Timing Cover: Service and Repair

Removing, Installing Timing Case Cover

Shown On Engine 111.96, Part 1:

Shown On Engine 111.96, Part 2:

Shown On Engine 111.96, Part 3:

1 Disconnect ground cable of battery, connect
2 Remove left charge-air line assembly with hot-film air-mass sensor
- Engines with compressor and aluminum intake pipe

3 Remove oil-filter insert

NOTE: so that engine oil in the oil filter flows off into the oil pan

4 Remove viscous fan coupling
- Engines with viscous fan clutch

5 Remove fan shroud
- Vehicles with fan cowl

6 Remove oil pan
7 Remove poly V-belt of supercharger
- Engines with compressor

8 Remove poly V-belt
9 Drain coolant
10 Remove compressor
- Models 170, 202, 208, 210 with compressor

11 Remove generator bracket or generator/compressor bracket
12 Remove poly V-belt tensioning device
13 Remove front cover at cylinder head
14 Remove coolant pump
15 Remove belt pulley of power steering pump (44)

NOTE: In order to remove the screws, place poly-V-belt on pulley (44) and apply counterholder.

16 Unbolt bracket (47)
- Engines fitted with aluminum intake manifold

17 Remove bracket (46b)
- If AC not fitted

18 Remove brackets (46 and 46a)
- with AC fitted

19 Remove power steering pump (45) with lines connected and place to one side
20 Turn crankshaft to 20 degrees - 30 degrees after ignition TDC of cylinder 1 (arrow)
21 Lock camshafts in place with locating pins (01)
22 Mark camshaft gears (75) and (76) to timing chain with a colored marking (arrows)

CAUTION: Installation: Colored markings on timing chain and camshaft gears must line up with each other (arrows).

23 Remove chain tensioner (14)

CAUTION: If the complete chain tensioner is slackened, it must be removed, disassembled and reassembled as described.

24 Remove exhaust camshaft sprocket (76)

CAUTION: Replace bolts of camshaft sprocket, use only once.

25 Remove inlet camshaft sprocket (74)
- on engines without camshaft adjuster.

CAUTION: Replace bolts of camshaft sprocket, use only once.

26 Remove inlet camshaft with camshaft adjuster
- Engines with camshaft adjuster.

27 Remove slide rail pins (11)

CAUTION: Installation: Coat slide rail pins with sealant.

28 Remove bolts (A) to timing case cover

CAUTION: Installation: Replace bolts (A). Replace bolts + washers on engines as of 1994 (bolt head contact surface enlarged, 17 mm) diameter with Torx bolts without washer. Oil bolt head contact surface, tighten bolts to specified torque and tightening angle.

29 Remove belt pulley/vibration absorber (95)
30 Mark remaining bolts for timing-case cover to crankcase with colored marking
31 Remove bolts (1) and (2) for timing case cover
32 Take off timing case cover (65)

CAUTION:
- Do not damage cylinder-head gasket (arrows)
- Installation: Pull timing chain firmly upwards when installing the timing-case cover (65) to ensure that no chain loops are formed between the crankshaft gear and chain locking journals to the timing-case cover (65).

33 Replace front crankshaft radial seal .
34 Clean sealing surfaces at timing-case cover (65) and crankcase

CAUTION: Installation:
- Coat sealing surfaces with sealant.
- Make sure that no sealant succeeds in entering the oil reservoir (65a) for the chain tensioner.
- Replace O-rings (66).

35 Install in the reverse order

DANGER:
- Risk of accident from vehicle starting off by itself when engine running. Risk of injury from bruises and burns if you hold your hand into engine when it is started or when it is running.
- Secure vehicle to prevent it moving off by itself.
- Wear closed and close-fitting work clothes.
- Do not grasp hot or rotating parts.

36 Run engine and inspect for leaks.