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

ENGINE 113.990 in MODELS 211.076 /276

ENGINE 113.991 in MODELS 215.374, 220.074 /174

Fig 1: Identifying Timing Case Cover Remove/Install Components

Shown on engine 113.991

Fig 2: Identifying Timing Case Cover Remove/Install Components (Shown On Engine 113.991)

	Remove/install
	Risk of death caused by vehicle slipping or toppling off the lifting platform.	Align vehicle between columns of lifting platform and position four support plates at lifting platform support points specified by vehicle manufacturer.	AS00.00-Z-0010-01A
1.1	Activate Service mode in Tele-Aid emergency call system	Only models 215, 220 with Tele-Aid emergency call system (D2B) code 347, Tele-Aid code 855	AR82.95-P-0005-03AM
	Notes regarding the Tele-Aid emergency call system		AH82.95-P-0001-01AM
	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
2	Disconnect battery ground cable	Turn key in electronic ignition switch EIS into position "0". Key cannot be withdrawn. Vehicle with Keyless Go code 889: Switch off engine, remove Keyless Go cards from the vehicle and keep outside the range of the transmitter.
		Model 211.076	AR54.10-P-0003T
		Model 211.276	AR54.10-P-0003TA
		Model 220, 215	AR54.10-P-0003I
	Notes on battery	All models	AH54.10-P-0001-01A
3	Remove engine compartment paneling	Model 211	AR61.20-P-1105T
		Model 220, 215	AR61.20-P-1105M
	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
4	Drain coolant from radiator		AR20.00-P-1142RVK
5	Remove air filter	Unclip cover on front side of engine.	AR09.10-P-1150SVK
6	Remove fan shroud	Model 211	AR20.40-P-6800TC
		Model 215, 220	AR20.40-P-6800AB
7	Attach guard plate for radiator/condenser
	Guard plate for radiator/condenser		WF58.50-P-0110-01A
8	Remove poly-V-belt for supercharger		AR13.21-P-1202RVK
9	Remove poly-V-belt	Models 215.374, 220.074/174	AR13.22-P-1202R
		Model 211.076/276	AR13.22-P-1202RV
10	Remove cylinder head covers with ignition coils (3)		AR01.20-P-5014BV
			*BA01.20-P-1001-01E
			*BA01.20-P-1002-01E
11	Remove coolant line (circulation pump → coolant pump) (14) and coolant line (radiator → coolant pump) (15)		*WH58.30-Z-1001-06A
12	Remove coolant line (radiator → thermostat housing) (13)		*WH58.30-Z-1002-06A
13	Detach AC compressor (7)	Place to the side with lines connected.
			*BA83.55-P-1001-01A
14	Remove alternator (5)	Model 211	AR15.40-P-5032TC
		Models 215.374, 220.074/174	AR15.40-P-5032AM
15	Detach bracket for oil lines of automatic transmission (19)
16	Remove bottom part of oil pan (6)		AR01.45-P-7555R
17	Remove oil pan top section(18)	Model 211	AR01.45-P-7500TV
		Model 215, 220	AR01.45-P-7500R
18	Remove poly-V-belt tensioning device of compressor (21)	Installation: The threads for mounting tensioning device of compressor are not pretapped on a new timing case cover. For this reason, on a new timing case cover new selftapping bolts must be used for fastening. Observe tightening torque in the case of non-pretapped threads:	AR13.25-P-3217RVK
			*BA13.25-P-1006-01D
19	Remove poly-V-belt tensioning device (2)		AR13.25-P-3200R
			*BA13.25-P-1001-01D
20	Remove belt pulley/vibration damper (1)		AR03.30-P-1600RVK
21	Remove chain tensioner (11)	Models 211, 215, 220, 230	AR05.10-P-7800AM
22	Remove oil filter housing (4)		AR18.20-P-3471RKV
23	Detach power steering pump (8) with reservoir	Do not disconnect lines. Installation: On a new timing case over, the threads for fastening power steering pump (8) are not tapped. For this reason, on a new timing case cover new self-tapping bolts must be used for fastening. Observe tightening torque in the case of non-pretapped threads:
		Model 215, 220	*BA46.30-P-1010-01C
		Model 211	*BA46.30-P-1006-01M
24	Detach poly-V-belt guide pulley of compressor (22) at timing case cover		*BA13.25-P-1008-01D
25	Detach belt pulley at coolant pump (9)		*BA20.10-P-1002-01L
26	Remove coolant pump (9)		*BA20.10-P-1001-01L
27	Remove compressor (20)		AR09.50-P-4705SVK
28	Disconnect electrical coupling from coolant temperature sensor
29	Unscrew cylinder head bolts → timing case cover (17) on right and left		*BA01.40-P-1002-01C
30	Remove screws of the timing case cover	Installation: Apply sealant to bolts, for this step observe bolt diagram for timing case cover: ↓	*BR00.45-Z-1015-01A
		Bolt diagram for timing case cover	AR01.40-P-8000-01RVK
			*BA01.40-P-1001-01C
			*BA01.40-P-1002-01C
31	Take off timing case cover	Installation: Clean sealing surfaces, only apply sealant 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
		Installation: Replace sealing rings of timing case (16).
	Notes on application of sealant to timing case cover	Engine 112, 113	AH01.40-P-1000-01B
32	Replace front crankshaft radial sealing ring		AR03.20-P-3000BA
33	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
34	Check for leaks with engine running
35	Inspect cooling system for leaks	First of all, warm up engine to operating temperature.	AR20.00-P-1010RVK
36.1	Deactivate service mode in TELE AID emergency call system	Only models 215, 220 with Tele-Aid emergency call system (D2B) code 347, Tele-Aid code 855	AR82.95-P-0005-03AM
	Notes regarding the Tele-Aid emergency call system		AH82.95-P-0001-01AM
37	Render electrical system operational	Model 211	AR00.19-P-0200T
		Model 215, 220	AR00.19-P-0200M
38	Read out fault memory and erase	When work is complete stored faults must be worked on in the diagnostic trouble code memories and erased. The stored faults may be caused by removed cables during installation or test operations as well as by simulation.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system, Compact Passenger Car	*WH58.30-Z-1048-13A

CRANKCASE, TIMING CASE COVER, END COVER

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

BELT TENSIONING DEVICE

Number	Designation			Engines 113.990/ 991/ 992/ 993/995
BA13.25-P-1001-01D	Self-tapping bolt, belt tensioner to timing case cover	Thread not pre-tapped	Nm	35
BA13.25-P-1001-01D	Self-tapping bolt, belt tensioner to timing case cover	Thread pre-tapped	Nm	25
BA13.25-P-1006-01D	Self-tapping bolt, compressor belt tensioner to timing case cover	Thread not pretapped	Nm	35
BA13.25-P-1006-01D		Thread pretapped	Nm	25
BA13.25-P-1008-01D	Bolt, guide pulley for compressor and major assembly belts to timing case cover	M8x78	Nm	68

BELT TENSIONING DEVICE

Number	Designation			Engine 113.990/991/992/993/995
BA13.25-P-1001-01D	Self-tapping bolt, belt tensioner to timing case cover	Thread not pretapped	Nm	-
BA13.25-P-1001-01D	Self-tapping bolt, belt tensioner to timing case cover	Thread pre-tapped	Nm	-
BA13.25-P-1006-01D	Self-tapping bolt, compressor belt tensioner to timing case cover	Thread not pretapped	Nm	35
BA13.25-P-1006-01D		Thread pretapped	Nm	25
BA13.25-P-1008-01D	Bolt, guide pulley for compressor and major assembly belts to timing case cover	M8 x 78	Nm	68

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation			Engine 113.987/988/ 990/991
BA20.10-P-1001-01L	Bolt, coolant pump to timing case	M6	Nm	14
BA20.10-P-1001-01L	Bolt, coolant pump to timing case	M8	Nm	20
BA20.10-P-1002-01L	Belt pulley to coolant pump		Nm	9

POWER STEERING PUMP

Number	Designation			Model 215.374/375/378/179	Model 220.074/174
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			Model 211 with engines 112, 113
BA46.30-P-1006-01M	Bolt, power steering pump mount to timing case cover	Normal thread	Nm	20
BA46.30-P-1006-01M	Bolt, power steering pump mount to timing case cover	Thread, self tapping	Nm	35

REFRIGERANT COMPRESSOR

Number	Designation		Engine 113.987/988/98 9/990/991
BA83.55-P-1001-01A	Bolt, refrigerant compressor to bracket	Nm	20

CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number	Designation		Engine 113.987/988/990/991/993
BA01.20-P-1001-01E	Cylinder head cover bolt	Nm	8
BA01.20-P-1002-01E	Bolt, ignition coils to cylinder head cover	Nm	8

COMMERCIALLY AVAILABLE TOOLS

Number	Designation
WH58.30-Z-1001-06A	6 mm socket hexagon on flexible shaft for hose clamps with worm drive
WH58.30-Z-1002-06A	7 mm socket hexagon on flexible shaft for hose clamps with worm drive
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