Remove/install timing case cover

AR01.40-P-8000GT

Remove/install timing case cover

14.2.12

3.9.09

Value altered: Power steering pump screw - attachment

*BA46.30-P-1009-01B

 

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

AS54.10-Z-0001-01A

1

Activate Service mode in Tele-Aid emergency call system

 Only on model 463.322/323 with Code Tele-Aid car phone emergency call system ET2

AR82.95-P-0005-03GR



Notes regarding the Tele-Aid emergency call system

Model 463.243/244/245/247/248/250/ 254/270/309/322/323/332/333 TELE AID car telephone emergency call system ET2

AH82.95-P-0001-01GA

2

Disconnect battery ground line

Model 463.322/323

AR54.10-P-0003G

Model 461.302/331/332/342/345

AR54.10-P-0003GL



Notes on battery

All models

AH54.10-P-0001-01A

3

Remove underride guard

4

Drain coolant



Replace coolant

AP20.00-P-2080G



Notes on coolant

All engines

AH20.00-N-2080-01A

5

Drain/collect engine oil

 Installation: Replace seal for oil drain screw.



*BA01.45-P-1003-01A



*BF18.00-P-1001-01A

6

Remove trim panels (1, 2) for cylinder head cover (8)

Only on model 463.322/323

AR01.20-P-5014-02B

Only on model 461.331

AR01.20-P-5014-02GLC



*BA01.20-P-1002-01A



*BA01.20-P-1003-01A

7

Remove coolant hose (3, 4) on coolant thermostat (11)

 Inspect condition of hose clamps and coolant hoses (3, 4), replace if damaged.

6 mm socket hexagon on flexible shaft for hose clamps with worm drive

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

8

Remove air filter

AR09.10-P-1050GI

9

Remove radiator

AR20.20-P-3865GT

10

Attach a guard plate for radiator and/or condenser



Guard plate for radiator/condenser

WF58.50-P-0110-01A

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

11

Remove fuel injectors (Y76)

AR07.16-P-1000HB



Notes on injectors

Engine

611.960/961/962/980/981/987, 612.961/962/963/965/966/967/981, 613.960/961, 628.960/961/962/963, 640.941, 646.951/961/962/963, 647.961/981, 648.960/961, 668.914/940/941/942, 612.990

AH07.16-P-1000-01A

12

Remove cylinder head cover (8)

AR01.20-P-5014HB

13

Position piston of cylinder 1 to ignition TDC

 Do not reverse rotate the engine otherwise the timing chain could become jammed.

 Only crank engine at crankshaft The engine must not be turned at the camshaft sprocket bolt. The markings on the camshaft must be aligned with the camshaft bearing cap.

14

Install retaining lock for crankshaft / starter ring gear

AR03.30-P-5000HB

15

Remove chain tensioner (9)

 Installation: Replace sealing ring (10).

AR05.10-P-7800GT

16

Remove coolant thermostat (11)

 Installation: Ensure correct seating of the connection support (12).

AR20.10-P-2460GT

17

Remove front cover (13) at cylinder head

AR01.30-P-5700B

18

Remove high-pressure pump (14)

AR07.02-P-1020GS

19

Remove poly-V belt (15)

AR13.22-P-1202HB

20

Remove belt pulley (16) of power steering pump (17)



*603589004000

21

Remove oil filter (18)



Replace oil filter element, drain oil filter

AP18.00-P-0101-06EG

22

Remove mixing chamber (6)

AR09.20-P-1320GS

23

Remove power steering pump (17) at timing case cover (19)

 Attach power steering pump (17) at the side at the top in engine compartment with lines connected.



*BA46.30-P-1009-01B

24

Disconnect electrical connector at refrigerant compressor (A9)

Only on model 461.302/331/332/342/345 with AC system, Code H02

25

Unbolt refrigerant compressor (A9)

Only on model 461.302/331/332/342/345 with AC system, Code H02

 Attach refrigerant compressor (A9) with connected pipe system in the engine compartment.



*BA83.55-P-1001-01C

26

Detach coolant hose (20) for oil-water heat exchanger (21) at crankcase

 Installation: Check the condition of the coolant hose (20) and the hose clamp and replace them if required.

27

Remove coolant pump (24)

 Only when timing case cover (19) is replaced.

AR20.10-P-1271GT

28

Remove charge air pipe (25)

AR09.41-P-1311GS

29

Remove alternator (G2)

Model 461.302/331/332/342/345

AR15.40-P-5032GL

Model 463.322/323

AR15.40-P-5032GS

 Remove alternator (G2) with bracket.

30

Remove belt pulley with vibration damper (26)

AR03.30-P-1600HB

31

Slacken bolts of oil pan

 Remove bolts for oil pan on timing case cover (19). Loosen bolts for oil pan on timing case cover and lower oil pan.



*BA01.45-P-1001-01A



*BA01.45-P-1004-01A

32

Remove bolts (27), cylinder head to timing case cover (19)



*BA01.30-P-1001-01M

33

Remove timing case cover (19)

 Installation: Clean sealing surfaces. Install new rubber gasket (28). Pay attention to correct seating of fitting sleeve (29).



Notes on application of sealant to the timing case cover (19)

Engine 611.960/961/962, 612.961/962 /963/965/966/967, 613.960/961

Engine 611.980 in model 638.094/194/ 294
with code (MQ4) engine OM611 DE22 LA (75 kW)
with code (MQ5) engine OM611 DE22 LA (90 kW )

Engine 611.980 in model 638.094/194 with code (MQ3) engine OM611 DE22 A (60 kW)

Engine 611.981/987, 612.981

Engine 646.951 in model 211.004

Engine 646.961 in model 211.006/206/606

Engine 647.961 in model 211.016/216/616

Engine 646 in model 203

Engine 648.961 in model 211.026/226/023/223

Engine 648.960 in model 220.025/125

Engine 647.981

AH01.40-P-1000-01E



*112589002500

*BR00.45-Z-1013-01A

 Do not damage cylinder head gasket and oil pan gasket. Replace the damaged gasket as required. Refer to:



Remove/install cylinder head

AR01.30-P-5800GS

Remove/install oil pan

AR01.45-P-7500GT

 Check front crankshaft radial sealing ring and replace it if required. Refer to:



Replace front crankshaft radial seal.

AR03.20-P-3000HB

 Installation: Observe installation position of return flow check valve (31).

Bolt plan for the timing case cover (19)

AR01.40-P-8000-01HB



*BA01.40-P-1001-01A

34

Remove poly-V belt tensioning device

 Only when timing case cover (19) is replaced.

AR13.25-P-3200HB

35

Remove oil-water heat exchanger (21)

 Only when timing case cover (19) is replaced.

AR18.30-P-3481GS

36

Install in the reverse order

37

Deactivate service mode in TELE AID emergency call system

 Only on model 463.322/323 with Code Tele-Aid car phone emergency call system ET2

AR82.95-P-0005-03GR



Notes regarding the Tele-Aid emergency call system

Model 463.243/244/245/247/248/250/ 254/270/309/322/323/332/333 TELE AID car telephone emergency call system ET2

AH82.95-P-0001-01GA

38

Inspect cooling system for leaks

 For engine with new cylinder head gasket: do not pry off cooling system until engine has reached operating temperature.

AR20.00-P-1010HA

 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

39

Start engine and run at idling speed

 Observe oil pressure indicator in the process.

40

Check for oil leaks with engine running

 Danger!

Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure.

Keep all ignition sources out of hazard area.

Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

41

Check fuel system for leaks with engine running

42

Turn off engine

43

Read out fault memory and erase

 with STAR DIAGNOSIS.
Stored faults, which may result from wires being disconnected or from simulation during assembly or testing, have to be processed and erased in the fault memories after completing the work.



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS

Number

Designation

Engine 612.965

Engine 612.966

BA01.20-P-1002-01A

Bolt, trim panel of cylinder head cover to cylinder head cover

Nm

10

10

BA01.20-P-1003-01A

Bolt, charge air distribution pipe cover to charge air manifold

Nm

10

10

Number

Designation

Engine
612.961/962/963/965/966/967/981

BA01.30-P-1001-01M

Bolt, cylinder head to timing case cover

M8

Nm

20

Number

Designation

Engine 612.965/
966

BA01.40-P-1001-01A

Bolt, timing case cover to cylinder crankcase

M6

Nm

-

M8

Nm

20

Number

Designation

Engines
612.961/962/
963/965/966,
613.961

BA01.45-P-1001-01A

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

M10

Nm

-

BA01.45-P-1003-01A

Oil drain screw on oil pan

M12

Nm

-

M14

Nm

30

BA01.45-P-1004-01A

Bolt, oil pan to timing case cover

M6

Nm

9

Number

Designation

Model
461.302/
304/305/
331/332/
333/334/
340/342/
343/344/
345/346,
model
463.322/
323

BA46.30-P-1009-01B

Power steering pump bolt - mounting

Nm

-

Number

Designation

Engine 612.965/
966

BA83.55-P-1001-01C

Bolt, refrigerant compressor to timing case cover

Nm

20

Number

Designation

Engine
612.965

Engine
612.966

BF18.00-P-1001-01A

Engine oil

Filling capacity
(oil and filter change)

Liters

7.0

8.0

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-01A

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-03A

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

BB00.40-P-0228-05A

Sheet

BB00.40-P-0229-01A

BB00.40-P-0229-01A

Sheet

BB00.40-P-0229-03A

BB00.40-P-0229-03A

Sheet

BB00.40-P-0229-05A

BB00.40-P-0229-05A

Sheet

BB00.40-P-0229-31A

BB00.40-P-0229-31A

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite sealant 5970

A 003 989 98 20