AR01.40-P-8000V Remove/Install Timing Case Cover

Remove/install timing case cover








DANGER:
- Risk of explosion from hydrogen gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury to eyes and skin suffering caustic burns from battery electrolyte or from contact with damaged lead acid batteries.
- No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery.



NOTE:
- The battery is located below the rear seat.
- After connecting the ground cable, read out diagnostic trouble code memory, encode radio and normalize power windows. Vehicles with stationary heater: adjust time display on stationary heater.

2 Remove engine compartment paneling.

DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection.

3 Drain coolant at radiator.
4 Remove engine trim panel.
5 Remove viscous fan (1).

NOTE: Right-hand thread!

6 Remove the fan shroud (3).
7 Attach guard plate for radiator/condenser.
8 Remove poly V-belt (2).
9 Remove cylinder head covers (6)
10 Remove cylinder heads (15)
11 Detach coolant lines (18,19) at coolant pump (12)
12 Detach coolant line (17) at thermostat housing (13)
13 Remove bottom part of oil pan (9)
14 Remove oil filter housing together with oil-water heat exchanger (7)
15 Remove poly V-belt tensioning device (5)
16 Remove vibration damper (4)
17 Unbolt AC compressor (10)

NOTE: Place to the side with lines connected.

18 Unscrew power steering pump (11) with reservoir.

NOTE: Place to the side with lines connected.

19 Detach pulley (16) at coolant pump (12)

NOTE: Take off plastic cover of pulley.

20 Remove air pump (21)
21 Separate electric cable of coolant thermostat (B11/3)
22 Unscrew bolts of timing case cover.

NOTE: Installation: Apply sealant to bolts (arrows), observing the bolt diagram for the timing case cover: Screw diagram for timing case cover.

23 Take off timing case cover

NOTE: Installation:
- On new timing case covers the mounting threads for the coolant pump, belt tensioning device and power steering pump are not yet cut.
- For this reason, use new self-tapping bolts in combination with a new timing case cover for attaching the coolant pump, belt tensioning device and the power steering pump.
- Pay attention to the torque when tightening bolts into threads which are not tapped.

CAUTION:
- Information on application of sealant to timing case cover.
- Installation: Ensure that no sealing compound enters the oil ducts.
- Do not damage cylinder head gasket. Replace seals on timing case (19).

24 Replace front crankshaft radial seal.
25 Install in the reverse order.

DANGER:
- Risk of accident from vehicle starting off by itself when engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns.
- Secure vehicle to prevent it from moving. Wear closed and tight-fitting work clothes. Do not grasp hot or rotating parts.

26 Run engine and inspect for leaks.
27 Inspect cooling system for leaks.
- First of all, warm up engine to operating temperature.