Remove/install timing case cover

AR01.40-P-8000RX

Remove/install timing case cover

29.11.11

9.11.11

Operation sequence adapted to the change in repair method

 

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



Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

1

Turn key in ignition lock to position "0"

 Vehicles with code (889) Keyless-Go: Press Keyless-Go start/stop button repeatedly until ignition is switched off.

2

Remove air filter housing with engine air intake ducts

AR09.10-P-1150RX

3

Remove lower engine compartment paneling

AR61.20-P-1105R

4

Drain engine oil

AP18.00-P-0101RX

 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

5

Drain coolant at radiator

AR20.00-P-1142RX



Notes on coolant

AH20.00-N-2080-01A

6

Disconnect coolant hose on coolant temperature regulator housing

7

Detach coolant hose (3) at coolant pump

8

Remove fan shroud

AR20.40-P-6800RX

9

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

10

Remove poly-V-belt tensioning device

AR13.25-P-3200RX

11

Detach guide pulley (2)

AR13.21-P-3350RX

12

Remove air pump

AR14.30-P-7251RX

13

Remove coolant temperature control housing

 Installation: Install new O-ring and seal.

AR20.10-P-2460RX

14

Remove oil filter housing with oil-water heat exchanger

AR18.20-P-3471RX

15

Remove left and right air shutoff valve

AR14.30-P-7200RX

16

Remove intermediate flange (1) of air shutoff valve



*BA14.30-P-1004-02A

17

Rotate engine at crankshaft center bolt in direction of rotation of engine to a 40° crankshaft angle after ignition TDC



*001589650900

18

Install retaining lock for crankshaft/starter ring gear

AR03.30-P-5000RX

19

Remove belt pulley/vibration damper

AR03.30-P-1600RX

20

Remove front cover at left cylinder head

 Installation: After installing the front cover, check that the camshafts are positioned at 55° crank angle BTDC:


AR01.30-P-5700RX

Check basic position of camshafts.

AR05.20-P-6010RX

21

Remove front cover at the right cylinder head

 Installation: After installing the front cover, check that the camshafts are positioned at 55° crank angle BTDC:


AR01.30-P-5700RY

Check basic position of camshafts.

AR05.20-P-6010RX

22

Remove chain tensioner

 Installation: Install new chain tensioner. The previously installed chain tensioner must not be reinstalled because during removal, its pressure pin is pressed into the end position. The thrust pin latch prevents this return stroke. This would overstretch the timing chain on reinstalling.

AR05.10-P-7800RX

23

Remove camshaft adjuster for exhaust camshafts.

AR05.20-P-7201RY

24

Remove camshaft adjuster for intake camshafts.

AR05.20-P-7201RX

25

Remove alternator

AR15.40-P-5032RX

26

Remove the oil dipstick guide tube

AR18.40-P-3510RX

27.1

Detach power steering pump (8) from timing case cover (7) and put it on the side with connected line

Engine 272 without code (487) Active Body Control (ABC)

AR46.30-P-0500RY

27.2

Detach tandem pump from timing case cover (7) and place to one side with lines connected

Vehicles with code (487) Active Body Control (ABC)

AR46.30-P-0500RX

28

Detach refrigerant compressor (A9) and put it on the side with connected lines



*BA83.55-P-1001-01M

29

Remove oil pan

 If the oil pan cannot be released from the crankcase, warm oil pan in area of sealing surface with a hot air gun, then push mounting wedge between sealing surface to separate oil pan of oil pan.

AR01.45-P-7500RX

30

Remove screw/bolts (12, 13)



*BA01.30-P-1003-01O

31

Detach timing case cover (7)

 Installation: Observe different bolt lengths and diameters: 

Bolt plan for timing case cover:

AR01.40-P-8000-01VA

 Engine 272

*BA01.40-P-1001-01G

 Engine 273

*BA01.40-P-1001-01T

 Installation: Replace crankshaft radial sealing ring (9). Replace both sealing rings in timing case cover (7) and apply sealant to sealing surface of the timing case cover (7):





Notes on sealant path for timing case cover

AH01.40-P-1000-01VA



*112589002500

Loctite 5970 sealant

*BR00.45-Z-1013-01A



Clean

32

Clean oil pan sealing surfaces, oil pan bottom section and timing case cover (7)

 Do not use any sharp-edged tools or abrasive paper. The sealing surfaces will be damaged otherwise.

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 cleaning spray (150 ml)

*BR00.45-Z-1046-04A

33

Install in the reverse order

34

Check engine oil level; correct if necessary

AP18.00-P-0101RX

 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

35

Carry out an engine test run and check engine for leaks

36

Inspect cooling system for leaks

AR20.00-P-1010RX

Number

Designation

Engine
272

Engine
273

BA01.30-P-1003-01O

Cylinder head bolt on timing case

M8

Nm

20

20

Number

Designation

Engine
272

BA01.40-P-1001-01G

Screw/bolt, timing case cover to cylinder crankcase

M8

Nm

20

Number

Designation

Engine
273

BA01.40-P-1001-01T

Screw/bolt, timing case cover to cylinder crankcase

M8

Nm

20

Number

Designation

Engine
272

Engine
273

BA14.30-P-1004-02A

Screw/bolt, left air shutoff valve intermediate flange to cylinder head

Nm

14

14

Number

Designation

Engine 272

Engine 273

BA83.55-P-1001-01M

Screw/bolt, refrigerant compressor to timing case/crankcase/engine support

Nm

20

20

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