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

ENGINES 605, 606.910 in MODEL 124 

ENGINE 606.961 in MODEL 140 

ENGINE 604, 605 in MODEL 202 

ENGINE 604, 605, 606.912 /962 in MODEL 210 

Fig 1: Identifying Timing Case Cover Components (1 Of 3)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Timing Case Cover Components (2 Of 3)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Timing Case Cover Components (3 Of 3)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
1	Disconnect battery ground cable		AR54.10-P-0003A
2	Remove charge air pipe (3)	Engine 605.960 in model 202 Engine 605.962 in model 210	AR09.41-P-1311H
3	Remove viscous fan clutch	Engines 605, 606	AR20.40-P-5660HB
		Engine 604	AR20.40-P-5660HA
4	Remove poly-V-belt		AR13.22-P-1202HA
5	Remove radiator (14)	Model 124 with engine 606.910 Model 210 with engine 606.912	AR20.20-P-3865HA
		Model 210 with engine 606.962	AR20.20-P-3865HB
6	Remove pulleys of coolant pump (5) and power steering pump (6)	except VDA pump: To loosen bolts, place poly-V-belt on pulleys and attach counterholder.
			Fig 4
			*BA20.10-P-1001-01A
			*BA46.30-P-1001-01A
7	Remove cylinder head cover		AR01.20-P-5014HA
8	Remove vacuum pump (9)	Installation of vane-type pump (Barluk):  Replace O-ring (21) at oil spray nozzle.	AR43.05-P-1320A
9	Turn cylinder 1 to TDC	so that bracket for TDC sensor can be adjusted during assembly.
10	Install retaining lock (03) for crankshaft/ring gear	Use M690 bolts otherwise thread in rear end cover will be damaged.	AR03.30-P-5000HA
11	Remove oil-water heat exchanger (17) at oil pan	On vehicles with oil/water heat exchanger at oil pan.	AR18.30-P-3480HA
12	Remove vibration damper (77)		AR03.30-P-1600HA
13	Remove alternator	Model 202	AR15.40-P-5032EA
		Model 210	AR15.40-P-5032F
14	Remove alternator carrier (2)		Fig 10
15	Unscrew bolts for oil pan (8)	Unscrew bolts near timing case cover, only loosen all other bolts of oil pan.	*BA01.45-P-1001-01A
			*BA01.45-P-1002-01A
			Fig 10
16	Remove coolant hoses (1,4) at front cylinder head	Inspect condition of coolant hoses and hose clamps, replace if necessary.	*WH58.30-Z-1001-06A
			*WH58.30-Z-1002-06A
17	Unscrew power steering pump (30)	Attach with connected lines at side of engine compartment.	AR46.30-P-0500A
18	Unbolt fuel filter (70/2)	Unbolt fuel filter with connected lines and lay to one side.
19	Remove guide rail pins (32) at cylinder head		AR01.30-P-5800-04A
			Fig 6
			Fig 7
			Fig 8
		Installation:  Coat top slide rail pin with sealant and knock into the cylinder head as far as the stop. Ensure the guide rail is correctly installed in the cylinder head	*BR00.45-Z-1012-01A
		Sealant optional.	*BR00.45-Z-1009-01A
20	Remove poly-V-belt tensioning device (33)	Only if timing case cover is replaced.	AR13.25-P-3200HA
21	Unscrew injection pump (35) bolts on timing case cover		*BA07.02-P-1001-01A
		Installation:  Check start of delivery,	AD07.00-P-1464B
22	Unscrew bracket for TDC sensor (36)	Installation:  Screw on bracket in such a way that the pointer is aligned with TDC marking on the vibration damper (77), if necessary: ↓
		Check setting of bracket of TDC sensor and correct	AR03.00-P-1101HA
23	Unscrew bolts, cylinder head to timing case cover (34)		Fig 5
			*BA01.40-P-1002-01A
24	Remove timing case cover (40)	Installation:  Observe bolt length! Do not damage cylinder head gasket and oil pan gasket. If necessary, replace damaged gasket: ↓	*BA01.40-P-1001-01A
		Remove/install cylinder head Remove oil pan.↓	AR01.30-P-5800HA
		Remove oil pan, engines 604, 605 in model 202, engines 605, 606 in model 124.	AR01.45-P-7500HA
		Remove oil pan, engines 605, 606 in model 210, engine 606.961 in model 140.	AR01.45-P-7500C
		Remove oil pan, engine 604 in model 210. Check front crankshaft radial seal, if necessary according to condition: ↓	AR01.45-P-7500D
		Replace front crankshaft radial seal. Observe fitted sleeves (6).	AR03.20-P-3000HA
25	Clean sealing surfaces at timing case cover and at crankcase	Coat with sealant.	*BR00.45-Z-1012-01A
		Sealant optional.	*BR00.45-Z-1009-01A
26	Install in the reverse order
27	Fill cooling system		AR20.00-P-1142HW
	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
28	Run engine and inspect for leaks

Crankcase, timing case cover, end cover

Oil pan

Injection pump, unit pump, high pressure pump

Coolant pump, coolant thermostat

Power steering pump

Power steering pump

Power steering pump

Fig 4: Identifying Counterholder (603 589 00 40 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 5: Identifying T Hexagon Socket Wrench (116 589 03 07 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 6: Identifying Impact Extractor (116 589 20 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 7: Identifying Threaded Pin (116 589 01 34 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 8: Identifying Puller (605 589 00 33 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 9: Identifying External Torx Set (001 589 76 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 10: Identifying External Torx Set (001 589 76 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.