Removal and Installation of Timing Case Cover
Removing and installing timing case coverModel 124, 129 (Engine 104.98):
1. Disconnect ground cable at battery.
2. Pull air scoop off the air filter and remove. Refer to Powertrain Management - Fuel Delivery and Air Induction - Air Cleaner Housing - Air Cleaner Fresh Air Duct/Hose - Service and Repair - Procedures
3. Remove air cleaner. Refer to Powertrain Management - Fuel Delivery and Air Induction - Air Cleaner Housing - Service and Repair - Procedures
4. Unscrew bottom engine compartment panel.
5. Remove viscous fan clutch. Refer to Cooling System - Cooling Fan, Radiator - Fan Clutch - Service and Repair - Procedures Service and Repair
6. Slacken bolts (arrows).
7. Remove poly V-belt. Refer to Drive Belts, Mounts, Brackets and Accessories - Drive Belt - Service and Repair - Procedures Service and Repair
8. Unscrew bolts (arrows). take off belt pulleys of fan clutch (210), coolant pump (273) and power steering pump (284).
9. Remove belt pulley, vibration damper and hub. Refer to Cylinder Block Assembly - Harmonic Balancer - Crankshaft Pulley - Service and Repair- Procedures Service and Repair
10. Open cap of cooling system (release pressure).
11. Remove heating water return pipe. Hose remains connected. Seal opening at the coolant pump.
Installation Note: Replace seal between heating water return pipe (25) and coolant pump.
12. Remove front cover at top. Front Covers at Top, Removal and Installation
13. Mark timing chain with camshaft sprockets with colored dots.
14. Slacken bolt (211) and unscrew bolts (215, 651, 652) together with spring washers. Swivel bracket (213).
Installation Note: Apply sealant 002 989 45 20 to the front and rear of the mounting hole (arrow) of the bracket (213).
15. Unscrew bolts (277, 278). Swivel power steering pump (280) in direction of arrow.
16 Unscrew air pump from bracket (remains on vehicle with pipes connected).
17. Unscrew bolts (214, 214a) and remove fan bearing bracket (217). Unscrew nut (99). Take off TDC sensor (100) together with cable and place to the side.
NOTE: TDC sensor bracket (102) remains on timing case cover. If timing case cover is replaced, set TDC sensor. Refer to Powertrain Management - Computers and Control Systems - Crankshaft Position Sensor - Service and Repair - Procedures
18. Unplug cable connector at generator.
19. Unbolt generator together with support and take off.
Installation Note: Insert side and front bolts for support until they make contact. Tighten front bolts first of all so that support is installed free of stress.
20. Unbolt timing case cover in crankcase and oil pan.
21. Detach timing case cover together with bracket of TDC sensor.
NOTE: Do not damage oil pan gasket!
If necessary, replace oil pan gasket.
Examine radial seal; replace, if necessary.
22. Clean sealing surfaces of crankcase and of timing case cover. Apply an even coating of sealant 002 989 47 20 to the sealing surface of the timing case cover.
NOTE: The timing case cover is fixed in place by two roll pins on the crankcase.
Pay attention to projection of 6 mm (arrow).
Do not damage oil pan gasket.
First of all, tighten bolts of oil pan, tightening torque 10 Nm.
Timing case cover to crankcase:
M6 bolts: 9 Nm
M8 bolts: 21 Nm
23. Replace seal (97).
24. Install in the reverse order.
25. Check oil level in engine and adjust to correct level.
26. Run engine and check for leaks.
27. Encode radio.