Remove/install timing case cover

AR01.40-P-8000A

Remove/install timing case cover

1.12.09

6.8.97

Technical modification: bolts+washers of cylinder head to timing case cover are replaced by Torx bolts without washer

Step 28

 

Remove/install

1

Disconnect/connect battery ground line

AR54.10-P-0003A

2.1

Remove left charge-air line assembly with hot-film air-mass sensor

Engines with compressor and aluminum intake manifold

3

Remove oil-filter insert

 so that engine oil in the oil filter flows off into the oil pan

AP18.00-P-0101-06ED

4.1

Remove viscous fan clutch

Engines with viscous fan clutch

AR20.40-P-5660A

5.1

Remove fan shroud

Vehicles with fan cowl

AR20.40-P-6800HA

6

Remove oil pan

Engine 111.940/ 960 in model 124

Engines 111.920/921/941/945 /961/974 in model 202

Engine 111.946 in model 170

Engine 111.945 in model 208

AR01.45-P-7500A

Engine 111.977 in model 163

AR01.45-P-7500AG

Engine 111 in model 210

AR01.45-P-7500B

Engines 111.944/975 in models 202, 208

Engine 111.943/973 in model 170

AR01.45-P-7500E

7.1

Remove poly-V belt for supercharger

Engines with compressor

AR13.21-P-1202A

8

Remove poly-V belt

AR13.22-P-1202A

9

Drain coolant

AR20.00-P-1142HG

10.1

Remove compressor

Models 170, 202, 208, 210 with compressor

AR09.50-P-4705A

11

Remove alternator bracket or alternator/ compressor bracket

12

Remove poly-V-belt tensioning device

AR13.25-P-3200A

13

Remove front cover at cylinder head

AR01.30-P-5700A

14

Remove coolant pump

AR20.10-P-1271A

15

Remove belt pulley of power steering pump (44)



 In order to remove the screws, place poly-V belt on pulley (44) and apply counterholder.

*603589004000

AR46.30-P-0500A

16.1

Unscrewq retainer (47)

Engines fitted with aluminum intake manifold

17.1

Remove bracket (46b)

If AC not fitted

18.1

Remove brackets (46) and (46a)

with AC fitted

19

Unscrew power steering pump (45) with lines connected and place to one side

AR46.30-P-0500A

20

Turn crankshaft to a 20°-30° crank angle after ignition TDC on cylinder 1 (arrow).

21

Lock camshafts in place with locating pins (01)



*111589031500

22

Mark camshaft gears (75) and (76) to timing chain with a colored marking (arrows)

 Installation: The color markings on the timing chain and on the camshaft sprockets must be above each other (arrows).

23

Remove chain tensioner (14)

 If the complete chain tensioner is slackened, it must be removed, disassembled and reassembled as described.

AR05.10-P-7800A

24

Remove exhaust camshaft sprocket (76)



*000589011000



 Replace bolts for camshaft sprocket; use only once.

*BA05.20-P-1001-02A

25

Remove inlet camshaft sprocket (74)

 on engines without camshaft adjuster.

*000589011000



 Replace bolts for camshaft sprocket; use only once.

*BA05.20-P-1001-02A

26

Remove inlet camshaft with camshaft adjuster

Engines with camshaft adjuster, refer to 

Remove camshafts.

AR05.20-P-6992A

27

Pull out guide rail pins (11)



AR01.30-P-5800-04A

 Installation: Apply sealant to the slide rail pins

*BR00.45-Z-1012-01A



Modified bolts (Torx bolts) for cylinder head to timing case cover

BT01.30-P-0002-01A

28

Unscrew bolts (A) to timing case cover



 Installation: Replace bolts (A), bolts+washers of engines from 1994 (enlarged bolt head contact surface,

 17 mm) with Torx bolts without washers.
Oil bolt head contact surface, tighten bolts to specified torque and tightening angle.

*BA01.40-P-1002-01G



*000589011000

29

Remove belt pulley/vibration absorber (95)

AR03.30-P-1600A

30

Mark remaining bolts for timing-case cover to crankcase with colored marking

31

Unscrew bolts (1) and (2) for timing case cover



*BA01.40-P-1001-01G

32

Take off timing case cover (65)

 Do not damage cylinder-head gasket (arrows)

 Installation: Pull the timing chain firmly upwards when installing the timing-case cover (65) to ensure that no chain loops are formed between the crankshaft gear and the chain locking journals to the timing-case cover (65).

33

Replace front crankshaft radial seal .

AR03.20-P-3000A

34

Clean sealing surfaces at timing case cover (65) and at crankcase

 Installation: Coat sealing surfaces with sealant.

Ensure that sealant does not get into the oil reservoir (65a) for the chain tensioner.

Replace O-rings (66).

*BR00.45-Z-1012-01A

35

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

36

Check for leaks with engine running

Number

Designation

Engine
111

BA01.40-P-1001-01G

Bolt, timing case cover to cylinder crankcase

M8

Nm

25

BA01.40-P-1002-01G

Bolt, cylinder head to timing case cover

Stage 1

Nm

18

Stage 2

°

90

Number

Designation

Engine
111

BA05.20-P-1001-02A

Bolt for camshaft sprocket/flange shaft

Stage 1

Nm

20

Stage 2

°

60

Number

Designation

Order number

BR00.45-Z-1012-01A

Omnifit FD 3041 sealant

A 002 989 47 20 10