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Remove/install timing case cover - AR01.40-P-8000AMG (ML63 AMG): Notes

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ENGINE 156 

Fig 1: Identifying Timing Case Cover Remove/Install Components
G04958184Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES

6.2.07 Bolt, coolant pump to timing case cover and crankcase Engine 156 *BA20.10-P-1001-01V 
REMOVINGINSTALLING Remove/install    
DANGER Risk of death  caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A
1.1 Remove engine with front axle carrier Engine 156.980 in model 164, 251 AR01.10-P-2500GZS
1.2 Remove engine Engine 156.982 in model 209 AR01.10-P-2400QMG
    Engine 156.983 in model 211, 219 AR01.10-P-2400TMG
    Engine 156.984 in model 216, 221 AR01.10-P-2400SMG
2 Detach engine from front axle carrier Engine 156.980 in model 164, 251 AR01.10-P-2510GZS
3 Remove automatic transmission from engine    
4 Remove oil lines from automatic transmission to oil pan    
5 Mount engine onto assembly stand    
6 Rotate engine at crankshaft center bolt in direction of rotation of the engine to a 40° crankshaft angle after top dead center (TDC) IMPORTANT The 40° TDC marking on belt pulley/vibration damper (9) must be aligned with positioning edge (arrow) on timing case cover.  
7 Remove poly-V belt tensioning device (1) Model 164, 251 AR13.25-P-3200GZS
    Model 209, 211, 219 AR13.25-P-3200TMG
    Model 216, 221 AR13.25-P-3200SMG
8 Remove expansion reservoir (2) for power steering only model 164, 209, 211, 219, 251 AR46.25-P-1000GZS
9 Remove air shutoff valves (3) IMPORTANTRemoval:  The air lines are screwed off at the cylinder head.  
    Model 164, 251 AR14.30-P-7200GZS
    Model 209, 211, 219 AR14.30-P-7200TMG
    Model 216, 221 AR14.30-P-7200SMG
    IMPORTANTInstallation:  Replace the gaskets.  
10 Remove oil filter housing (4) Model 164, 251 AR18.20-P-3471GZS
    Model 209, 211, 219 AR18.20-P-3471TMG
    Model 216, 221 AR18.20-P-3471SMG
11 Remove cylinder head covers (5) Model 164, 251 AR01.20-P-5014GZS 
    Model 209, 211, 219 AR01.20-P-5014TMG
    Model 216, 221 AR01.20-P-5014SMG
12 Remove camshaft adjuster Up to engine number 001177 AR05.20-P-7201ANG
    from engine number 001178 AR05.20-P-7201AMG
13 Remove power steering pump (6) at timing case cover (7)   AR46.30-P-0500GZS
14 Remove refrigerant compressor (A9)    
15 Remove alternator (G2) Model 164, 251 AR15.40-P-5032GZS
    Model 209, 211, 219 AR15.40-P-5032TMG
    Model 216, 221 AR15.40-P-5032SMG
16 Remove chain tensioner Model 164, 251 AR05.10-P-7800GZS
    Model 209, 211, 219 AR05.10-P-7800TMG
    Model 216, 221 AR05.10-P-7800SMG
17 Remove belt pulley/vibration damper (9) Model 164, 251 AR03.30-P-1600GZS
    Model 209, 211, 219 AR03.30-P-1600TMG
    Model 216, 221 AR03.30-P-1600SMG
18 Disconnect electrical connector from thermostat housing    
19 Remove guide pulley (10, 11, 12) TORQUE SPECIFICATION *BA13.25-P-1003-01U 
    TORQUE SPECIFICATION *BA13.25-P-1004-01U 
    TORQUE SPECIFICATION *BA13.25-P-1005-01U 
20 Remove oil pan bottom section Model 164, 251 AR01.45-P-7555GZS 
    Model 209, 211, 219 AR01.45-P-7555TMG
    Model 216, 221 AR01.45-P-7555SMG
21 Remove oil pan Model 164, 251 AR01.45-P-7500GZS 
    Model 209 AR01.45-P-7500QMG
    Model 211, 219 AR01.45-P-7500TMG
    Model 216, 221 AR01.45-P-7500SMG
22 Remove bolts (13) at timing case cover (7), remove timing case cover (7) IMPORTANTInstallation:  Pay attention to different lengths of bolts: ↓  
    Bolt plan for timing case cover AR01.40-P-8000-01AMG 
    TORQUE SPECIFICATION *BA20.10-P-1001-01V 
    TORQUE SPECIFICATION *BA01.40-P-1001-01W 
    TORQUE SPECIFICATION *BA01.40-P-1002-01W 
    IMPORTANT *BA01.40-P-1003-01W 
    Installation:  Replace crankshaft radial sealing ring (14), coolant passage seal and radial shaft sealing ring for oil centrifuge. Clean sealing surfaces and apply sealant to sealing surface on timing case cover (7).  
IMPORTANT Notes on sealant path for timing case cover   AH01.40-P-1000-01AMG
    SPECIAL TOOL Squeeze gun Fig 2
    SPECIAL TOOL Drift Fig 3
    Sealant *BR00.45-Z-1015-01A 
    LU cleaner *BR00.45-Z-1032-04A 
23 Install in the reverse order    
24 Read out fault memory and erase if necessary IMPORTANT Stored faults which may be caused by disconnecting cables or by simulation during test operations, must be erased in the fault memory after completing the work.  
REFER TO SELF-DIAGNOSTIC SYSTEMS Connect STAR DIAGNOSIS and read out fault memory STAR DIAGNOSIS diagnostic system AD00.00-P-2000-04A
25 Perform basic programming Model 216, 221  
    Model 164 AR00.19-P-0200GZ
    Model 209 AR00.19-P-0200Q
    Model 211 AR00.19-P-0200T
    Model 219 AR00.19-P-0200TX
    Model 251 AR00.19-P-0200RT
DANGER 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 engine as it is running Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.		 AS00.00-Z-0005-01A
26 Conduct engine test run and check engine for leaks    
BELT TENSIONING DEVICE

Number Designation Engine 156
BA13.25-P-1003-01U Guide pulley on coolant pump housing (between power steering pump and guide pulley with grooved channel profile) Nm 30
BA13.25-P-1004-01U Guide pulley to coolant pump housing (between alternator and smooth guide pulley) Nm 20
BA13.25-P-1005-01U Guide pulley (between poly-V belt tensioning device and coolant pump) Nm 20
COOLANT PUMP, COOLANT THERMOSTAT

Number Designation Engine 156
BA20.10-P-1001-01V Bolt, coolant pump to timing case cover and crankcase M6x30 Nm 9
M6 x 80 Nm 9
M8 x 80 Nm 20
M8 x 100 Nm 20
CRANKCASE, TIMING CASE COVER, END COVER

Number Designation Engine 156
BA01.40-P-1001-01W Bolt, timing case cover to crankcase M8 Nm 20
BA01.40-P-1002-01W Bolt, cylinder head bolt to timing case cover chain box on the outside M8 Nm 20
BA01.40-P-1003-01W Cylinder head to timing case chain box on the inside M8 Nm 20
Fig 2: Identifying Squeeze Gun (112 589 00 25 00)
G04958185Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Drift (156 589 00 15 00)
G04958186Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1015-01A Loctite sealant 5970 A 003 989 98 20 10
BR00.45-Z-1032-04A LU cleaner Wurth GmbH
D - 74650 Kunzelsau
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