Remove/install timing case cover

AR01.40-D-8000S

Remove/install timing case cover

18.12.09

 

Remove, Install

1

Disconnect ground cable from battery

2

Remove bottom engine compartment panel

3

Drain engine oil

4

Remove radiator with front end

AR20.20-D-3870A

5

Remove fan

AR20.40-D-5660B

6

Remove poly-V belt

AR13.22-D-1202B

7

Remove poly-V-belt tensioning device

 Only when replacing timing case cover

AR13.25-D-3200B

8

Remove guide pulley (24)

9

Remove guide pulley bracket (25)

10

Remove cylinder head cover (4)

AR01.20-D-5014B

11

Remove vacuum pump

AR43.05-D-1320A

12

Remove vibration damper

Engine 602.984

AR03.30-D-1600E

Engine 602.985

AR03.30-D-1600F

13

Unscrew oil dipstick guide tube from cylinder head

14

Remove belt pulley from coolant pump (27)

15

Unscrew power steering pump (12)

Engine 602.984

 Lay power steering pump down to side with lines connected and fasten in engine compartment

16

Remove alternator

AR15.40-D-5032A

17

Unscrew generator support (22)



*BA15.40-N-1005-01I

18

Remove compressor

Engine 602.985

AR13.30-D-5510B

19

Unscrew compressor support

Engine 602.985

20

Unscrew hexagon head bolts (7) and remove fuel filter with bracket (8)

Engine 602.984

 Attach with connected lines at side of engine compartment.

21

Unscrew hexagon socket head bolt (6) on cylinder head to timing case cover



*BA01.30-N-1003-01B



*116589030700

22

Unscrew bolts (17) with square nuts (9) to injection pump or intermediate flange

*BA07.13-N-1003-01A

23

Unscrew hexagon head bolt (11) from oil pan (10) in area of timing case cover (16)

 Only loosen all other hexagon head bolts on oil pan.

*BA01.45-N-1001-01H

24

Unscrew hexagon head bolt (20) on timing case cover to cylinder crankcase

 Installation: 

Bolt plan for timing case cover

AR01.40-D-8000-01A



*BA01.40-N-1001-01B

25

Take off timing case cover (16)

 Do not damage oil pan gasket, replace if necessary

 Installation: Clean sealing surfaces and apply sealant.

*BR00.45-Z-1017-01A

26

Replace O-ring (26)

On engines with vane-type vacuum pump (Barluk)

27

Install in the reverse order

Number

Designation

Engine 602.984/
985

BA01.30-N-1003-01B

Cylinder head on timing case cover

M8

Nm

23

Number

Designation

Engine
602.984/
985

BA01.40-N-1001-01B

Bolt, timing case cover to cylinder crankcase

M6

Nm

9

M8

Nm

-

Number

Designation

Engine
602.984/
985

BA01.45-N-1001-01H

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

23

M10

Nm

-

Number

Designation

Engine 602.984/
985

BA07.13-N-1003-01A

Bolts, intermediate flange to crankcase

Nm

23

Number

Designation

Engine 602.984

Engine 602.985

BA15.40-N-1005-01I

Bolt, generator support on cylinder crankcase

Nm

23

23

Number

Designation

Order number

BR00.45-Z-1017-01A

Sealant, SV flame starting system replaced with: A001 989 25 20

A 000 989 54 20