Removal and Installation of Timing Case Cover
NOTE: For tightening torques not included within procedure,
1. Remove viscous fan clutch. Service and Repair
2. Slacken bolts of fan belt pulley, using tool (1) 603 589 00 40 00 to hold tight.
3. Remove front covers at top. Front Covers at Top, Removal and Installation
4. Remove poly V-belt and tensioning device. Drive Belts, Mounts, Brackets and Accessories
5. Set engine to 45° before ignition TDC at No. 1 cylinder.
6. Unscrew bottom engine compartment lining.
7. Unscrew left exhaust pipe and cover of starter mounting.
8. Use locking tool 116 589 0140 00 to prevent engine from turning.
9. Mark all four camshaft timing gears and the timing chain with colored dots (arrows).
10. Secure all camshaft gears on left and right side with pins (1) 111 589 03 16 00 to prevent them turning.
11. Unscrew armature (4) of camshaft adjuster.
Installation Note: The camshaft adjuster roll pin (arrow) in the armature (4) must be aligned with the flat face on the timing plunger (18).
12. Slacken nut (6) on left and right camshaft adjuster.
13. Remove alternator together with carrier.
Installation Note: The bolts must be coated with sealant when fitted.
14. Remove chain tensioner. Timing Chain Tensioner
15. Remove top slide rails. Timing Chain Guide
16. Detach both camshaft adjusters by unscrewing nut (6) and raising timing chain.
Take off cover with ring (12) and camshaft gear (13) together with adjusting piston (14) and spring (14a).
Installation Note: Install timing chain onto the markings beginning at the left exhaust camshaft.
17. Drain coolant at radiator. Cooling System
18. Remove coolant hoses at the fan carrier and thermostat housing.
19. Unscrew belt pulley of fan carrier.
20. Unscrew with angle bracket and take off.
Installation Note: Install air pump angle bracket free of tension.
21. Unscrew fan carrier from crankcase.
22. Remove belt pulley together with vibration damper, hub and seat. Service and Repair
23. Remove radial seal. Service and Repair
24. Unscrew bolts (1), take off cover (2) of coolant pump with engine lifting eye, discard gasket (2a).
Installation Note: Replace coolant pump gasket.
25. Unscrew coolant pump, take off.
Installation Note: Install bolts with washers as specified in image.
26. Unscrew bolts (1) with washers.
- Take off carrier with guide pulley.
27. Unscrew air conditioning bolts (1) with washers and nut (2).
- Place air conditioning compressor to the side with lines connected.
28. Unscrew TDC sensor on timing case cover and take off.
29. Unscrew bolts (1) with washers, take off bracket.
30. Remove oil pump. Service and Repair
31. Use a plastic-headed hammer to knock out dipstick guide tube upward.
Installation Note: Use special tool 117 589 00 3100 to knock in dipstick guide tube
32. Unscrew top section of oil pan and lower oil pan downward. Service and Repair
33. Unscrew bolts on front of timing case cover and on cylinder head.
- Refer to bolt diagram shown below.
34. Take off timing case cover and detach the oil pump chain from the crankshaft gear when performing this step.
CAUTION: Do not damage cylinder head gaskets.
Installation Note: Renew all four O-rings for seating the water ducts.
35. Clean sealing surfaces and coat sealing surface of timing case cover with sealant 002 989 47 20 10.
36. Coat cylinder head gaskets with engine oil.
37. When installing on timing case cover, fit the oil pump chain onto the crankshaft gear with a bent sheet of metal
38. Screw on timing case cover, install bolts with washers 1, 5, 7, 9, 10, 11 and 12 and tighten to 21 Nm.
39. Tighten bolt-and-washer assemblies of cylinder heads to timing case cover as shown in image with a torque of 25 Nm.
40. Install in reverse order from step 30. Observe all installation notes.
41. Check for leaks.