Remove/install timing case cover

AR01.40-P-8000RT

Remove/install timing case cover

14.2.12

28.5.08

Clean sealing surfaces - added

Step 29

 

Remove/install

 Danger!

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof

Keep body parts and limbs well clear of moving parts.

AS00.00-Z-0011-01A

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

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

 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 goggles. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A



Notes on battery

All models

AH54.10-P-0001-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A



 External torx set

*001589760900

1

Open engine hood and raise to vertical position

AR88.40-P-1000RT

2

Disconnect ground line from battery

 Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery.

AR54.10-P-0003RT

3

Raise vehicle with vehicle lift

AR00.60-P-1000RT

4

Remove engine compartment paneling

 Installation: Install engine compartment paneling only after engine test run.

AR61.20-P-1105RT

5

Remove air filter housing

AR09.10-P-1150RT

6

Drain coolant at radiator

AR20.00-P-1142GZ



Notes on coolant

All engines

AH20.00-N-2080-01A



Coolant specifications

Sheet 310.1

BB00.40-P-0310-01A



Anticorrosion/antifreeze agents (Sheet 325.0)

Sheet 325.0

BB00.40-P-0325-00A

 Test cap

*210589009100

 Cooler vacuum filling device

*285589002100

 Cooling system

*BF20.00-P-1001-02X

7

Remove electric air pump

AR14.30-P-7251RT



*BA14.30-P-1003-01A

8

Remove poly-V belt

AR13.22-P-1202RT

9

Remove alternator

 Place to the side with lines still connected.

AR15.40-P-5032RT



*BA15.40-P-1005-01N

10

Remove cylinder head covers with ignition coils

AR01.20-P-5014RT



*BA01.20-P-1001-01E

11

Detach coolant line (4, 6) from coolant pump (5).

12

Detach coolant line (4, 6) at radiator

13

Detach coolant line (7) from thermostat housing (8)

14

Remove coolant pump (5) at timing case cover (1).

 Only necessary when the timing case cover (1) is replaced.

AR20.10-P-1271RT

 Installation:Replace gasket of coolant pump (2).

 Installation: Observe bolt diagram.

AR20.10-P-1271-03GZ



*BA20.10-P-1001-01C



*BA20.10-P-1002-01C

15

Detach control rod at front axle sensor of headlight range adjustment

 Only on vehicles with Xenon headlamp units, code 612.

16

Remove oil pan bottom section

AR01.45-P-7555RT

17

Remove oil pan

AR01.45-P-7500RT

18

Remove refrigerant compressor

 Place to the side with lines still connected.

AR83.55-P-5300RT

19

Remove poly-V-belt tensioning device

AR13.25-P-3200RT



*BA13.25-P-1001-01D

20

Remove belt pulley/vibration damper (16)

AR03.30-P-1600RT



*BA03.30-P-1001-01D

21

Remove chain tensioner (15)

AR05.10-P-7800RT



*BA05.10-P-1002-01B

22

Remove oil filter housing (9) with oil-water heat exchanger

AR18.20-P-3471RT



*BA18.20-P-1001-01D



*BA18.20-P-1002-01D

23

Detach power steering pump

 Place to the side with lines still connected.

AR46.30-P-0500RT

24

Lever off plastic cover on guide pulley (13) using a suitable tool

25

Remove bolt from guide pulley (13) on the coolant pump (5)



*BA20.10-P-1008-01C

26

Remove guide pulley

27

Remove bolts of timing case cover (1)

 Installation: Apply sealant and observe bolt diagram:



Bolt plan for timing case cover

AR01.40-P-8000-01B



*BA01.40-P-1001-01C



*BA01.40-P-1002-01C

Loctite 5970 sealant

*BR00.45-Z-1013-01A

28

Remove timing case cover (1)

 On a new timing case cover, the mounting threads for the coolant pump, the tensioning device and the power steering pump are not precut; new self-tapping bolts must therefore be used Pay attention to differences in tightening torque for threads which are not pre-tapped and threads which are pre-tapped.



Notes on sealant path for timing case cover

AH01.40-P-1000-01B

 Installation: make sure that sealant does not enter the oil ducts and take care not to damage the cylinder head gasket in order to avoid engine damage.

 Installation: replace sealing rings in timing case cover.



*BA20.10-P-1001-01C



*BA13.25-P-1001-01D

Loctite 5970 sealant

*BR00.45-Z-1013-01A



Clean

29

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

30

Replace front crankshaft radial sealing ring

AR03.20-P-3000RT

31

Install in the reverse order

32

Inspecting cooling system for leaks

AR20.00-P-1010GZ

33

Check engine oil level and correct if required

 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

34

Conduct engine test run and check engine for leaks while it is running

 In the event of oil loss, determine and eliminate cause otherwise malfunctions, transmission damage, and serious environmental pollution may occur.

35

Perform basic programming

AR00.19-P-0200RT

Number

Designation

Engine 113

BA01.20-P-1001-01E

Cylinder head cover bolt

Stage 1

Nm

9

Stage 2

°

-

Number

Designation

Engine 113.940/941/
942/943/944/
948/960/961/
962/963/964/
965/966/967/
968/969/971/
980/981/982/
984/986/992/
995

BA01.40-P-1001-01C

Timing case cover to crankcase

Nm

20

BA01.40-P-1002-01C

Bolt, cylinder head to timing case cover

Nm

20

Number

Designation

Engine 113.94/96/97/98

BA03.30-P-1001-01D

Central bolt to vibration damper

Stage 1

Nm

200

Stage 2

°

90

Number

Designation

Engine 113.940/941/
942/943/944/
948/960/961/
962/963/964/
965/966/967/
968/969/971/
980/981/982/
984/986/992/
993/995

BA05.10-P-1002-01B

Chain tensioner housing in timing case cover

Nm

80

Number

Designation

Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986/987/988

BA13.25-P-1001-01D

Self-tapping bolt of belt tensioner to timing case cover

Thread not pre-tapped

Nm

35

Thread pre-tapped

Nm

25

Number

Designation

Engine
113.940/941/
942/943/944/
945/946/948/
960/961/962/
963/964/965/
966/967/968/
969/971/980/
981/982/984/
986

BA14.30-P-1003-01A

Bolt connecting air pump bracket to timing case

Nm

12

Number

Designation

Engine
113
in model
164, 251

BA15.40-P-1005-01N

Self-tapping bolt, alternator to timing case

Thread not pre-tapped

Nm

60

Thread pre-tapped

Nm

45

Number

Designation

Engine 113.964/
971

BA18.20-P-1001-01D

Screw cap at oil filter

Nm

25

BA18.20-P-1002-01D

Bolt, oil filter housing to timing case

Nm

70

Number

Designation

Engine
113.964/
971

BA20.10-P-1001-01C

Self-tapping bolt, connecting coolant pump to timing case

Thread not pre-tapped

M6

Nm

14

Thread not pre-tapped

M8

Nm

35

Thread pre-tapped

M6

Nm

10

Thread pre-tapped

M8

Nm

25

BA20.10-P-1002-01C

Belt pulley on coolant pump

Nm

10

BA20.10-P-1008-01C

Bolt, guide pulley to coolant pump housing

M8

Nm

20

Number

Designation

Model
251
with engine 113

BF20.00-P-1001-02X

Cooling system

Total filling capacity

Liters

6.6

Capacity of anticorrosion/antifreeze agent down to -37 °C

Liters

3.3

Filling capacity of anticorrosion/ antifreeze down to -45°C

Liters

3.6

Service specifications

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A

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