ar0140p8000tk

Remove/install timing case cover

Type ar · topic 01.40 · version 0203 · 2011-05-18

Applies to: ENGINES 271.941 in MODEL 211.042 /242 ENGINES 271.956 in MODEL 211.041 /241

Where it sits

Function group 1 Engine › 01 Complete engine, crankcase ventilation, cylinder head, crankcase › 01.40 Crankcase, timing case cover, end cover — Series 211 (models 041, 042, 241, 242)

EinPAS 15 Engine › 15.15 Combustion engine, complete/engine housing/crank assembly › 15.15.30 Timing case/flywheel housing — Series 211 (models 041, 042, 241, 242)

Also applies to engines/gearboxes: 271 941, 271 956

AR01.40-P-8000TK

Remove/install timing case cover

18.5.11

ENGINES 271.941 in MODEL 211.042 /242

ENGINES 271.956 in MODEL 211.041 /241

Remove/install timing case cover

P01.40-2094-09

1 Engine air intake duct

2 Belt pulley

3 Compressor

4 Bolts

5 Bolt

A9 Refrigerant compressor

A9x1 Refrigerant compressor connector

M16/6 Throttle valve actuator

6 Intake muffler

7 Bolts

8 Pressure connection fitting

11 Bolts

Remove/install timing case cover

P01.40-2095-11

9 Slide rail pins

10 Bolts

Modification notes

26.5.09

Value altered: Bolt, belt pulley to coolant pump

*BA20.10-P-1001-01I

Remove/install

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

1

Remove engine air intake duct (1)

2

Remove air filter housing

AR09.10-P-1150Q

3

Remove cylinder head cover

AR01.20-P-5014TK

4

Remove poly-V belt

AR13.22-P-1202QK

5

Remove front cover at cylinder head

AR01.30-P-5700QK

6

Spin engine at crankshaft in direction of rotation until piston in first cylinder is positioned on TDC

The exhaust camshaft cams and intake camshaft cams must be positioned at fourth cylinder onto valve overlap.

7

Remove chain tensioner

AR05.10-P-7800QK

8

Detach belt pulley (2) from coolant pump

*BA20.10-P-1001-01I

9

Detach compressor (3) from timing case cover by unscrewing bolts (4)

*BA09.50-P-1001-01C

10

Detach compressor (3) from engine support by unscrewing bolt (5)

*BA09.50-P-1002-01C

11

Detach intake muffler (6) from oil filter housing

*BA09.50-P-1006-01C

12

Remove bolts (7) and disconnect pressure connection (8) from throttle valve actuator (M16/6)

*BA09.41-P-1004-02A

13

Press compressor (3) slightly away from timing case cover

14

Detach power steering pump from timing case cover and place to the side

Do not remove high pressure expansion hose.

AR46.30-P-0500QK

15

Remove belt pulley/vibration damper

AR03.30-P-1600QK

16

Pull out slide rail bolt (9) at cylinder head

Use a screwdriver to remove plug.

AR01.30-P-5800-04GS

17

Detach timing case cover from cylinder head by unscrewing bolts (10)

*BA01.40-P-1002-01G

18

Mount front cover onto cylinder head

To lift engine, the front cover must be mounted at cylinder head.

AR01.30-P-5700QK

19

Detach refrigerant compressor (A9), for this step unscrew bolts (11)

Disconnect refrigerant compressor connector (A9x1) and attach refrigerant compressor (A9) with connected lines, laterally at bottom of engine compartment.

*BA83.55-P-1001-01G

20

Remove oil pan

AR01.45-P-7500TK

21

Detach timing case cover from the crankcase

Installation: Observe different bolt lengths and diameters:

Bolt plan for timing case cover

AR01.40-P-8000-01QK

*BA01.40-P-1001-01G

22

Take off timing case cover

Installation: Replace crankshaft radial sealing ring. Apply sealant to the sealing surface of the timing case cover.

Notes on sealant path for timing case cover

AH01.40-P-1000-01TK

Squeeze gun

*112589002500

Loctite 5970 sealant

*BR00.45-Z-1013-01A

Clean

23

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

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

24

Install in the reverse order

Crankcase, timing case cover, end cover

Number

Designation

Engine
271

BA01.40-P-1001-01G

Bolt, timing case cover to cylinder crankcase

M8

Nm

20

BA01.40-P-1002-01G

Bolt, cylinder head to timing case cover

Stage 1

Nm

20

Stage 2

°

-

Charge air duct

Number

Designation

Engine
271

BA09.41-P-1004-02A

Bolt connecting charge air duct downstream of charge air cooler to pressure damper

Nm

8

Supercharger

Number

Designation

Engine
271

BA09.50-P-1001-01C

Bolt, supercharger to timing case

M8

Nm

20

BA09.50-P-1002-01C

Bolt, supercharger to engine support

M8

Nm

20

BA09.50-P-1006-01C

Bolt, intake muffler to oil filter housing

M6

Nm

11

Coolant pump, coolant thermostat

Number

Designation

Engine
271

BA20.10-P-1001-01I

Bolt, pulley to coolant pump

Nm

13

Refrigerant compressor

Number

Designation

Engine
271
except in model 204, 207

BA83.55-P-1001-01G

Bolt, refrigerant compressor to bracket

Nm

20

Remove/install timing case cover

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

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

Referenced documents