Removal and Installation of Timing Case Cover

Removal and Installation:

Moving Hood Into Vertical Position:

1. Set hood vertical.
2. Disconnect battery ground cable.

Air Scoop:

3. Unscrew bolt (338). Pull air scoop (339a) from air filter in direction of arrow and remove.
4. Remove, install air filter.

Lower Engine Cover:

5. Unscrew bolts (504) and take off engine compartment covering (505).
6. Remove radiator.
7. Remove viscous fan cutch.

Pulleys:

8. Loosen bolts (arrows).
9. Remove poly V-belt.
10. Unscrew bolts (arrows), tightening torque 10 Nm (7.5 ft lbs). Take off belt pulleys from fan clutch (210), coolant pump (273) and tandem pump (284).
11. Remove belt pulley, vibration damper and hub.

Heater Return Line:

12. Loosen bolt (271). Withdraw heating water return line (270) from coolant pump and place to one side. Unscrew nut (225) and withdraw bolt (218) from the front.

Installation note: Replace heating water return line seal (270).

Heater Hose:

13. With self-levelling suspension, loosen clip (arrow). Detach hose (275) and plug line (608).
14. Remove front upper cover, Upper Cover





15. Loosen bolt (211) and remove bolts (215, 651, 652) together with spring washers. Swivel bracket (213).

Note: Hold nut of bolt (651) to prevent it turning.

Bracket:

Installation note: Apply sealant 001 989 29 20 to the front and rear sides of the attachment hole (arrow) of the bracket (213).

Hydraulic Pump:

16. Unscrew bolts (277, 278). Swivel tandem pump (280) in direction of arrow.





17. Unscrew bolts (214), tightening torque 21 Nm, and remove fan bearing support (217). Unscrew nut (99). Take off TDC sensor (100) together with cable and place to one side.

Note: TDC sensor bracket (102) remains on timing case cover. If replacing timing case cover, adjust TDC sensor.

18. Disconnect wiring connector at the alternator (326).

Bracket:

19. Unscrew bolts (91, 92). Remove bracket (93) and alternator (326).
20. Remove chain tensioner. Service and Repair





21. Unscrew bolts (138), tightening torque 10 Nm (7.5 ft lbs), and bolts (139), tightening torque 21 Nm (15.5 ft lbs), on the oil pan. With self-levelling suspension: Place retaining clip with high-pressure hose to the side.

Timing Cover:

22. Unscrew bolts (95,105) and remove timing case cover (96).

Note:
- Do not damage oil pan gasket!
- If necessary, replace oil pan gasket.
- Check crankshaft front seal (295); renew if necessary.

23. Clean sealing surfaces on crankcase and on timing case cover. Apply an even coat of sealant 001 989 45 20 to sealing surface of timing case cover. Also, clean sealing surfaces of oil pan and coat with sealant 001 989 61 20 10.

Note: The timing case cover is held in place by two roll pins in the engine block. Do not damage oil pan gasket. Tightening torque 10 Nm (7.5 ft lbs).
Timing case cover to engine block torque:
M6: 9 Nm (6.7 ft lbs)
M8: 21 Nm (15.5 ft lbs).

Seal Location:

24. Replace seal (97).
25. Install in reverse sequence.
26. Check engine oil level in and top up if needed.
27. Check engine for leaks with engine running.