Timing Cover: Service and Repair

Timing Chain Cover Replacement (Part 1 Of 3) Engine 604 Shown, Engine 606 Similar:

Timing Chain Cover Replacement (Part 2 Of 3) Engine 604 Shown, Engine 606 Similar:

Timing Chain Cover Replacement (Part 3 Of 3) Engine 604 Shown, Engine 606 Similar:

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

REMOVAL
1. Disconnect ground cable of battery
2. Remove viscous fan coupling, refer to Cooling System.
3. Remove poly V-belt. Service and Repair

NOTE: Prior to removing belt, and using counterhold tool No. 603 589 00 40 00, or equivalent, loosen bolts of coolant pump and power steering pump.

WARNING:
^ Risk of scalding as a result of hot coolant spraying out
^ Do not open the cap of the expansion reservoir or radiator unless the coolant temperature is below 90°C.
^ Carefully turn cap to the first detent or slowly about 1/2 turn.
^ Wear protective clothing.

4. Remove radiator (14), refer to Cooling System.

5. Remove belt pulleys of coolant pump (5) and power steering pump (6)
- Except VDA pump:
6. Remove cylinder head cover
7. Remove vacuum pump (9)
8. Rotate cylinder No. 1 to TDC
- To enable bracket for TDC sensor to be correctly set when installing
9. Install locking plate (03) for crankshaft/ ring gear, refer to Installing/Removing Crankshaft Retaining Lock. [1][2]Procedures
- Use 6 x 90 mm bolts otherwise the threads in the rear end cover will be damaged
10. Remove vibration damper (77)
11. Remove generator bracket (2)
12. Unscrew bolts of oil pan (8)
- Unscrew bolts in the area of timing case cover; only slacken all other bolts of the oil pan
13. Disconnect coolant hoses (1, 4) at front of cylinder head
- Inspect condition of coolant hoses and hose clips and replace if necessary
14. Unbolt power steering pump (30) without disconnecting hoses.
- Attach to the side in engine compartment with piping connected
15. Unbolt fuel filter (70/2) without disconnecting lines.
- Unbolt fuel filter with piping connected and place to the side
16. Remove guide rail pins (32) at cylinder head, refer to Guide Rail Pin. Service and Repair
17. If Timing Cover is to be replaced, remove poly V-belt tensioning device. Service and Repair
18. Unscrew bolts of injection pump (35) at timing case cover
- After installing, check start of delivery
19. Unbolt bracket for TDC sensor (36)
20. Unscrew bolts of cylinder head at timing case cover (34)
21. Remove timing case cover (40)
- Pay attention to bolt length

CAUTION:
^ Do not damage cylinder head gasket and gasket of oil pan.
^ Replace gasket if damaged.

INSTALLATION
- Reverse procedures to install, noting the following:
- Clean sealing surfaces on timing case cover and at crankcase
- Coat with Loctite 574 sealant or Omnifit FD 3041, or equivalent sealant
- Install timing case cover (40)
Pay attention to bolt length
Do not damage cylinder head gasket and gasket of oil pan.
Replace gasket if damaged.
Inspect front crankshaft radial seal and depending findings replace front crankshaft radial seal
Pay attention to dowel sleeve (6)
- When installing vane cell vacuum pump "(Barluk)" replace O-ring (21) at oil spray nozzle
- When installing top guide rail pin, coat with Loctite 574 sealant or Omnifit FD 3041, or equivalent sealant and knock into the cylinder head as far as the stop.
Ensure the guide rail is correctly positioned in the cylinder head
- After installing injection pump (35), check start of delivery, refer to Powertrain Management.
- Installation of TDC sensor, bolt on bracket so that the pointer is aligned with the TDC marking on vibration damper (77), if necessary
Check setting of bracket and correct, refer to Powertrain Management.
Remove ring gear locking plate
- Tighten the following as noted:
Timing case cover to crankcase: 10 Nm
Cylinder head bolts to timing case cover: 25 Nm
Oil pan bolts to crankcase:
6 mm Bolt: 10 Nm
8 mm Bolt: 25 Nm
Transmission bellhousing bolts to oil pan: 40 Nm
Injection pump flange: 20 Nm
Coolant Pump Belt pulley to coolant pump: 10 Nm
Power steering pump Belt pulley bolts: 30 Nm
- Check for leaks with engine running

WARNING:
^ Risk of accident as a result of vehicle starting off when engine running.
^ Secure vehicle to prevent it moving off.
^ Risk of injury as a result of bruises and burns if you insert your hands into engine when it is being started or when it is running.
^ Wear appropriated work clothes when carrying out work on the vehicle.