AR01.40-P-8000PV Remove/Install Timing Case Cover
Remove/install timing case cover
DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries.
- No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect ground cable of battery
CAUTION:
- Only model 209, 211: Do not connect quiescent current retention unit, as this may damage the control module.
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.
2 Drain coolant at radiator.
3 Remove electric fan
4 Remove air pump (20)
5 Remove poly V-belt (2)
6 Remove generator (G2)
7 Remove cylinder head covers with ignition coils (6)
8 Dismount coolant line (circulation pump -> coolant pump) (17) to coolant pump
9 Dismount coolant line (radiator -> coolant pump) (18) to coolant pump
10 Dismount coolant line (radiator -> thermostat housing) (16) to thermostat housing
11 Detach control rod at front axle sensor of headlight range adjustment
- On vehicles with Xenon headlamps code 612b.
12.1 Lower front axle
- Except model 211 and model 203 with 4MATIC.
12.2 Removing and installing front axle
CAUTION: Do not overstretch connected feed lines to front axle beam, in order to avoid any damage.
13 Raise front axle carrier
- Except model 211 and model 203 with 4MATIC.
CAUTION: When raising the front axle carrier, ensure that the bottom part of the steering column does not jam on the underside of the vehicle.
14 Screw in finger-tight bolts of front axle carrier.
- Except model 211 and model 203 with 4MATIC.
15 Remove top part of oil pan (22)
16 Remove refrigerant compressor (A9)
NOTE: Place to the side with lines connected.
17 Remove tensioning device (5) of poly-V-belt
18 Remove belt pulley/vibration damper (4)
19 Remove chain tensioner (14)
20 Remove oil filter housing with oil/water heat exchanger
21 Dismount power steering pump (11) with reservoir and place to the side
NOTE: Do not disconnect lines.
22 Detach guide pulley (15) at coolant pump (12)
NOTE: Take plastic cover off guide pulley (15).
23 Remove compressor.
24 Separate the electric cable from the pressure and temperature sensor of refrigerant compressor (A9).
25 Unscrew bolts of cylinder head -> timing case cover (21).
26 Remove screws of the timing case cover.
NOTE: Installation: Apply sealant to bolts (arrows), observing the bolt diagram for the timing case cover.
27 Take off timing case cover
NOTE: Installation:
- On a new timing case cover, the mounting threads for the coolant pump (12), belt tensioning device and power steering pump (11) are not yet cut.
- For this reason a new timing case cover requires new self-cutting bolts to be used. Pay attention to differences in tightening torque for threads which are not pre-tapped and threads which are pre-tapped.
CAUTION:
- Information on application of sealant to timing case cover.
- Installation: Make sure that sealing compound does not enter the oil ducts, do not damage the cylinder head gasket and replace timing case sealing rings (19).
28 Replace front crankshaft radial seal
29 Install in the reverse order.
DANGER:
- Risk of accident. Accidents may result if the vehicle starts off unintentionally with the 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 snug-fitting work clothes. Do not grasp hot or rotating parts.
30 Run engine and inspect for leaks.
31 Bleed coolant system.
NOTE: Warm up the engine to normal operating temperature and fully open temperature regulator of heating (position "warm").
32 Inspect cooling system for leaks
NOTE: First of all, warm up engine to operating temperature.
33 Perform basic programming.
34 Read out fault memory with STAR DIAGNOSIS and erase if necessary.