Remove thermostat housing (9)

 Installation: Pay attention to connection fitting (14).



*BA20.10-P-1005-01A

19

Remove front cover (7) at cylinder head

AR01.30-P-5700B

20

Remove high-pressure pump (19)

Engine 611.962, 612.962/967

AR07.02-P-1020HB

Engine 612.990

AR07.02-P-1020PF

21

Remove poly-V belt (8)

AR13.22-P-1202HB

22

Remove the belt pulley (12) of the power steering pump (13)



*BA46.30-P-1005-01D



*603589004000

23

Remove oil filter (11)



*BA18.20-P-1002-01G

24.1

Remove mixing chamber (35) with exhaust gas recirculation pipe

Engine 611.962, 612.962/967

25

Unscrew the power steering pump (13) at the timing case cover (26)

 Attach power steering pump (13) at the side at the top in engine compartment with lines connected.



*BA46.30-P-1001-01D

26.1

Disconnect electrical connector at the refrigerant compressor (A9)

With Code (580) Automatic air conditioning or code (581) Comfort automatic air conditioning

27.1

Detach refrigerant compressor (A9)

With Code (580) Automatic air conditioning or code (581) Comfort automatic air conditioning

 Attach the refrigerant compressor (A9) with the connected refrigerant lines on the side at the bottom in the engine compartment.



*BA83.55-P-1001-01C

28

Detach the coolant hose (30) for the oil-water heat exchanger (31) at the crankcase

 Inspect condition of hose clamp and coolant hose (30) and replace if required.

29.1

Detach transmission oil lines at the oil-water heat exchanger (31)

Transmission 722.6

30

Remove coolant hoses (24, 25) at the coolant pump (20)

31

Detach the cap (32) on the guide pulley (33)

32

Remove guide pulley (33)

A mounting screw of the coolant pump (20) is located behind the guide pulley (33).

33.1

Remove coolant pump (20)

Only when the timing case cover (26) is replaced.

AR20.10-P-1271HB

34.1

Unscrew the charge air pipe (110/6) at the turbocharger and at the alternator (G2)

Engine 611.962, 612.962/967

35

Remove alternator (G2)

Engine 611.962, 612.962/967

AR15.40-P-5032PD

Engine 612.990

AR15.40-P-5032PF

36

Remove belt pulley/vibration damper (23)

AR03.30-P-1600HB

37

Loosen oil pan bolts and drain the oil pan



*BA01.45-P-1001-01A



*BA01.45-P-1004-01A

38

Detach the guide tube for the engine oil dipstick at the oil pan

 Installation: Replace O-ring, in order to avoid leakage.

39

Unscrew bolts of the cylinder head (34) to the timing case cover (26)

 Engine 611.962

*BA01.30-P-1005-01A

 Engine 612.962/967/990

*BA01.30-P-1001-01M

40

Remove timing case cover (26)

Observe fitting sleeves (27).

 Do not damage cylinder head gasket and oil pan gasket. If required, replace damaged seal to avoid leaks.

See: 

Remove/install cylinder head

AR01.30-P-5800PP

Remove/install oil pan

AR01.45-P-7500PP

 Installation: Observe installation position of return flow check valve (36).

Install new rubber gasket (28).

Coat sealing surfaces with sealant.



*112589002500

Loctite sealant 5970

*BR00.45-Z-1013-01A

Observe the bolt plan for the timing case cover (26).

AR01.40-P-8000-01HB



*BA01.40-P-1001-01A



Notes on sealant path for timing case cover

Engine 611.962, 612.962/967

AH01.40-P-1000-01E



Clean

41

Clean sealing surfaces

 Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Cleaning spray, Loctite 7063 (150ml)

*BR00.45-Z-1046-04A

42

Check front crankshaft radial sealing ring, replace if required

AR03.20-P-3000HB

43

Remove poly-V-belt tensioning device

Only when timing case cover (26) is replaced.

AR13.25-P-3200HB

44

Remove oil-water heat exchanger (31)

Only when timing case cover (26) is replaced.

AR18.30-P-3481PP

Installation: Clean sealing surfaces. Insert new rubber gasket (29), in order to avoid engine leakage.

45

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.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

46

Start the engine and check for oil leaks with the engine running

 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

47

Check fuel system for leaks with the engine running, switch off the engine

48

Read out fault memory and erase



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

Number

Designation

Engine 611.960/
961/962

Engine 612.961/
962/967

Engine 612.990

BA01.20-P-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

10

8

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

10

10

-

Number

Designation

Engine 611.962

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

Engine
612.990

BA01.30-P-1001-01M

Bolt, cylinder head to timing case cover

M8

Nm

20

20

Number

Designation

Engine 611.962

Engine 612.962

Engine 612.967

Engine 612.990

BA01.40-P-1001-01A

Bolt, timing case cover to cylinder crankcase

M6

Nm

-

-

-

-

M8

Nm

20

20

20

20

Number

Designation

Engine 611.960/
961/962

Engine
612.961/962/
963/965/966,
613.961

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

-

-

BA01.45-P-1003-01A

Oil drain screw on oil pan

M12

Nm

-

-

M14

Nm

30

30

BA01.45-P-1004-01A

Bolt, oil pan to timing case cover

M6

Nm

9

9

Number

Designation

Engine 612.967

Engine
612.990

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

9

M8

Nm

20

20

M10

Nm

-

-

BA01.45-P-1003-01A

Oil drain screw on oil pan

M12

Nm

-

-

M14

Nm

30

30

BA01.45-P-1004-01A

Bolt, oil pan to timing case cover

M6

Nm

9

9

Number

Designation

Engine 611.960/
961/962

Engine
612.961/962/
963/967/990, 613.960/961

BA18.20-P-1002-01G

Threaded cap on oil filter

Nm

25

25

Number

Designation

Engine
611.962

Engine
612.962/
967

Engine
612.990

BA20.10-P-1005-01A

Bolt, coolant thermostat housing to cylinder head

Nm

9

9

9

Number

Designation

Model 203
with
code 480

Model 203
with engine
611, 612
except
code 480

Model 209
with engine
112, 113,
156, 271,
612

BA46.30-P-1001-01D

Bolt, power steering pump to control housing

Nm

20

20

20

BA46.30-P-1005-01D

Bolt, belt pulley to power steering pump

Nm

20

25

25

Number

Designation

Engine 611.962

Engine 612.962/
967

Engine
612.990

BA83.55-P-1001-01C

Bolt, refrigerant compressor to timing case cover

Nm

20

20

20

Number

Designation

Engine
611.962 with ASSYST

Engine 612.962/967

Engine
612.990

BF18.00-P-1001-01A

Engine oil

Filling capacity
(oil and filter change)

Liters

6.5

6.5

6.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-01A

BB00.40-P-0228-01A

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

BB00.40-P-0228-05A

Sheet

BB00.40-P-0229-01A

BB00.40-P-0229-01A

BB00.40-P-0229-01A

Sheet

BB00.40-P-0229-03A

BB00.40-P-0229-03A

BB00.40-P-0229-03A

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

BB00.40-P-0229-05A

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite sealant 5970

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

Cleaning spray, Loctite 7063 (150ml)

A 001 986 71 71 10