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Removing and installing timing case cover - RA01001192100X(01-2100)

WARNING: This page does not describe the selected car, but rather 42 other vehicles, including the 1999 Mercedes-Benz S600, 1999 Mercedes-Benz S500, 1999 Mercedes-Benz S420, 1999 Mercedes-Benz S320, and 1999 Mercedes-Benz CL600. However, it is still accessible from the selected car via links, so may be relevant.

Operation no. of operation texts and work units or standard texts and flat rates

01-0080 

  1. Engine 119.960 
    Fig 1: Identifying Timing Case Cover Remove/Install Components (Engine 119.960)
    G04676802Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Viscous fan clutch remove, install (20-3120) .
    Bolts of belt pulley fan support slacken, tighten (10 Nm, step 2).
    Front covers at top (30, 30a) remove, install 01-2120 .
    Poly V-belt and tensioning device (24) remove, install (13-3450) .
    Engine set to 45° before ignition TDC at No. 1 cylinder (step 5).
    Bottom engine compartment panel remove, install (step 6).
    Left exhaust pipe and cover of starter mounting detach, attach (step 7).
    Engine retaining lock insert (step 8), special tool 116 589 01 40 00.
    All four camshaft gears together with mark and pin, special tool 111 589 03 15 00
    timing chain (steps 9 and 10).
    Nut at left and right camshaft adjuster slacken, tighten (65 Nm, step 12).
    Alternator (3) together with carrier (8) remove, install, seal bolts (step 13).
    Chain tensioner (6) remove, install (05-3100) .
    Top slide rails remove, install (05-3350) .
    Both camshaft adjusters (5, 5a) partially remove, install (05-2170) .
    Coolant at radiator drain, pour in (20-0100) .
    Coolant hoses at fan carrier (2) and thermostat housing take off, install (step 18).
    Fan carrier belt pulley (2a) unscrew, screw on (step 19).
    Air pump (1) with angle bracket (25) remove, install (step 20).
    Fan carrier (2) remove, install (step 21).
    Belt pulley (12) with vibration damper (13) and hub (16) remove, install (03-3420) .
    Radial seal (17) remove, install (03-3240) .
    Coolant pump cover (11a) remove, install (step 24).
    Coolant pump (11) remove, install (step 25).
    Carrier with guide pulley remove, install (step 26).
    If air conditioning fitted: air conditioning compressor (22) with lines connected detach, attach (step 27).
    TDC sensor remove, install (step 28).
    Carrier (21), air conditioning compressor or guide pulley remove, install (step 29).
    Oil pump (25) remove, install (18-2100) .
    Dipstick guide tube (4) remove, install. Special tool 117 589 00 31 00 (step 31).
    Top section of oil sump (20) detach, install (01-3100) .
    Bolts of timing case cover at front and on cylinder head unscrew, screw on (steps 33, 38 and 39).
    Timing case cover (9) with oil pump chain (25a) remove, install (steps 34 to 37).
    O-rings (23) of timing case cover renew.
    Leaktightness check.
    TIGHTENING TORQUE SPECIFICATION

    Armature of camshaft adjuster 7
    Nut of camshaft adjuster 65
    Angle bracket to fan bearing bracket 25
    Bolts of belt pulley to hub 35
    Coolant pump to crankcase 21
    TIGHTENING TORQUE SPECIFICATION

    Air conditioning compressor or guide pulley to carrier 21
    Bracket of air conditioning compressor to crankcase 21
    Bolts of cylinder head to timing case cover 21
    Radiator drain plug (reference value) 1.5-2
    Belt pulley to fan carrier 10
    Timing case cover to crankcase 21
    Mounting bracket of alternator 21

    Special tools 

    Fig 2: Identifying Special Tool (603 589 00 40 00)
    G04676803Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 3: Identifying Special Tool (111 589 03 15 00)
    G04676804Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 4: Identifying Special Tool (116 589 01 40 00)
    G04676805Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 5: Identifying Special Tool (001 589 72 21 00)
    G04676806Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 6: Identifying Special Tool (001 589 65 09 00)
    G04676807Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 7: Identifying Special Tool (119 589 01 14 00)
    G04676808Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 8: Identifying Special Tool (117 589 00 31 00)
    G04676809Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 9: Identifying Special Tool (119 589 01 63 00)
    G04676810Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Removing, installing 

    1. Remove viscous fan clutch (20-3120) .
    2. Slacken bolts of fan belt pulley, using tool (1) 603 589 00 40 00 to hold tight.
    3. Remove front covers at top 01-2120 .
    4. Remove poly V-belt and tensioning device (13-3450) .
      Fig 10: Identifying Tool
      G04676811Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    5. Set engine to 45° before ignition TDC at No. 1 cylinder.
    6. Unscrew bottom engine compartment lining (Maintenance Manual 6190).
    7. Unscrew left exhaust pipe and cover of starter mounting.
    8. Use locking tool 116 589 01 40 00 to prevent engine from turning.
      Fig 11: Identifying Engine Setting Point
      G04676812Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    9. Mark all four camshaft timing gears and the timing chain with colored dots (arrows).
      Fig 12: Locating Colored Dots On Camshaft Timing Gears And Timing Chain
      G04676813Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    10. Secure all camshaft gears on left and right side with pins (1) 111 589 03 15 00 to prevent them turning.
      Fig 13: Identifying Pins
      G04676814Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    11. Unscrew armature (4) of camshaft adjuster.

      Installation note 

      The 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.
      Fig 14: Identifying Roll Pin, Armature And Timing Plunger
      G04676815Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    13. Remove alternator together with carrier.

      Installation instruction 

      The bolts must be coated with sealant when fitted.

    14. Remove chain tensioner (05-3100) .
    15. Remove top slide rails (05-3350) .
      Fig 15: Identifying Ring, Camshaft Gear, Adjusting Piston And Spring
      G04676816Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    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 instruction 

      Fit timing chain onto the markings beginning at the left exhaust camshaft.

    17. Drain coolant at radiator (20-0100) .
    18. Remove coolant hoses at the fan carrier and thermostat housing.
    19. Unscrew belt pulley of fan carrier.
    20. Unscrew air pump with angle bracket and take off.

      Installation instruction 

      Install angle bracket free of tension.

    21. Unscrew fan carrier from crankcase.
      Fig 16: Identifying Air Pump
      G04676817Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    22. Remove belt pulley together with vibration damper, hub and seal (03-3420) .
    23. Remove radial seal (03-3240) .
      Fig 17: Removing Radial Seal
      G04676818Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    24. Unscrew bolts (1), take off cover (2) of coolant pump with engine lifting eye.

      Installation instruction 

      Renew gasket (2a).

      Fig 18: Identifying Coolant Pump Components
      G04676819Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    25. Unscrew coolant pump, take off.

      Installation instruction 

      Replace gasket, install bolts with washers as specified in diagram.

      Fig 19: Identifying Tightening Sequence Of Bolts
      G04676820Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
      1 Bolt M8x60 5 Bolt M8x60
      2 Bolt M8x60 6 Bolt M8x90
      3 Bolt M8x60 7 Bolt Mbx35
      4 Bolt M8x85 8 Bolt M8x65
    26. Unscrew bolts (1) with washers. Take off carrier with guide pulley.
      Fig 20: Identifying Bolts
      G04676821Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    27. If air conditioning fitted: unscrew 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.
      Fig 21: Identifying Bolts And Nut
      G04676822Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    29. Unscrew bolts (1) with washers, take off bracket.
    30. Remove oil pump (18-2100) .
      Fig 22: Identifying Bolts
      G04676823Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    31. Use a plastic-headed hammer to knock out dipstick guide tube upward.

      Installation instruction 

      Use special tool 117 589 00 31 00 to knock in dipstick guide tube.

    32. Unscrew top section of oil sump and lower oil sump downward (01-3100) .
    33. Unscrew bolts on front of timing case cover and on cylinder head. Refer to steps  37 and  38 for bolt diagram.

      Bolt diagram, see steps  38 and  39.

      Fig 23: Knocking Out Dipstick Guide Tube Upward
      G04676824Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    34. Take off timing case cover and detach the oil pump chain from the crankshaft gear when performing this step.

      IMPORTANT

      Do not damage cylinder head gaskets.

      Installation instruction 

      Renew all four O-rings for sealing 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 fitting on timing case cover, fit the oil pump chain onto the crankshaft gear with a bent sheet of metal.
      38. Fig 24: Identifying Tightening Sequence Of Bolts
      G04676825Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    38. Screw on timing case cover. Install bolts with washers 1, 5, 7, 9, 10, 11 and 12 and tighten to 21 Nm.
      1 Bolt M8x50
      2 Bolt M8x75
      3 Bolt M8x70
      4 Bolt M8x150
      5 Bolt M8x50
      6 Hexagon socket bolt M8x80
      7 Bolt M8x30
      8 Hexagon socket bolt M8x60
      9 Bolt M8x50
      10 Bolt M8x50
      11 Bolt M8x50
      12 Bolt M8x50
    39. Tighten bolt-and-washer assemblies of cylinder heads to timing case cover as shown in diagram with a torque of 25 Nm.
      a Hexagon socket bolt+washer M8x120
      b Hexagon socket bolt+washer M8x90
      c Hexagon socket bolt+washer M8x75
      d Hexagon socket bolt+washer M8x50
      e Hexagon socket bolt+washer M8x75
      f Hexagon socket bolt+washer M8x50
    40. Install in the reverse order as from step  30.
    41. Check for leaks.
      Fig 25: Identifying Tightening Sequence Of Bolts
      G04676826Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  2. Engine 119.97/98 

    Preceding work:

    Tensioning device removed (13-3450) .

    Cylinder head covers removed (01-0500) .

    Operation no. of operation texts and work units or standard texts and flat rates

    01-5800 

    Fig 26: Identifying Timing Case Cover Remove/Install Components - Engine 119.97/98 (1 Of 3)
    G04676827IMPORTANTCourtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Cylinder 1 position to 45° before ignition TDC (arrow).
    Camshafts fix in position with pins (01), special tool 111 589 03 15 00.
    Left cylinder head: bolts (1), (1a) and (2) unscrew, screw on (21 Nm).
    Mounting plate with power steering pump (11) and oil lines connected place to the side, install.
    Installation note 
    Coat bolt (2) with sealant 002 989 47 20 10.
    Engine 119.97: install bolt (1a) with retaining bracket (4) of wiring harness.
    Front covers at top (30) and (30a) remove, install 01-2120 .
    Timing chain mark relative to camshaft sprockets (31), (32), (33) and (34) with colored marking (arrows).
    Chain tensioner (6) remove, install (05-3100) .
    Camshaft adjusters (32), (33) and exhaust camshaft sprockets (31) and (34) remove, install (05-2170) .
    Vibration damper remove, install (03-3420) .
    Oil sump detach, lower, bolt on (01-3100) .
    IMPORTANT
    Do not damage oil sump gasket; remove oil sump, if necessary, and replace gasket (01-3100) .
    Fig 27: Identifying Timing Case Cover Remove/Install Components - Engine 119.97/98 (2 Of 3)
    G04676828Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Coolant pump (3) remove, install (20-2100) .
    Screwplug (35) with seal (36) unscrew, screw on (15 Nm).
    Installation note 
    Replace seal (36) according to condition.
    Tensioning rail pin (37) remove with impact puller (02) and threaded insert (03), special tools 116 589 20 33 00 and 116 589 01 34 00.
    Tensioning rail (38) remove, install.
    Fit collar bolts (a) and (b) and bolts (d) and (e) of timing case cover unscrew, screw on (21 Nm).
    NOTE: When performing repairs, fit collar bolts or the bolts+washers should be installed depending on the bolts fitted previously.

    On engines 119.98, the center bolts (b and e) are discontinued; if the timing case cover is replaced on engines 119.97, it should be bolted on to the left and right cylinder head with two bolts each.
    Fig 28: Identifying Timing Case Cover Remove/Install Components - Engine 119.97/98 (3 Of 3)
    G04676829Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Front crankshaft radial seal (15) remove, replace (03-3240) .
    Oil pump (25) remove, install (18-2100) .
    Bolts (f), (g) and (h) at front of timing case cover (9) unscrew, screw on (21 Nm).
    Timing case cover (9) take off, fit on.
    NOTE: Use a bent piece of metal to detach oil pump chain (26) at the crankshaft sprocket (27) and attach.

    Replace front crankshaft radial seal (03-3240) .
    IMPORTANT Do not damage cylinder head gaskets (arrows).
    O rings (23) and (24) for sealing the coolant ducts replace.
    Sealing surfaces clean.
    Sealing surfaces coat with sealant 002 989 47 20 10
    Cylinder head gaskets (arrows) coat with engine oil.
    Dowel sleeve (29) and dowel pin (29a) note.
    Leaks check with engine running.

    Special tools 

    Fig 29: Identifying Special Tool (001 589 72 21 00)
    G04676830Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 30: Identifying Special Tool (116 589 20 33 00)
    G04676831Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 31: Identifying Special Tool (116 589 01 34 00)
    G04676832Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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