Remove/install timing case cover - AR01.40-P-8000GZ (ML500): Notes

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ENGINES 113.964 in MODEL 164.175

Fig 1: Identifying Timing Case Cover Remove/Install Components - Engines 113.964

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

9.1.06

Central bolt to vibration damper

*BA03.30-P-1001-01D

	Remove/install
	Notes on self-locking nuts and bolts	All models	AH00.00-N-0001-01A
		External Torx set	Fig 2
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, liftgates or sliding roof	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
1	Open engine hood and raise to vertical position		AR88.40-P-1000GZ
	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 goggles. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
2	Disconnect ground line from battery	Insulate clamping device of the ground line in order to prevent inadvertent contact with the ground point of the battery.	AR54.10-P-0003GZ
	Notes on battery	All models	AH54.10-P-0001-01A
	Risk of death caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
3	Raise vehicle with vehicle lift		AR00.60-P-1000GZ
4	Remove engine compartment paneling	Installation: Install engine compartment paneling only after engine test run.	AR61.20-P-1105GZ
5	Remove air filter housing		AR09.10-P-1150GZ
	Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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
6	Drain coolant at radiator		AR20.00-P-1142GZ
	Notes on coolant	All engines	AH20.00-N-2080-01A
	Coolant specifications	Sheet 310.1	BB00.40-P-0310-01A
	Anticorrosion/antifreeze agents (Sheet 325.0)	Sheet 325.0	BB00.40-P-0325-00A
		Test cap	Fig 3
		Cooler vacuum filling device	Fig 4
		Cooling system	*BF20.00-P-1001-02K
7	Remove electric air pump		AR14.30-P-7251GZ
			*BA14.30-P-1003-01A
8	Remove poly-V belt		AR13.22-P-1202GZ
9	Remove alternator	Place to the side with lines still connected.	AR15.40-P-5032GZ
			*BA15.40-P-1005-01N
10	Remove cylinder head covers with ignition coils		AR01.20-P-5014GZ
			*BA01.20-P-1001-01E
11	Detach coolant line (4, 6) from coolant pump (5).
12	Detach coolant line (4, 6) at radiator
13	Detach coolant line (7) at thermostat housing (8)
14.1	Remove coolant pump (5) at timing case cover (1).	Only necessary when replacing timing case cover (1). Installation: Replace gasket of coolant pump (2).	AR20.10-P-1271GZ
		Installation: Observe bolt diagram.	AR20.10-P-1271-03GZ
			*BA20.10-P-1001-01C
			*BA20.10-P-1002-01C
15.1	Detach control rod at front axle sensor of headlight range adjustment	Only on vehicles with Xenon headlamp units, code 612.
16	Remove oil pan bottom section		AR01.45-P-7555GZ
17	Remove oil pan		AR01.45-P-7500GZ
18	Remove refrigerant compressor	Place to the side with lines still connected.	AR83.55-P-5300GZ
19	Remove poly-V-belt tensioning device		AR13.25-P-3200GZ
			*BA13.25-P-1001-01D
20	Remove belt pulley/vibration damper (16)		AR03.30-P-1600GZ
			*BA03.30-P-1001-01D
21	Remove chain tensioner (15)		AR05.10-P-7800GZ
			*BA05.10-P-1001-01C
22	Remove oil filter housing (9) with oil/water heat exchanger		AR18.20-P-3471GZ
			*BA18.20-P-1001-01D
			*BA18.20-P-1005-01D
23	Detach power steering pump	Place to the side with lines still connected.	AR46.30-P-0500GZ
24	Lever off plastic cover on guide pulley (13) using a suitable tool
25	Remove bolt from guide pulley (13) on the coolant pump (5)		*BA20.10-P-1008-01C
26	Remove guide pulley
27	Remove bolts of timing case cover (1)	Installation: Apply sealant and observe bolt diagram: ↓
		Bolt plan for timing case cover	AR01.40-P-8000-01B
			*BA01.40-P-1001-01C
			*BA01.40-P-1002-01C
		Sealant	*BR00.45-Z-1013-01A
28	Remove timing case cover (1)	On a new timing case cover, the mounting threads for the coolant pump, the tensioning device and the power steering pump are not pre-cut; new self-tapping bolts must therefore be used Pay attention to differences in tightening torque for threads which are not pre-tapped and threads which are pre-tapped.
	Notes on sealant path for timing case cover		AH01.40-P-1000-01B
		Installation: make sure that sealant does not enter the oil ducts and take care not to damage the cylinder head gasket in order to avoid engine damage. Installation: replace sealing rings in timing case cover.
			*BA20.10-P-1001-01C
			*BA13.25-P-1001-01D
		Sealant	*BR00.45-Z-1013-01A
29	Replace front crankshaft radial sealing ring		AR03.20-P-3000GZ
30	Install in the reverse order
31	Inspecting cooling system for leaks		AR20.00-P-1010GZ
32	Check engine oil level and correct if required	The vehicle must be on a level surface otherwise false measurements will occur.	AR18.00-P-3035-01GZ
	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
33	Conduct engine test run and check engine for leaks while it is running	In the event of oil loss determine and eliminate cause, otherwise malfunctions, transmission damage, and serious environmental pollution may occur.
34	Read out fault memory and erase if necessary	STAR DIAGNOSIS diagnostic system
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A

CRANKCASE VENTILATION, CYLINDER HEAD COVER

Number	Designation		Engine 113
BA01.20-P-1001-01E	Cylinder head cover bolt	Nm	9

CRANKCASE, TIMING CASE COVER, END COVER

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/ 986/992/995
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

FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR

Number	Designation			Engine 113.94/96/ 97/98
BA03.30-P-1001-01D	Central bolt to vibration damper	Stage 1	Nm	200
BA03.30-P-1001-01D	Central bolt to vibration damper	Stage 2	∠°	90

TIMING CHAIN, CHAIN TENSIONER

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/ 990/991/992/ 993/995
BA05.10-P-1001-01C	Chain tensioner in timing case cover	Nm	80

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
BA13.25-P-1001-01D	Self-tapping bolt of belt tensioner to timing case cover	Thread not pre-tapped	Nm	35
BA13.25-P-1001-01D	Self-tapping bolt of belt tensioner to timing case cover	Thread pre-tapped	Nm	25

AIR PUMP

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
BA14.30-P-1003-01A	Bolt connecting air pump bracket to timing case	Nm	12

ALTERNATOR

Number	Designation			Engine 113 in model 164, 251
BA15.40-P-1005-01N	Self-tapping bolt, alternator to timing case	Thread not pre-tapped	Nm	60
BA15.40-P-1005-01N	Self-tapping bolt, alternator to timing case	Thread pre-tapped	Nm	45

OIL FILTER

Number	Designation		Engine 113.964/ 971
BA18.20-P-1001-01D	Screw cap at oil filter	Nm	25
BA18.20-P-1005-01D	Oil filter housing to crankcase	Nm	-

COOLANT PUMP, COOLANT THERMOSTAT

Number	Designation				Engine 113.964/971
BA20.10-P-1001-01C	Self-tapping bolt, connecting 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 on coolant pump			Nm	10
BA20.10-P-1008-01C	Bolt, guide pulley to coolant pump housing		M8	Nm	20

COOLING SYSTEM

Number	Designation			Engine 113.964 in model 164
BF20.00-P-1001-02K	Cooling system	Total filling capacity	Liters	≈ 10, 00
		Capacity of anti-corrosion antifreeze agent down to -37°C	Liters	≈ 5, 00
		Filling capacity of anti-corrosion antifreeze down to -45°C	Liters	≈ 5, 5
		Specifications for Operating Fluids	Sheet	BB00.40-P-0310-01A
		Specifications for Operating Fluids	Sheet	BB00.40-P-0325-00A

Fig 2: Identifying External Torx Set (001 589 76 09 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 3: Identifying Test Cap (210 589 00 91 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Vacuum-Type Cooling System Filler (285 589 00 21 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

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