Remove/install timing case cover

AR01.40-S-8000C

Remove/install timing case cover

2.3.10

21.1.08

Value changed: oil drain screw to oil pan

*BA01.45-N-1003-01H

 

Remove/install

1

Disconnect battery ground line

AR54.10-S-0005A

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

2

Drain coolant

AR20.00-S-1142A

3

Drain engine oil

AP18.00-D-0101A



*BA01.45-N-1003-01H

4

Remove cylinder head cover (1)

AR01.20-S-5014D

5

Position piston of cylinder 1 to ignition TDC

AR01.00-S-0120D

6

Install retaining lock for crankshaft/starter ring gear (2)

AR03.30-S-5000C

7

Remove chain tensioner (3)

AR05.10-S-7800D

8

Remove high-pressure pump (4)

 Ensure scrupulous cleanliness.

AR07.02-S-1020A

9

Remove front cover (5) at cylinder head

AR01.30-S-5700A

10.1

Remove bolt from refrigerant line to oil pan holder (22)

for code H06 (Air conditioning)



*001589760900

11.1

Unscrew bolts on refrigerant compressor (6)

for code H06 (Air conditioning)

Attach refrigerant compressor (6) with piping connected at lower side in the engine compartment.



*BA83.55-N-1005-01A



*001589760900

12

Unscrew bolts for power steering pump (7)

Expose power steering pump (7) with attached lines.



*BA46.30-N-1011-01A



*001589760900

13

Remove coolant pump (16)

AR20.10-S-1271D

14

Unscrew bolts from three-phase alternator (9) to timing case cover (17 )

 Support three-phase alternator.



*BA15.40-P-1001-01D



*001589760900

15

Remove belt pulley/vibration damper (18)

AR03.30-P-1600HB

16

Unscrew bolts (10) from timing case cover (17)

 Unscrew bolts (10) in the area of the timing case cover (17) to the oil pan. Only slacken all other bolts of the oil pan.



*BA01.45-N-1001-01H



*BA01.45-N-1005-01H



*001589760900

17

Unscrew bolts from cylinder head to timing case cover (17)



*BA01.30-P-1005-01A

18

Remove timing case cover (17)

 Collect escaping coolant and engine oil. Do not allow to flow into the oil pan. Cover the opening to the oil pan when cleaning sealing surfaces with a rag. Ensure scrupulous cleanliness.

 Do not damage cylinder head gasket and the oil pan gasket. Replace damaged seal in case of damage 

Remove/install cylinder head

AR01.30-S-5800D

Remove/install oil pan (22)

AR01.45-S-7500D

 Installation: Clean sealing surfaces. Pay attention to dowel sleeves (20). Install new rubber gasket (28). Coat sealing surface of the timing case cover (17) with sealant. Refer to:



Notes on sealant path for timing case cover

Engine 611.960/961/ 962/980/981/987, 612.961/962/963/981, 613.960/961

AH01.40-P-1000-01E

Loctite sealant 5970

*BR00.45-Z-1013-01A

 Squeeze gun

*112589002500

 Inspect front crankshaft radial seal, if necessary according to condition 

Replace front crankshaft radial seal (23)

AR03.20-P-3000HB

Bolt plan for timing case cover

AR01.40-P-8000-01HB



*BA01.40-N-1001-01B



*001589760900

19.1

Remove poly-V belt tensioning device

 Only if timing case cover is replaced.

without code H06 (Air conditioning)

AR13.25-S-3200D

with code H06 (Air conditioning)

AR13.25-S-3200E

20.1

Remove oil filter

 Only if timing case cover is replaced.

*BA18.20-N-1001-01A



*103589020900

21.1

Remove oil-water heat exchanger (8)

 Only when replacing the timing case cover.

AR18.30-S-6840C

22

Install in the reverse order



Checking

23

Inspect cooling system for leaks

 Engine with new cylinder head gasket:

Do not pressure-test cooling system until engine has reached operating temperature.

AR20.00-S-1010A

 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

24

Check for leaks with engine running

25

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Refer to:

Diagnosis manual for diesel engine, Volume 1.2

Number

Designation

Engine 611.980

BA01.30-P-1005-01A

Bolt, cylinder head to timing case cover

M8

Nm

20

Number

Designation

Engine
611.980

BA01.40-N-1001-01B

Bolt, timing case cover to cylinder crankcase

M6

Nm

-

M8

Nm

20

Number

Designation

Engine
611.980

BA01.45-N-1001-01H

Bolt, oil pan to cylinder crankcase

M6

Nm

9

M8

Nm

20

M10

Nm

-

BA01.45-N-1003-01H

Oil drain screw on oil pan

M14

Nm

30

BA01.45-N-1005-01H

Bolt, oil pan to timing case cover

M6

Nm

9

Number

Designation

Engine
611, 612

BA15.40-P-1001-01D

Bolt, alternator to timing case cover

Nm

20

Number

Designation

Engine 611.980

BA18.20-N-1001-01A

Oil filter screw cap

Nm

25

Number

Designation

Model
638 with steering 763.000

BA46.30-N-1011-01A

Bolt, power steering pump to timing case cover

8.8

Nm

18.5

10.9

Nm

-

Number

Designation

Model
638 with engine 611.980 without H06,
HH7

BA83.55-N-1005-01A

Bolt, refrigerant compressor to timing case cover

Nm

20

Number

Designation

Order number

BR00.45-Z-1013-01A

Loctite sealant 5970

A 003 989 98 20