Remove/install timing case cover - AR01.40-P-8000GZA (ML350, ML550, GL450, GL550): Notes

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ENGINE 272, 273 in MODEL 164, 251

Fig 1: Identifying Timing Case Cover Remove/Install Components - Engine 272, 273 (1 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 2: Identifying Timing Case Cover Remove/Install Components - Engine 272, 273 (2 Of 2)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

11.5.07	Bolt connecting exhaust rubber mount bracket (inner) to body	Engine 272, 273 in model 164
11.5.07	Bolt connecting exhaust rubber mount bracket (outer) to bumper bracket	Engine 272, 273 in model 164

	Remove/install
	Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof.	Keep body parts and limbs well clear of moving parts.	AS00.00-Z-0011-01A
	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
	Information on preventing damage to electronic components due to electrostatic discharge		AH54.00-P-0001-01A
1	Turn key in ignition lock to position "0"	Vehicles with Keyless Go, code 889: Press Keyless Go start/stop button repeatedly until ignition is switched off.
2	Remove air filter housing with engine intake air ducts		AR09.10-P-1150GZA
3	Remove lower engine compartment paneling	Model 164	AR61.20-P-1105GZ
		Model 251	AR61.20-P-1105RT
4	Drain engine oil	Installation: Replace sealing ring.
			*BA01.45-P-1001-01M
		Engine oil	*BF18.00-P-1001-01M
	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
5	Drain coolant at radiator		AR20.00-P-1142GZC
	Notes on coolant		AH20.00-N-2080-01A
6	Disconnect coolant line (1) on coolant thermostat housing (5)
7	Detach coolant lines (2) at coolant pump
8	Remove electric fan	Model 164	AR20.40-P-5000GZA
		Model 251	AR20.40-P-5000RTA
9	Attach guard plate for radiator / condenser
	Guard plate for radiator / condenser		WF58.50-P-0110-01A
10	Remove poly-V belt, clamping device and guide pulley (3)		AR13.20-P-0001GZA
11	Remove electric air pump (M33)		AR14.30-P-7251GZA
12	Remove coolant thermostat housing (5)	Installation: Install new O-ring and seal.	AR20.10-P-2460GZA
13	Remove oil filter housing (6) with oil/water heat exchanger		AR18.20-P-3471GZA
14	Remove aspirator shutoff valve (7) and intermediate flange (7a) at left cylinder head (8)		AR14.30-P-7200GZA
15	Remove aspirator shutoff valve (9) at right cylinder head		AR14.30-P-7200GZA
16	Remove air pump switchover valve (Y32)		AR14.30-P-7255GZA
17	Rotate engine at crankshaft center bolt in direction of rotation of engine to a 40° crankshaft angle after ignition TDC		Fig 4
18	Install retaining lock for crankshaft/starter ring gear		AR03.30-P-5000GZA
19	Remove belt pulley/vibration damper (10)		AR03.30-P-1600GZA
20	Remove the front cover at left cylinder head	Installation: After fitting front cover, check position of camshafts is at a 55° crankshaft angle before ignition TDC: ↓	AR01.30-P-5700GZA
		Inspect basic position of camshafts.	AR05.20-P-6010GZA
21	Remove front cover (11) on right cylinder head	Installation: After fitting front cover (11), check position of camshafts is at a 55° crankshaft angle before ignition TDC: ↓	AR01.30-P-5700GZC
		Inspect basic position of camshafts.	AR05.20-P-6010GZA
22	Remove segmental disks (12) for camshaft adjuster and retighten central valves (13) finger-tight	See "Removing camshaft adjuster":
		Exhaust camshaft adjuster	AR05.20-P-7201GZA
		Intake camshaft adjuster	AR05.20-P-7201GZC
23	Remove alternator (G2)	Model 164	AR15.40-P-5032GZA
		Model 251	AR15.40-P-5032RTA
24	Remove oil dipstick guide tube (14).		AR18.40-P-3510GZA
25	Remove chain tensioner	Chain tensioner with thread M24 X 1.5 (only for engine 272)	AR05.10-P-7800GZA
		Chain tensioner using thread M22 X 1.5 In case of engine 272 both chain tensioners can be removed whereby for engine 273 only chain tensioner with thread M22 X 1.5 is installed.	AR05.10-P-7800GZG
26	Remove power steering pump (15)	Remove power steering pump (15) with expansion reservoir from front cover (11) or from timing case cover (19) and place to one side with attached lines.
		Model 164	AR46.30-P-0500GZ
		Model 251	AR46.30-P-0500RT
27	Remove coolant compressor (A9) from timing case cover (19) and engine support, to do this unscrew the bolts (16)	Disconnect refrigerant compressor connector (A9x1) and attach refrigerant compressor (A9) with connected pipe system, laterally at bottom of engine compartment.
28	Remove complete exhaust system		AR49.10-P-7100GZA
29	Unscrew engine mount bolts at front axle carrier	Model 164 with engine 272	AR22.10-P-1100GZA
		Model 164 with engine 273	AR22.10-P-1260GZA
		Model 251	AR22.10-P-1260RTC
30	Detach engine support frame	Model 164	AR33.10-P-0100-01GZ
		Model 251	AR33.10-P-0100-01RT
		Observe manufacturer's assembly specifications and safety information. Engine support frame, see GOTIS http://gotis.aftersales.daimlerchrysler.com Engine lifting device side adapter for model 251, see GOTIS http://gotis.aftersales.daimlerchrysler.com
31	Raise engine	When lifting engine, ensure that steering coupling is not damaged, no lines are damaged and engine does not contact partition wall.
32	Remove oil pan bottom section	If the oil pan bottom section cannot be released from the oil pan, warm oil pan bottom section in area of sealing surface with a hot air gun, then push mounting wedge between sealing surface to separate oil pan bottom section of oil pan.	AR01.45-P-7555GZA
33	Remove oil pan	If the oil pan cannot be released from the crankcase, warm oil pan in area of sealing surface with a hot air gun, then push mounting wedge between sealing surface to separate oil pan of oil pan.	AR01.45-P-7500GZA
34	Lower engine and remove engine hoist
35	Remove bolts (17, 18)		*BA01.30-P-1003-01O
36	Detach timing case cover (19)	Installation: Observe different bolt lengths and diameters: ↓
		Bolt plan of the timing case cover (19)	AR01.40-P-8000-01VA
		Engine 272	*BA01.40-P-1001-01G
		Engine 273	*BA01.40-P-1001-01T
		Installation: Replace crankshaft radial sealing ring. Clean the sealing surfaces, replace both the sealing rings in the timing case cover (19) and apply sealing compound to the sealing surface of the timing case cover (19): ↓
		Notes on application of sealant to the timing case cover (19)	AH01.40-P-1000-01VA
			Fig 3
		Sealant	*BR00.45-Z-1013-01A
	Clean
37	Clean sealing surfaces on oil pan, oil pan bottom section and timing case cover	Remove sealant residues. Do not use any sharp edged tools or emery cloth, otherwise damages can occur to the sealing surfaces.
		Loctite 7200	*BR00.45-Z-1038-04A
38	Install in the reverse order
39	Change engine oil and oil filter element	Installation: Replace sealing ring.
			*BA01.45-P-1001-01M
		Engine oil	*BF18.00-P-1001-01M
	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
40	Carry out an engine test run and check the engine for leaks
41	Inspect cooling system for leaks		AR20.00-P-1010GZC

CYLINDER HEAD

Number	Designation				Engine 272	Engine 273
BA01.30-P-1003-01O	Cylinder head bolt to timing case	M8	Stage 1	Nm	15	15
BA01.30-P-1003-01O	Cylinder head bolt to timing case	M8	Stage 2	∠°	90	90

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation			Engine 272
BA01.40-P-1001-01G	Bolt, timing case cover to crankcase	M8	Nm	20

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation			Engine 273
BA01.40-P-1001-01T	Bolt, timing case cover to crankcase	M8	Nm	20

OIL PAN

Number	Designation		Engine 272	Engine 273
BA01.45-P-1001-01M	Oil drain screw to oil pan	Nm	30	30

ENGINE LUBRICATION

Number	Designation			Engine 272	Engine 273.922/923/924/960/961/962/ 963/965/967/ 968
BF18.00-P-1001-01M	Engine oil	Filling capacity without oil filter	Liters	-	-
		Filling capacity with oil filter	Liters	8.0	8.5
		Specifications for service products	Sheet	BB00.40-P-0229-01A	BB00.40-P-0229-01A
			Sheet	BB00.40-P-0229-03A	BB00.40-P-0229-03A
			Sheet	BB00.40-P-0229-05A	BB00.40-P-0229-05A

Fig 3: Identifying Squeeze Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig 4: Identifying Wrench Socket (001 589 65 09 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
BR00.45-Z-1038-04A	Loctite 7200	Henkel Loctite Deutschland GmbH Arabellastrasse 17 81925 Munchen Germany Tel. +49-899268-0 Fax +49-899101978 www.Loctite.de