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

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ENGINES 642 in MODEL 164

Fig 1: Removing/Installing Timing Case Cover

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

	Remove/install
	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
	Risk of death caused by vehicle slipping or toppling off of 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
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
	Notes on sealant path for timing case cover		AH01.40-P-1000-01PI
1	Remove strut tower brace	Model 164.8 only Remove strut tower brace from strut tower mounts.	AR62.30-P-2500GY
2	Remove engine trim panel		AR01.10-P-2405GZB
3	Remove poly-V belt, poly-V belt tensioning device (3) and lower guide pulley (5)		AR13.20-P-0001GZB
4	Remove mixing chamber		AR09.20-P-1320GZB
5	Remove coolant pump switchover valve	With switchable coolant pump	AR20.10-P-3000SXI
6	Remove bracket for the coolant pump switchover valve	With switchable coolant pump
7	Set piston on 1st cylinder to ignition top dead center (OT)	Crank the engine at the crankshaft in the running direction. The TDC marking on belt pulley/vibration damper (4) must be aligned with the stay on the timing case cover (1).	AR05.10-P-6858GZB
8	Remove bottom section of soundproofing		AR94.30-P-5300GZ
9	Drain engine oil	Collect oil in suitable container. Installation: Replace sealing ring of oil drain screw.	AP18.00-P-0101TQ
10	Remove oil pan bottom section		AR01.45-P-7555GZB
11	Fit retaining lock		AR03.30-P-5000GZB
12	Remove belt pulley/vibration damper (4)	After removing belt pulley/vibration damper (4), check whether engine is still at top dead center otherwise timing case cover (1) cannot be removed.	AR03.30-P-1600GZB
13	Remove bolts (2) from timing case cover (1)	Installation: Replace factory-installed aluminum bolts installed with steel bolts
14	Remove bolts (6) from timing case cover (1)	Installation: Replace factory-installed aluminum bolts installed with steel bolts.
			*BA01.45-P-1008-01Q
15	Remove timing case cover (1)	Installation: Remove fitting sleeves (7) and dispose of them. The fitting sleeves are only foreseen for first assembly. The fitting sleeve must not remain mounted. The later application of sealant can be destroyed otherwise and this would lead to leakage. Installation: First apply sealant, then place timing case cover (1) in place and then tighten the lower bolts (2). Loosen lower bolts (2) again and introduce centering sleeve and then tighten all bolts (2, 6).
		Centering sleeve	Fig 2
		Loctite sealant 5970	*BR00.45-Z-1013-01A
	Clean
16	Clean sealing surfaces	Do not use any sharp-edged tools or abrasive paper as this will damage the sealing surfaces.	AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Cleaning spray, Loctite 7063 (150ml)	*BR00.45-Z-1046-04A
17	Remove front crankshaft radial sealing ring	Only when replacing belt pulley/ vibration damper (4) or in the event of leaks at crankshaft radial sealing ring.	AR03.20-P-3000GZB
18	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 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
19	Check for oil leaks with engine running

CRANKCASE, TIMING CASE COVER, END COVER

Number	Designation			Engine 642
BA01.40-P-1004-01S	Bolt, timing case cover to cylinder crankcase	M6	Nm	10

OIL PAN

Number	Designation			Engine 642
BA01.45-P-1008-01Q	Bolt, oil pan to timing case cover	M6	Nm	14

Fig 2: Identifying Centering Sleeve (642 589 00 14 00)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite sealant 5970	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
BR00.45-Z-1046-04A	Cleaning spray, Loctite 7063 (150ml)	A 001 986 71 71 10