Remove/install timing case cover

AR01.40-D-8000RU

Remove/install timing case cover

18.02.2020

Engine

646 in model 909

Modification notes

15.11.2016

Remove guide pulley holder and install, added.

Operation steps 8.1, 26.2

21.11.2016

Detach heat exchanger and mount for replacement of the timing case cover, added.

Operation steps 15, 16

Shown on engine 646 with code HH9 (Semi-automatic regulated A/C, TEMPMATIC)

4

Coolant pump

5

Front cover

6

Poly-V belt tensioning device

7

Oil filter cover

8

Power steering pump

9

Belt pulley

10

Oil pan

11

Timing case cover

12

Refrigerant compressor

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

 Danger

Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC.

No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

Topical note

Notes on battery

AH54.10-P-0001-01A



Remove

1

Detach battery ground line

2

Remove coolant pump(4)

AR20.10-D-1271R

3

Remove the chain tensioner

AR05.10-D-7800R

4

Remove front cover (5)

AR01.30-D-5700R

5

Remove poly-V belt tensioning device (6)

AR13.25-D-3200R

6

Detach coolant hose on the heat exchanger

AR18.30-D-3481R

7

Detach power steering pump (8) on engine and place with attached lines to one side

AR46.30-D-0500R

8.1

Remove guide pulley holder

Engine 646 in model 909
except code HH9 (Air conditioner, automatic heater control)

AR13.20-D-2001-01R

8.2

Detach A/C compressor (12) on engine and place with attached lines to one side

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

AR83.55-D-5300R

9

Remove belt pulley(9)

AR03.30-D-1600R

10

Unscrew oil filter cover (7) on oil filter housing

When replacing the oil filter element.



AP18.20-D-0100-04R

 Wrench socket

*103589020900

11

Remove oil pan (10)

AR01.45-D-7500R

12

Remove both screw plugs on timing case cover (11)

When replacing the timing case cover (11).

13

Unscrew screw/bolts from timing case cover (11)

AR01.40-D-8000-01R

 Pay attention to different screw/bolt lengths and screw/bolt diameters.

14

Press off timing case cover (11) with a suitable tool


Carefully pry off timing case cover (11).
The cylinder head gasket can get damaged otherwise.

If the cylinder head gasket is damaged



Replace cylinder head gasket.

AR01.30-D-5800RU

15

Detach heat exchanger

When replacing the timing case cover (11).

AR18.30-D-3481R



Install

16

Mount the heat exchanger

When replacing the timing case cover (11).

AR18.30-D-3481R

17

Check oil pressure relief valve for damage

If damaged



Replace oil pressure relief valve.

AR18.10-D-5031R

18

Clean sealing surfaces on crankcase and timing case cover (11)

AR01.00-P-0050-01A

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

19

Apply sealant to sealing surfaces of timing case cover (11) using squeeze gun

Notes on sealant path for timing case cover

AH01.40-P-1000-01SD

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

20

Position timing case cover (11) and tighten screw/bolts

Bolt plan for timing case cover

AR01.40-D-8000-01R

 Pay attention to different screw/bolt lengths and screw/bolt diameters.

 Screw/bolt, timing case cover to crankcase

*BA01.40-N-1001-01Q

21

Screw in and tighten both screw plugs on timing case cover (11)

When replacing the timing case cover (11).

 Screw plug to timing case

*BA01.40-N-1004-01Q

22

Install oil pan (10)

AR01.45-D-7500R

23

Screw oil filter cover (7) onto oil filter housing and tighten

When replacing the oil filter element.



AP18.20-D-0100-04R

 Threaded cap to oil filter housing

*BA18.20-N-1001-01O

 Wrench socket

*103589020900

24

Replace front radial shaft sealing ring

AR03.20-D-3000R

25

Install belt pulley (9)

AR03.30-D-1600R

26.1

Mount A/C compressor (12) on engine

Engine 646 in model 909
with code HH9 (Air conditioner, automatic heater control)

AR83.55-D-5300R

26.2

Install guide pulley holder

Engine 646 in model 909
except code HH9 (Air conditioner, automatic heater control)

AR13.20-D-2001-01R

 Bolt, guide pulley carrier to timing case cover

*BA13.25-N-1006-01P

 Bolt, guide pulley carrier to engine support

*BA13.25-N-1007-01P

27

Mount power steering pump (8) on engine

AR46.30-D-0500R

28

Attach coolant hose to the heat exchanger

AR18.30-D-3481R

29

Install poly-V belt tensioning device (6)

AR13.25-D-3200R

30

Install front cover (5)

AR01.30-D-5700R

31

Install the chain tensioner

AR05.10-D-7800R

32

Install coolant pump (4)

AR20.10-D-1271R

33

Mount ground line to battery

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off 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 leaktightness around the timing case cover (11)

 Crankcase, timing case cover, end cover

Number

Designation

Engine 646.701 in model 909

BA01.40-N-1001-01Q

Screw/bolt, timing case cover to crankcase

M8

Nm

20

 Crankcase, timing case cover, end cover

Number

Designation

Engine 646.701 in model 909

BA01.40-N-1004-01Q

Screw plug to timing case

M101

Nm

9

M221.5

Nm

45

 Belt tensioning device

Number

Designation

Engine 646 in model 909

BA13.25-N-1006-01P

Bolt, guide pulley carrier to timing case cover

Nm

20

 Belt tensioning device

Number

Designation

Engine 646 in model 909

BA13.25-N-1007-01P

Bolt, guide pulley carrier to engine support

Nm

20

 Engine lubrication, oil filter housing

Number

Designation

Engine 646 in model 909

BA18.20-N-1001-01O

Threaded cap to oil filter housing

Nm

25

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10

BR00.45-Z-1038-04A

Loctite 7200

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09