Remove/install timing case cover

AR01.40-S-8000B

15.12.09

ENGINES 601 in MODEL 638

S01.40-2507-05

1 Bearing bolt

2 Guide pulley (engine 601.970)

3 Allen head bolts

4 Bolt+washer

S01.40-2001-06

5 AC compressor

6 Bolt+washer

7 Belt pulley

8 Power steering pump

9 Poly-V belt tensioning device

10 Shock absorber

11 Belt tensioning pulley

12 Vacuum pump

13 Belt pulley/vibration damper

14 Alternator support

15 Support

16 Combination bolt (to injection pump)

17 Square nut

18 Bolt+washer

19 Oil pan

20 Timing case cover

S01.40-2002-06

20 Timing case cover

21 TDC sensor bracket

22 Dowel sleeves

23 Crankshaft radial seal

"A" Combination bolt (M660)

"b" Combination bolt (M670)

"c" Combination bolt (M640)

 	Remove/install
1	Disconnect ground cable from battery	 Installation: Code radio. Set timer.	AR54.10-S-0005A
2	Remove front grille		AR88.00-S-2115A
3	Remove front end cross member		AR88.00-S-2302A
4.1	Remove A/C compressor (5)	 Only applies to code H06 (air conditioning)
		with refrigerant compressor 10PA15C	AR83.55-S-5310A
		with refrigerant compressor 7SB16	AR83.55-S-5310B
5	Remove cylinder head cover		AR01.20-S-5014B
6	Remove combination bolt (6) from belt pulley (7) of power steering pump (8)		*BA46.30-N-1004-01A
		 External torx set	*001589760900
7	Remove poly-V belt
			AP13.22-D-1381A
8	Remove belt pulley (7) on power steering pump (8)
9	Remove power steering pump (8) at timing case cover (20)	 Expose power steering pump with attached hydraulic oil lines.
			*BA46.30-N-1001-01A
10.1	Remove poly-V-belt deflection device (2)	 Only withengine 601.970	AR13.22-S-0001A
11	Remove poly-V-belt tensioning device (9)	 Do not remove shock absorber (10) and belt tensioning pulley (11) at clamping lever.	AR13.25-S-3200B
12	Remove bearing bolt (1) using impact extractor and threaded stud	Threaded stud	*116589013400
		 Impact extractor	*116589203300
		 Puller for a sluggish bearing bolt.	*115589203300
		 Threaded stud for a sluggish bearing bolt.	*115589013400
		 Installation: Coat threaded stud (1) using sealant.	*BR00.45-Z-1012-01A
13	Remove vacuum pump (12)		AR43.05-S-1320A
14	Remove belt pulley/vibration damper (13)		AR03.30-S-1600B
15	Remove alternator carrier (14)	 Do not remove support (15).	AR15.40-S-6232B
16	Remove combination bolts (16) for injection pump	 Remove with square nut (17). The lower combination bolt can only be removed when the timing case cover is removed.  Installation: Insert lower combination bolt before installing on timing case cover.
			*BA07.11-N-1007-01A
17	Mark installation position of TDC sensor (21) bracket
18	Remove TDC sensor (21) bracket	 Installation: Install TDC sensor (21) bracket after identification; check adjustment of TDC sensor bracket or adjust as necessary.	AR03.00-S-1101A
			*BA01.40-N-1001-01B
19	Remove hexagon socket head screws (3) to timing case cover (20)		*BA01.30-N-1003-01B
20	Remove combination bolt (4) to timing case cover (20)		*BA47.20-N-1002-02B
21	Remove combination bolts (18) in the area of the timing case cover (20)	 Loosen all other combination bolts for oil pan (19).
			*BA01.45-N-1001-01H
			*BA01.45-N-1002-01H
			*BA01.45-N-1010-01H
22	Remove combination bolts (a, b, c)	 Installation: Observe bolt allocation; tighten combination bolts (a, b, c) evenly.
			*BA01.40-N-1001-01B
23	Take off timing case cover (2)	 Note cylinder head and oil pan gasket; replace a damaged gasket if necessary 
		Remove/install cylinder head	AR01.30-S-5800B
		Remove/install oil pan	AR01.45-S-7500B
		 Note fitting sleeves (22); check condition of crankshaft radial sealing ring (23) 
		Replace crankshaft radial seal if necessary.	AR03.20-S-3000B
24	Clean sealing surfaces and coat with sealant		*BR00.45-Z-1012-01A
25	Install in the reverse order
	Checking
26	Check for leaks

 Cylinder head

Number	Designation			Engine 601.942 601.970


BA01.30-N-1003-01B	Cylinder head on timing case cover	M8	Nm	25

 Crankcase, timing case cover, end cover

Number	Designation			Engine 601.942/ 970


BA01.40-N-1001-01B	Bolt, timing case cover to cylinder crankcase	M6	Nm	9
		M8	Nm	-

 Oil pan

Number	Designation			Engine 601.942	Engine 601.970


BA01.45-N-1001-01H	Bolt, oil pan to cylinder crankcase	M6	Nm	10	10
		M8	Nm	23	23
		M10	Nm	-	-
BA01.45-N-1002-01H	Bolt, transmission bell housing to oil pan		Nm	55	55
BA01.45-N-1010-01H	Bracket, oil pan to crankcase	M8	Nm	-	20

 Diesel injection system - generally

Number	Designation		Engine 601.942 601.970


BA07.11-N-1007-01A	Injection pump on crankcase	Nm	23

 Power steering pump

Number	Designation		Model 638 with steering 763.000


BA46.30-N-1001-01A	Power-steering pump on timing case cover / holder	Nm	21
BA46.30-N-1004-01A	Bolts for belt pulley to power steering pump	Nm	30