Remove/install timing case cover

AR01.40-P-8000V

Remove/install timing case cover

14.2.12

 

Remove/install



 Torx bit set

*000589011000

 External torx set

*001589760900

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

AS54.10-Z-0001-01A

1

Disconnect battery ground line

 The battery is located below the rear seat.

AR54.10-P-0003A



Notes on battery

All models

AH54.10-P-0001-01A

 Installation: After connecting the ground cable, read out diagnostic trouble code memory, encode radio and normalize power windows.

Vehicles with stationary heater: adjust time display on stationary heater.

2

Remove engine compartment paneling

AR61.20-P-1105AB

 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

3

Drain coolant at radiator

AR20.00-P-1142HA

4

Remove engine trim panel

5

Remove viscous fan (1)

 Right-hand thread!

AR20.40-P-5660C

6

Remove fan shroud (3)

7

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

8

Remove poly-V belt (2)

AR13.22-P-1202BA

9

Remove cylinder head covers (6)

AR01.20-P-5014B

10

Remove cylinder heads (15)

AR01.30-P-5800BA

11

Detach coolant lines (18, 19) at coolant pump (12)

12

Detach coolant line (17) at thermostat housing (13)

13

Remove oil pan bottom section (9)

AR01.45-P-7555VA

14

Remove oil filter housing together with oil-water heat exchanger (7)

AR18.20-P-3471BA

15

Remove poly-V belt tensioning device (5)

AR13.25-P-3200BA



*BA13.25-P-1001-01M

16

Remove vibration damper (4)

AR03.30-P-1600CA

17

Unbolt AC compressor (10)

 Place to the side with lines still connected.



*BA83.55-P-1001-01A

18

Unbolt power steering pump (11) with reservoir

 Place to the side with lines still connected.



*BA46.30-P-1010-01A

19

Detach pulley (16) at coolant pump (12)

 Take off plastic cover of pulley.



*BA20.10-P-1001-01M

20

Remove air pump (21)

AR14.30-P-7251A

21

Separate electric cable of
coolant temperature sensor (B11/3)

22

Unscrew bolts for timing case cover

 Installation: Apply sealant to bolts (arrows), observing bolt diagram for timing case cover: 

*BR00.45-Z-1013-01A

Bolt plan for timing case cover

AR01.40-P-8000-01B



*BA01.40-P-1001-01C



*BA01.40-P-1002-01C

23

Take off timing case cover

 Installation: Fastening threads for coolant pump, belt tensioning device and power steering pump are not cut into a new timing case cover.

For this reason, use new self-tapping bolts in combination with a new timing case cover for attaching the coolant pump, belt tensioning device and the power steering pump.

Pay attention to the torque when tightening bolts into threads which are not tapped.



*BA20.10-P-1001-01M



*BA13.25-P-1001-01M



*BA46.30-P-1010-01A

*BR00.45-Z-1013-01A



Notes on sealant path for timing case cover

Engine 112, 113

AH01.40-P-1000-01B

 Installation: Ensure that no sealant enters the oil ducts.

Do not damage cylinder head gasket.

Replace seals on timing case (19).

24

Replace front crankshaft radial sealing ring

AR03.20-P-3000BA

25

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

26

Check for leaks with engine running

27

Inspect cooling system for leaks

First warm up engine to operating temperature.

AR20.00-P-1010HA

Number

Designation

Engine
112 except 112.951 /
976

Engine
112.951/
976

BA01.40-P-1001-01C

Timing case cover on crankcase

Nm

20

20

BA01.40-P-1002-01C

Bolt, cylinder head to timing case cover

Nm

20

20

Number

Designation

Engine
112.910/911/912/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
972/973/975

BA13.25-P-1001-01M

Self-tapping bolt, belt tensioner to timing case cover

Thread not pre-tapped

Nm

35

Thread pre-tapped

Nm

25

Number

Designation

Engine 112.910/911/912/913/914/915/
916/917/920/
921/922/923/
940/941/942/
943/944/945/
946/947/949/
953/954/955/
960/961/970/
972/973/975

BA20.10-P-1001-01M

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

Number

Designation

Model 210.061/062/063/
065/070/074/
081/082/083/
261/262/263/
265/270/274/
281/282/283/
663

BA46.30-P-1010-01A

Self-tapping bolt, power steering pump to timing case

Thread not pre-tapped

Nm

35

Thread pre-tapped

Nm

20

Number

Designation

Engine
112, 113
in model 202, 208, 210

BA83.55-P-1001-01A

Bolt, refrigerant compressor to bracket

Nm

20

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite 5970 sealant

A 003 989 98 20