Remove/install timing case cover

AR01.40-P-8000OLI

Remove/install timing case cover

16.07.2020

Engine

654 in model 205, 253

Modification notes

18.06.2020

Screw, oil pan/crankcase lower section

Engine 654

BA01.40-P-1007-01X

14.07.2020

Repair method modified.

1

Timing case cover

2

Bolts

3

Bolts

4

Oil pan top section

5

Fuel lines

a

Fitting sleeves

22

Engine suspension lug

23

Bolts

25

Screw

26

Intermediate gear

24

Sealant

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 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

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A



Remove

1.1

Remove engine with transmission.

Engine 654 in model 205, 253
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2401OLI

1.2

Remove engine with front axle carrier.

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2500OLI

2

Remove transmission from engine.

Engine 654 in model 205, 253 with transmission 725.0

AR27.10-P-0500OLI

Engine 654 in model 205, 253 with transmission 716.7

AR26.10-P-0020LWB

3

Remove engine from front axle carrier.

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2510OLI

4

Attach engine to assembly stand.



000 588 08 31 00 Mounting fork adapter

WS01.00-P-0186B



000 588 00 31 00 Assembly stand for cars

WS01.00-N-3028B

 Commercially available devices/tools
Engine crane

5

Remove flywheel/drive plate.

AR03.30-P-8001OLI

6

Remove rear cover at cylinder head.

AR01.30-P-5702OLI

7

Remove fuel lines (5) from timing case cover (1) and crankcase.

8

Remove the glow output stage.

AR15.20-P-4500OLI

9

Unclip vacuum line from timing case cover (1).

10

Expose and remove engine lifting lug (22).

11

Remove the chain tensioner.

AR05.10-P-7800OLI

12

Remove the camshaft housing with camshafts.

AR05.20-P-6997OLI

13

Remove screw (25) and intermediate gear (26).

14

Remove heat shield from timing case cover (1).

AR49.20-P-0007-01OLC

15

Remove oil pan.

Engine 654 in model 205
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.45-P-7500OLI

16

Remove oil feed line from timing case cover (1).

Engine 654 in model 205, 253
with code M014 (Engine uprated)

AR09.40-P-6022OLL

Engine 654 in model 205, 253
except code M014 (Engine uprated)

AR09.40-P-6022OLI

17

Remove rear bracket of the diesel particulate filter.

Engine 654 in model 205.### 1# , 253.### 1#

18

Remove screws (23) in reverse order of the tightening procedure.

AR01.30-P-5800-01OLC

19

Remove screws (2, 3) in reverse order of the tightening procedure.

AR01.40-P-8000-01OLC

20

Pry off timing case cover (1).


When prying off the timing case cover (1), do not damage sealing surfaces.
Leaks can occur otherwise.

21

Remove the rear radial shaft sealing ring.

AR03.20-P-3003OLI

22

Clean sealing surfaces on crankcase, oil pan upper part (4) and timing case cover (1).

AR01.00-P-0050-01A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

Loctite 7200

*BR00.45-Z-1038-04A

23

Check sealing surface of the timing case cover (1) for damage.

If there is a problem,



replace timing case cover (1).



Install

24

Apply sealant to sealing surfaces of timing case cover (1) using a squeeze gun.

Topical note

Notes on sealant path for timing case cover

AH01.40-P-1000-01CD

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

25

Apply sealant (24) with squeeze gun.

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

26

Position timing case cover (1).

 The pilot bushing must engage in the cutout in the timing case cover (1).

27

Tighten screws (2, 3) in sequence of tightening procedure.

AR01.40-P-8000-01OLC

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

 Bolt, timing case cover to crankcase/cylinder head/oil pan top section

*BA01.40-P-1001-01X

 Screw/bolt, oil pan/lower crankcase section

*BA01.40-P-1007-01X

28

Tighten screws (23) in sequence of tightening procedure.

AR01.30-P-5800-01OLC

 Bolt, cylinder head to timing case cover

*BA01.30-P-1001-01V

29

Install rear radial shaft sealing ring.

AR03.20-P-3003OLI

 Replace rear radial shaft sealing ring.

30

Install intermediate gear (26) and screw in screw (25).

 Bolt, journal/intermediate gear to cylinder head

*BA05.10-P-1001-02B

31

Install the chain tensioner.

AR05.10-P-7800OLI

32

Install camshaft housing with camshafts.

AR05.20-P-6997OLI

33

Install engine lifting lug (22).

 Lifting eye at rear on cylinder head (longitudinally mounted)

*BA01.30-P-1006-01V

 M61

*BA00.10-P-1002-04A

34

Clip in vacuum line at timing case cover (1).

35

Install glow output stage.

AR15.20-P-4500OLI

36

Install rear bracket of the diesel particulate filter.

 Bolt, diesel particulate filter bracket to crankcase

*BA49.10-P-1010-02H

37

Install oil feed line on timing case cover (1).

Engine 654 in model 205, 253
with code M014 (Engine uprated)

AR09.40-P-6022OLL

Engine 654 in model 205, 253
except code M014 (Engine uprated)

AR09.40-P-6022OLI

38

Install oil pan.

Engine 654 in model 205
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.45-P-7500OLI

39

Install heat shield on timing case cover (1).

AR49.20-P-0007-01OLC

 Bolt, heat shield for diesel particulate filter to timing case/crankcase/bracket for exhaust gas turbocharger/engine support/bracket

*BA14.40-P-1002-01F

40

Attach fuel lines (5) to timing case cover (1) and crankcase.

 M61

*BA00.10-P-1002-04A

41

Install rear cap on cylinder head.

AR01.30-P-5702OLI

42

Install flywheel/drive plate.

AR03.30-P-8001OLI

43

Remove engine from assembly stand.



000 588 08 31 00 Mounting fork adapter

WS01.00-P-0186B



000 588 00 62 00 Load tilter

WS01.00-P-0102B



000 588 00 31 00 Assembly stand for cars

WS01.00-N-3028B

 Commercially available devices/tools
Engine crane

44

Attach engine to front axle carrier.

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2510OLI



Check

45

Check whether fitting sleeves (a) on timing case cover (1) are seated correctly.

If there is a problem,



Install fitting sleeves (a).

46

Attach transmission to engine.

Engine 654 in model 205, 253 with transmission 725.0

AR27.10-P-0500OLI

Engine 654 in model 205, 253 with transmission 716.7

AR26.10-P-0020LWB

47.1

Install engine with front axle carrier.

Engine 654 in model 205, 253
with code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2500OLI

47.2

Install engine with transmission.

Engine 654 in model 205, 253
except code M005 (Vehicles with 4MATIC/all-wheel drive)

AR01.10-P-2401OLI

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Tightening torques, cylinder head

Number

Designation

Engine 654

BA01.30-P-1001-01V

Bolt, cylinder head to timing case cover

M8

Nm

20

 Tightening torques, cylinder head

Number

Designation

Engine 654

BA01.30-P-1006-01V

Lifting eye at rear on cylinder head (longitudinally mounted)

Nm

29

 Crankcase, timing case cover, end cover

Number

Designation

Engine 654

BA01.40-P-1001-01X

Bolt, timing case cover to crankcase/cylinder head/oil pan top section

M8

Nm

20

 Crankcase, timing case cover, end cover

Number

Designation

Engine 654

BA01.40-P-1007-01X

Screw/bolt, oil pan/lower crankcase section

to timing case cover

M8

Nm

20

to crankcase

M6

Stage 1

Nm

1

Stage 2

Nm

10

M8

Stage 1

Nm

20

Stage 2

°

90

 Gearwheel drive

Number

Designation

Engine 654

BA05.10-P-1001-02B

Bolt, journal/intermediate gear to cylinder head

Nm

57

 Diesel particulate filter

Number

Designation

Engine 654

BA14.40-P-1002-01F

Bolt, heat shield for diesel particulate filter to timing case/crankcase/bracket for exhaust gas turbocharger/engine support/bracket

Nm

8

 Exhaust system

Number

Designation

Model 205 with engine 654

Model 253 with engine 654

BA49.10-P-1010-02H

Bolt, diesel particulate filter bracket to crankcase

front

Nm

20

20

Rear

Nm

25

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