Remove/install timing case cover - AR01.40-P-8000B

ENGINE 112 in model 129, 163, 170, 202, 208, 210.061 /063 /065 /261 /263 /265 /663, 220

ENGINE 113 (except 113.991) in MODELS 129,163, 202, 208, 210, 215, 220, 230.475 /474 (except, 215.374,220.074/174)

Shown on engine 112 in model 210

Fig 1: Identifying Timing Case Cover Components - Shown On Engine 112 In Model 210

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Modification notes

1.9.04	Value changed from 10 Nm to 14 Nm	Value in row 1003 changed for engine 112.910/911/912/913/914/915/916/917/ 920/921/922/923/940/941/942/943/944/ 945/946/947/949/953/954/955/960/961 / 970/972/973/975	*BA20.10-P-1003-01M
1.9.04	Value changed from 10 Nm to 14 Nm	Value in series 1004 changed for engine 112.910/911/912/913/914/915/916/917/ 920/921/922/923/940/941/942/943/944/ 945/946/947/949/953/954/955/960/961 / 970/972/973/975	*BA20.10-P-1004-01M

	Remove/install
	Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Disconnect battery ground cable	Models 129, 163, 170, 202, 208, 210	AR54.10-P-0003A
		Model 215, 220	AR54.10-P-0003I
		Model 230.474 /475	AR54.10-P-0003R
	Notes on battery	All models	AH54.10-P-0001-01A
2	Remove engine compartment paneling	Model 129,202,208,210	AR61.20-P-1105AB
		Models 163.172/174/175	AR61.20-P-1105GH
		Model 170	AR61.20-P-1105A
		Model 215, 220	AR61.20-P-1105M
		Model 230	AR61.20-P-1105R
	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.	Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses.	AS20.00-Z-0001-01A
3	Drain coolant from radiator	Engine 112, 113 in models 129, 163, 202, 208, 210,215,220	AR20.00-P-1142HA
		Engine 113.963 in models 230.475
		Engine 112.960 in model 170.466	AR20.00-P-1142RVK
		Engine 113.992 in model 230.474
		Engine 113.963 in models 230.475
		Engine 112.947 in model 170.465	AR20.00-P-1142SV
		Engine 112.960 in model 170.466
4.1	Remove engine cover with integrated air filter	Model 129 Type 170.465 Model 202.033/ 093 Model 208.370 /374 /470 Model 220 Type 230.475 Unclip covering on front side of engine. Remove the engine cover with integrated air filter from the cylinder head covers vertically in the upward direction.
4.2	Remove air filter	Engine 112.960 in model 170.466 Engine 113.992 in model 230.474	AR09.10-P-1150SVK
5.1	Remove viscous fan clutch (1)	Engine 112 in model 210, 202, 129 Engine 112 in model 163.154 /157 Engine 113 in model 210, 208, 202, 129 Engine 113 in model 163.172 Right-hand thread!	AR20.40-P-5660C
6.1	Remove heater unit	Model 170.465 with retrofitted stationary heater Thermo Top C.	AR83.70-P-5302NB
7.1	Remove fan shroud (3)	Engine 113 in model 215 Engine 112 in model 220 Engine 113 in model 220 Engine 113.963 in models 230.475 Engine 113.992 in model 230.474	AR20.40-P-6800AB
7.2	Remove electric fan	Model 163 unscrew bolts at bottom of fan shroud.
		Engine 113.965 in model 163.175	AR20.40-P-5000GH
		Engine 113.981 in model 163.174
		Engine 112.947 in model 170.465	AR20.40-P-5000SV
		Engine 112.960 in model 170.466
8	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser	Engines 112, 113, 137, 271, 272, 275, 285, 602, 604, 605, 606, 611, 612, 613, 628, 648	WF58.50-P-0110-01A
9.1	Remove poly-V-belt for supercharger	Engine 113.992 in model 230.474	AR13.21-P-1202RVK
9.2	Remove poly V-belt (2)	ENGINE 112 in models 129, 163	AR13.22-P-1202B
		Engine 113 in model 129, 202, 208, 210
		Engine 113 (except 113.965 /981) in model 163
		Engine 112 in model 202, 208, 210	AR13.22-P-1202BA
		Engine 112 in model 220
		Engine 113 in model 215.373 /375
		Engine 113 in models 220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875
		Engine 113.965 in model 163.175
		Engine 113.981 in model 163.174
		Engine 113.984 in model 208.374 /474
		Engine 113.963 in models 230.475	AR13.22-P-1202R
		Engine 113.992 in model 230.474
		Engine 112.947 in model 170.465	AR13.22-P-1202SV
10	Remove cylinder head covers (6)	Engine 112, 113 air filter located on vehicle side	AR01.20-P-5014B
10	Remove cylinder head covers (6)	Engine 112, 113 air filter located on engine side	AR01.20-P-5014BV
11	Detach coolant line (17, 18) from coolant pump (12).
12	Detach coolant line (16) at thermostat housing (13).
13	Dismount refrigerant compressor (A9)	Place to the side with lines connected.	*BA83.55-P-1001-01A
14.1	Remove alternator (G2)	Engine 113.963 in models 230.475 Engine 113.992 in model 230.474	AR15.40-P-5032R
15.1	Remove ATF line bracket (23).	Model 230
15.2	Detach ATF line from front axle carrier	Model 163
16	Remove oil pan bottom section (9)	Engine 112.942 in model 163.154	AR01.45-P-7555V
		Engine 112.970 in model 163.157
		Engine 113.942 in model 163.172
		Engine 113.965 in model 163.175	AR01.45-P-7555VE
		Engine 113.981 in model 163.174
		Engine 112 in models 210, 208, 202, 170, 129, engine 113 in model 210, 208, 202, 129	AR01.45-P-7555VA
		Engine 112 (except 112.975) in model 220
		Engine 113 (except 113.948 /966) in model 220
		Engine 112.975 in model 220	AR01.45-P-7555IW
		Engines 113.948/ 966 in model 220
		Engine 113.963 in models 230.475	AR01.45-P-7555R
		Engine 113.992 in model 230.474
17.1	Remove oil pump	Engine 112, 113 in model 163	AR18.10-P-6020B
18.1	Remove oil pan (22)	Engine 112, 113 in model 129	AR01.45-P-7500FD
		Engine 112.942 in model 163.154	AR01.45-P-7500FB
		Engine 112.970 in model 163.157
		Engine 113.942 in model 163.172
		Engine 113.965 in model 163.175
		Engine 113.981 in model 163.174
		Engine 112.947 in model 170.465 with transmission 722.6	AR01.45-P-7500SV
		Engine 112.960 in model 170.466 with transmission 722.6
		Engine 112 in model 202, 208	AR01.45-P-7500FC
		Engine 113 in model 208
		Engine 113.944 in model 202.033 /093
		Engine 112 in models 210.06 /26 /66	AR01.45-P-7500F
		Engine 113 in model 210
		Engine 112 (except 112.975) in model 220	AR01.45-P-7500I
		Engine 113 (except 113.948 /966) in model 220
		Engine 112.975 in model 220	AR01.45-P-7500IW
		Engines 113.948/ 966 in model 220
		Engine 113.963 in models 230.475	AR01.45-P-7500R
		Engine 113.992 in model 230.474
19.1	Remove tensioning device for compressor poly-V-belt	Engine 113.992 in model 230.474	AR13.25-P-3217RVK
20	Remove poly-V-belt tensioning device (5)	Engine 112 in models 129, 163	AR13.25-P-3200B
		Engine 113 in model 129, 202, 208, 210
		Engine 113 (except 113.965 /981) in model 163
		Models 129, 202, 210 with manual transmission. Unscrew damper of belt tensioning device at coolant pump.
		Engine 113.963 in models 230.475	AR13.25-P-3200R
		Engine 113.992 in model 230.474
21	Remove vibration damper (4)	Engine 112 in models 129, 163	AR03.30-P-1600C
		Engine 113 in models 129, 202.033 /093
		Engine 113 (except 113.981) in model 163
		Engine 113 (except 113.980) in model 210
		Engine 113 (except 113.984) in model 208
		Engine 112.947 in model 170	AR03.30-P-1600CA
		Engine 112 in model 202, 208, 210, 220
		Engine 113.981 in model 163.174
		Engine 113 (except 113.991) in models 215, 220.
		Engine 113.963 in models 230.475
		Engine 113.992 in model 230.474	AR03.30-P-1600RVK
22	Remove chain tensioner (14)	ENGINE 112 in models 129, 163 Engine 113 (except 113.965 /981) in model 163 Engine 113 in model 129, 202, 208, 210	AR05.10-P-7800C
		Engine 112 in model 170, 202, 208, 210 Engine 113 in model 163.174 /175	AR05.10-P-7800CA
		Engine 112 in model 220 Engine 113 in model 215.373 /375 Engine 113 in models 220.070 /073 /075 /083 /084 /170 /173 /175 /183 /184 /875 Engine 113 in model 230.474 /475	AR05.10-P-7800AM
23.1	Remove oil filter housing	Engine 113.992 in model 230.474	AR18.20-P-3471RKV
23.2	Remove oil filter housing with oil/water heat exchanger (7)	Engine 112 in models 170, 202, 208, 210, 220	AR18.20-P-3471BA
		Engine 113 in model 220 Engine 113.963 in models 230.475 Engine 113.965 in model 163.175 Engine 113.981 in model 163.174
		Engine 112 in models 129, 163	AR18.20-P-3471B
		Engine 113 in model 129, 202, 208, 210 Engine 113 (except 113.965/981) in model 163
24.1	Remove oil reservoir on power steering pump (11)	Model 163 Removal: Extract oil from reservoir. Remove circlip. Installation: Replace sealing ring. Check that circlip is correctly seated.
	Power steering - checking and correcting oil level		AP46.00-P-4611BB
	Power steering - checking and correcting oil level	Hand pump	Fig 2
24.2	Detach power steering pump (11) with oil reservoir.	Do not disconnect lines.
			*BA46.30-P-1005-01A
			*BA46.30-P-1010-01A
			*BA46.30-P-1010-01C
25.1	Detach guide pulley at timing case cover	Model 230.474	*BA13.25-P-1008-01D
25.2	Take off guide pulley (15) at coolant pump	Except model 230.474 Take plastic cover off guide pulley.
			*BA20.10-P-1001-01C
			*BA20.10-P-1001-01M
26.1	Remove compressor	Engine 112.960 in model 170.466 Engine 113.992 in model 230.474	AR09.50-P-4705SVK
27	Remove air pump (20)	Engine 112 (except 112.960) in model 170 Engine 112 in 163, 202, 208, 210 Engines 113 in 163, 202, 208, 210	AR14.30-P-7251A
		Engine 112.922 in model 220.063	AR14.30-P-7251AA
		Engine 112.923 in model 129.059 Engine 112.943 in model 129.064 Engine 112.944 in model 220.065 /165 Engine 112.972 in model 220.067 /167 Engine 112.975 in model 220.087 /187 Engine 113.941 in models 220.070/170 Engine 113.948 in model 220.083 /183 Engine 113.960 in model 220.075/175 Engine 113.960 in model 215.375 Engine 113.961 in model 129.068 Engine 113.963 in models 230.475 Engine 113.966 in model 220.084 /184
		Engine 113.992 in model 230.474	AR14.30-P-7251RVK
28	Separate electrical line from coolant temperature sensor
29	Unscrew bolts (21) of cylinder head to timing case cover on right and left		*BA01.40-P-1002-01C
30	Remove screws of the timing case cover	Installation: Apply sealant to marked bolts, observing the bolt diagram for the timing case cover: ↓	*BR00.45-Z-1015-01A
		Bolt diagram for timing case cover engine 112, 113	AR01.40-P-8000-01B
		Bolt diagram for timing case cover engine 113.992,	AR01.40-P-8000-01RVK
			*BA01.40-P-1001-01C
			*BA01.40-P-1002-01C
31	Take off timing case cover	Installation: The bolt threads for the coolant pump, the belt tensioning device, and the power steering pump are not cut into a new timing case cover. For this reason, use new self-tapping bolts in combination with a new timing case cover for attaching the coolant pump, the belt tensioning device and the power steering pump. Pay attention to tightening torque with non-pre-tapped threads.
			*BA13.25-P-1001-01D
			*BA13.25-P-1001-01M
			*BA13.25-P-1005-01D
			*BA13.25-P-1006-01D
			*BA13.25-P-1007-01D
			*BA20.10-P-1001-01C
			*BA20.10-P-1001-01M
			*BA20.10-P-1002-01C
			*BA20.10-P-1002-01M
			*BA20.10-P-1003-01C
			*BA20.10-P-1003-01M
			*BA20.10-P-1004-01C
			*BA20.10-P-1004-01M
			*BA46.30-P-1010-01A
			*BA46.30-P-1010-01C
		Clean sealing surfaces, apply sealant only to specified surfaces in form of bead with height and width of 2.0 mm ± 0.5 mm. The sealant must be applied within 10 minutes! The silicone bead must not be spread!	*BR00.45-Z-1013-01A
	Notes on application of sealant to timing case cover		AH01.40-P-1000-01B
		Installation: If sealing compound enters the oil ducts, this is carried by the oil flow and will clog the oil supply bores. Do not damage cylinder head gasket. Replace seals on timing case (19). Replace front crankshaft radial sealing ring: ↓
		Engine 112 in model 129 Engine 113 in model 129 Engine 113 in model 163, 202, 208, 210	AR03.20-P-3000B
		Engine 112 in models 170, 202, 208, 210, 220 Engine 113 in model 215, 220 Engine 113.981 in model 163.174 Engine 113.963 in models 230.475 Engine 113.992 in model 230.474	AR03.20-P-3000BA
32	Install in the reverse order
	Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the running engine	Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
33	Run engine and inspect for leaks
34	Inspect cooling system for leaks	First warm up engine to operating temperature.
		Engine 112 (except 112.947 /960) Engine 113 (except 113.992 /963)	AR20.00-P-1010HA
		Engine 112 in Model 170	AR20.00-P-1010P
35	Perform basic programming	Model 215, 220 All except model 215, 220: Code radio and normalize power window. Vehicles with stationary heater: adjust time display on stationary heater.	AR00.19-P-0200M
36.1	Read out fault memory and erase	All except models 215, 220, 230 Stored faults which can result from cables being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work: ↓ Diagnosis Manual Volume 2 Index 0: Connecting and using test equipment.
36.2	Read out fault memory with STAR DIAGNOSIS and erase if necessary.	Model 220, 230
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system Stored faults which can result from removal and installation or test work, have to be processed and erased in the fault memories after completing the work.	*WH58.30-Z-1048-13A

Crankcase, timing case cover, end cover

Number	Designation		Engine 112 except 112.951/ 976	Engine 112.951/ 976	Engine 113.987/ 988/990/ 991/993
BA01.40-P-1001-01C	Timing case cover to crankcase	Nm	20	20	20
BA01.40-P-1002-01C	Bolt, cylinder head to timing case cover	Nm	20	20	20

Crankcase, timing case cover, end cover

Number	Designation		Engines 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/992/995	Engine 113.987/ 988/990/ 991/993
BA01.40-P-1001-01C	Timing case cover to crankcase	Nm	20	20
BA01.40-P-1002-01C	Bolt, cylinder head to timing case cover	Nm	20	20

Belt tensioning device

Number	Designation			Engine 112.910/911/91 2/913/914/915/ 916/917/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 953/954/955/ 960/961/970/ 972/973/975
BA13.25-P-1001-01M	Self-tapping bolt of belt tensioner to timing case cover	Thread not pre-tapped	Nm	35
BA13.25-P-1001-01M	Self-tapping bolt of belt tensioner to timing case cover	Thread pre-tapped	Nm	25

Belt tensioning device

Number	Designation			Engine 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/964/965/ 966/967/968/ 969/971/980/ 981/982/984/ 986/987/988	Engine 113.990/ 991/992/ 993/995
BA13.25-P-1001-01D	Self-tapping bolt of belt tensioner to timing case cover	Thread not pre-tapped	Nm	35	35
BA13.25-P-1001-01D	Self-tapping bolt of belt tensioner to timing case cover	Thread pre-tapped	Nm	25	25
BA13.25-P-1005-01D	Bolt of belt tensioner to timing case cover	M7 x 25	Nm	35	35
BA13.25-P-1006-01D	Self-tapping bolt of compressor belt tensioner to timing case cover	Thread not pre-tapped	Nm	-	35
BA13.25-P-1006-01D		Thread pre-tapped	Nm	-	25
BA13.25-P-1007-01D	Bracket for charge air cooler water pipes		Nm	7	14
BA13.25-P-1008-01D	Bolt of guide pulley for compressor and major assembly belts to timing case cover	M8x78	Nm	-	68

Coolant pump, coolant thermostat

Number	Designation				Engine 113.940/941/ 942/943/944/ 945/946/948/ 960/961/962/ 963/965/966/ 967/968/969/ 980/981/982/ 984/986/992 993/995
BA20.10-P-1001-01C	Self-tapping screw for coolant pump to timing case	Thread not pre-tapped	M6	Nm	14
		Thread not pre-tapped	M8	Nm	35
		Thread pre-tapped	M6	Nm	10
		Thread pre-tapped	M8	Nm	25
BA20.10-P-1002-01C	Belt pulley to coolant pump			Nm	10
BA20.10-P-1003-01C	Bolt, coolant thermostat housing		M6	Nm	10
BA20.10-P-1004-01C	Coolant pump at the timing case		M7	Nm	10

Coolant pump, coolant thermostat

Number	Designation				Engine 112.910/911/91 2/913/914/915/ 916/917/920/ 921/922/923/ 940/941/942/ 943/944/945/ 946/947/949/ 953/954/955/ 960/961/970/ 972/973/975
BA20.10-P-1001-01M	Self-tapping screw for coolant pump to timing case	Thread not pre-tapped	M6	Nm	14
		Thread not pre-tapped	M8	Nm	35
		Thread pre-tapped	M6	Nm	10
		Thread pre-tapped	M8	Nm	25
BA20.10-P-1002-01M	Belt pulley to coolant pump			Nm	9
BA20.10-P-1003-01M	Bolt, coolant thermostat housing		M6	Nm	14
BA20.10-P-1004-01M	Coolant pump at the timing case		M7	Nm	14

Power steering pump

Number	Designation		Model 170
BA46.30-P-1005-01A	Screw, power steering pump to cylinder liner collar seat or crankcase	Nm	25

Power steering pump

Number	Designation			Model 208.365/370/ 374/465/470	Models 210.061/063/ 065/070/074/08 1/082/083/261/ 263/265/270/27 4/281/282/283/ 663
BA46.30-P-1010-01A	Self-tapping bolt, power steering pump to timing case	Thread not pre-tapped	Nm	35	35
BA46.30-P-1010-01A	Self-tapping bolt, power steering pump to timing case	Thread pre-tapped	Nm	20	20

Power steering pump

Number	Designation			Model 202.026/029/ 033/086/089/093	Model 129.059/ 064/068
BA46.30-P-1010-01A	Self-tapping bolt, power steering pump to timing case	Thread not pre-tapped	Nm	35	35
BA46.30-P-1010-01A	Self-tapping bolt, power steering pump to timing case	Thread pre-tapped	Nm	20	20

Power steering pump

Number	Designation			Model 215.374/ 375/378/ 379	Model 220.083/084/08 7/183/184/187
BA46.30-P-1010-01C	Self-tapping bolt, power steering pump to timing case	Thread not pre-tapped	Nm	35	35
BA46.30-P-1010-01C	Self-tapping bolt, power steering pump to timing case	Thread pre-tapped	Nm	20	20

Power steering pump

Number	Designation			Models 220.063/065/ 070/073/075/ 165/170/173/ 175 without code 487a	Model 230 without code 487	Model 230 with code 487
BA46.30-P-1010-01C	Self-tapping bolt, power steering pump to timing case	Thread not pre-tapped	Nm	35	35	35
BA46.30-P-1010-01C	Self-tapping bolt, power steering pump to timing case	Thread pre-tapped	Nm	20	20	20

Refrigerant compressor

Number	Designation		Engine 112.910/911/ 920/921/940/941, 113.940/943/944/980 /984 in model 202, 208, 210	Engine 112.923/943, 113.961 in model 129
BA83.55-P-1001-01A	Bolt, refrigerant compressor to bracket	Nm	20	20

Refrigerant compressor

Number	Designation		Engine 111.977,112.942, 112.970,113.942 / 965/981 in model 163	Engine 112.947/960 in model 170
BA83.55-P-1001-01A	Bolt, refrigerant compressor to bracket	Nm	20	20

Refrigerant compressor

Number	Designation		Engines 112.922/944 in model 220	Engine 113.960 in model 215
BA83.55-P-1001-01A	Bolt, refrigerant compressor to bracket	Nm	20	20

Refrigerant compressor

Number	Designation		Engine 113.941/960 in model 220	Engine 113.963/992/995 in model 230
BA83.55-P-1001-01A	Bolt, refrigerant compressor to bracket	Nm	20	20

Fig 2: Identifying Hand Pump (210 589 00 71 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Commercially available tools

Number	Designation
WH58.30-Z-1048-13A	STAR DIAGNOSIS diagnosis system, Compact Passenger Car	6511 1801 00

Repair materials

Number	Designation	Order number
BR00.45-Z-1013-01A	Sealant	A 003 989 98 20
BR00.45-Z-1015-01A	Sealant	A 002 989 71 20