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Remove/Install Timing Case Cover - AR01.40-P-8000MRA

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Engine 274.9 in model 205 

Engine 274.9 in model 253 

Shown on Engine 274.9 in model 205.047 

Fig 1: Timing Case Cover Components Location - Engine 274.9 In Model 253 (Shown In Model 205.047)
G14547549DANGERWARNINGCAUTIONREMOVINGNOTESSPECIAL TOOLSPECIAL TOOLNOTESINSTALLINGNOTESSPECIAL TOOLTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONTORQUE SPECIFICATIONIMPORTANTIMPORTANTSPECIAL TOOLREFER TO MAINTENANCEWARNINGCourtesy of MERCEDES-BENZ USA
DANGER Risk of death  when working on component parts and systems with U >= 30 V alternating voltage (AC) or U >= 60 V direct voltage (DC) Do not touch damaged or defective live component parts and lines or non-insulated electrical connections and lines. Engine 274.9 in model 205.047/147/247
Engine 274.9 in model 253.354/954		 AS00.00-Z-0035-01A
WARNING Risk of injury  to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the overpressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
CAUTION Risk of injury  to skin and eyes due to handling of Engine oil. Risk of poisoning  caused by swallowing Engine oil Wear protective gloves, protective clothing and safety glasses.
Do not fill Engine oil into beverage containers.		 AS18.00-Z-0001-01A
Notice  General information on vehicles with high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment Engine 274.9 in model 205.047/147/247
Engine 274.9 in model 253.354/954		 AH00.00-Z-0300-01A
Notice  Notes on avoiding damage through contamination and foreign objects   AH00.00-P-5000-01A
Notice  Notes on coolant   AH20.00-P-2080-01KOA
REMOVING Remove     
1 Deactivate memory package over the COMAND operating unit Engine 274.9 in model 205 with code 275 (Memory Package (driver's seat, steering column and mirror))
Engine 274.9 in model 253
with code 275 (Memory Package (driver's seat, steering column and mirror))		  
2 Turn front wheels to straight-ahead position and fix steering wheel in place with holding device NOTES The steering wheel must not be turned for a separated steering coupling.
Otherwise the clock spring contact will be destroyed.
SPECIAL TOOL Retainer device		 Fig 4
3 Disconnect ground line of battery   AR54.10-P-0003LW
4 Secure vehicle on vehicle lift   AR00.60-P-0100CW
5 Drain off coolant   AR20.00-P-1142LW
6 Remove air filter housing   AR09.10-P-1150MRA
7 Remove ATL heat shield   AR09.40-P-6025MRA
8 Remove charge air pipe between charge air cooler and ATL    
9 Remove belt pulley   AR03.30-P-1600MRA
10.1 Remove belt tensioner Engine 274.9 in model 205 (except 205.047/147/247)
Engine 274.9 in model 253 (except 253.354/954)		 AR13.20-P-0001MRA
10.2 Remove screw/bolt (6) Engine 274.9 in model 205.047/147/247
Engine 274.9 in model 253.354/954		  
11 Remove upper guide pulley for poly-V belt Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949		  
12.1 Remove A/C compressor from engine, place with attached lines to one side and secure against falling down Engine 274.9 in model 205 (except 205.047/147/247) except code ME06 (Hybrid drive 60 kW variant (incl. plugin))
Engine 274.9 in model 253 (except 253.354/954)		 AR83.55-P-5310LW
12.2 Remove electrical A/C compressor from engine, place with attached lines to one side and secure against falling down Engine 274.9 in model 205.047/147/247 with code ME06 (Hybrid drive 60 kW variant (incl. plugin))
Engine 274.9 in model 253.354/954		 AR83.55-P-5311LWH
13 Remove oil pan (3)   AR01.45-P-7500MRA 
14 Detach coolant line between charge air cooler and low-temperature cooler from timing case cover (2)    
15.1 Remove alternator from engine, place with attached lines to one side and secure against falling down Engine 274.9 in model 205 (except 205.047/147/247)
Engine 274.9 in model 253 (except 253.354/954)		 AR15.40-P-5032LWA
15.2 Remove electric vacuum pump from engine, place with attached lines to one side and secure against falling down Engine 274.9 in model 205.047/147/247
Engine 274.9 in model 253.354/954		  
    Engine 274.9 in model 253.354/954 AR43.05-P-0001LVH
    Engine 274.9 in model 205.047/147/247 AR43.05-P-0001MRD
16.1 Remove electric coolant pump Engine 274.9 in model 205 (except 205.048/049/148/248/348/349/448/449)
Engine 274.9 in model 253 (except 253.349/948/949)		 AR20.10-P-1281MRA
16.2 Remove mechanical coolant pump Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949		 AR20.10-P-1271MRS
17 Remove coolant hose between coolant pump and coolant thermostat SPECIAL TOOL Hose clamp pliers Fig 2
18 Remove coolant line Engine 274.9 in model 205 (except 205.048/049/148/248/348/349/448/449)
Engine 274.9 in model 253 (except 253.349/948/949)		 AR20.20-P-7441MRA
19 Remove boost pressure control pressure transducer   AR07.17-P-7002MRA
20 Remove bracket for boost pressure control pressure transducer    
21 Release and disconnect electrical connection (7)    
22 Push out electrical connection (8) from timing case cover (2)    
23 Remove screw/bolt/bolts (5)    
24 Remove oil lines Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949		 AR18.30-P-6850MRA
25 Remove screw/bolts of oil cooler connecting flange and remove oil cooler connecting flange Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949		  
26 Remove screw/bolts (1) opposite to the tightening sequence Bolt plan for timing case cover AR01.40-P-8000-01MR 
27 Remove timing case cover (2) NOTES Do not hammer in a tool to pry off between timing case cover (2) and cylinder crankcase.
The sealing surfaces can be damaged otherwise.		  
INSTALLING Install     
28 Clean sealing surfaces NOTES Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.		 AR01.00-P-0050-01A
    Loctite 7200 *BR00.45-Z-1038-04A 
    Loctite 7063 (400 ml) cleaning spray *BR00.45-Z-1046-04A 
29 Apply sealant to timing case cover (2) Notes on sealant path for timing case cover   AH01.40-P-1000-01MR
    Sealant, Loctite 5970, 50 ml *BR00.45-Z-1013-01A 
    SPECIAL TOOL Application gun Fig 3
30 Install timing case cover (2)    
31 Screw in and tighten screw/bolts (1) Bolt plan for timing case cover
TORQUE SPECIFICATION Bolt, timing case cover to crankcase		 AR01.40-P-8000-01MR 
*BA01.40-P-1001-01K 
32 Install new cap (4) When replacing timing case cover (2).  
33 Install a new front crankshaft radial shaft sealing ring When replacing timing case cover (2). AR03.20-P-3000MRA
34 Install oil cooler connecting flange Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949
TORQUE SPECIFICATION Screw/bolt, oil cooler connecting flange to timing case/crankcase		 *BA18.30-P-1003-01L 
35 Install oil lines Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949		 AR18.30-P-6850MRA
36 Screw in screws/bolts (5) and tighten them TORQUE SPECIFICATION Bolt, cylinder head to timing case cover *BA01.30-P-1002-01Y 
37 Pull electrical connection (8) with new sealing ring into timing case cover (2)    
38 Connect and lock electrical connector (7)    
39 Install bracket for boost pressure control pressure transducer TORQUE SPECIFICATION M6X1 *BA00.10-P-1002-04A 
40 Install boost pressure control pressure transducer   AR07.17-P-7002MRA
41 Install coolant line Engine 274.9 in model 205 (except 205.048/049/148/248/348/349/448/449)
Engine 274.9 in model 253 (except 253.349/948/949)		 AR20.20-P-7441MRA
42 Install coolant hose between coolant pump and coolant thermostat TORQUE SPECIFICATION M6X1 *BA00.10-P-1002-04A 
    SPECIAL TOOL Hose clamp pliers Fig 2
43.1 Install electric coolant pump Engine 274.9 in model 205 (except 205.048/049/148/248/348/349/448/449)
Engine 274.9 in model 253 (except 253.349/948/949)		 AR20.10-P-1281MRA
43.2 Install mechanical coolant pump Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949		 AR20.10-P-1271MRS
44.1 Fasten alternator on engine Engine 274.9 in model 205 (except 205.047/147/247)
Engine 274.9 in model 253 (except 253.954)		 AR15.40-P-5032LWA
44.2 Fasten electrical vacuum pump to engine Engine 274.9 in model 205.047/147/247
Engine 274.9 in model 253.354/954		  
    Engine 274.9 in model 205.047/147/247 AR43.05-P-0001MRD
    Engine 274.9 in model 253.354/954 AR43.05-P-0001LVH
45 Fasten coolant line between charge air cooler and low-temperature cooler on timing case TORQUE SPECIFICATION M6X1 *BA00.10-P-1002-04A 
46 Install oil pan (3)   AR01.45-P-7500MRA 
47.1 Attach A/C compressor to engine Engine 274.9 in model 205 (except 205.047/147/247) except code ME06 (Hybrid drive 60 kW variant (incl. plugin))
Engine 274.9 in model 253 (except 253.354/954)		  
      AR83.55-P-5310LW
47.2 Attach electrical A/C compressor to engine Engine 274.9 in model 205.047/147/247 with code ME06 (Hybrid drive 60 kW variant (incl. plugin))
Engine 274.9 in model 253.354/954		 AR83.55-P-5311LWH
48 Install upper guide pulley for poly-V belt Engine 274.9 in model 205.048/049/148/248/348/349/448/449
Engine 274.9 in model 253.349/948/949
TORQUE SPECIFICATION Bolt, guide pulley to alternator		 *BA13.25-P-1004-01Z 
49.1 Install the belt tensioner Engine 274.9 in model 205 (except 205.047/147/247)
Engine 274.9 in model 253 (except 253.354/954)		 AR13.20-P-0001MRA
49.2 Screw in screw/bolt (6) and tighten Engine 274.9 in model 205.047/147/247
Engine 274.9 in model 253.354/954 TORQUE SPECIFICATION Bolt, timing case cover to crankcase		 *BA01.40-P-1001-01K 
50 Install the belt pulley   AR03.30-P-1600MRA
51 Install charge air pipe between charge air cooler and ATL TORQUE SPECIFICATION M6X1 *BA00.10-P-1002-04A 
52 Install ATL heat shield   AR09.40-P-6025MRA
53 Install air filter housing IMPORTANT Do not install upper Engine cover until after the leak test. AR09.10-P-1150MRA
54 Fill in coolant IMPORTANT Only install lower Engine compartment lining after leak test. AR20.00-P-1142LW
55 Remove locking clip from vehicle on vehicle lift   AR00.60-P-0100CW
56 Remove holding device of steering wheel SPECIAL TOOL Retainer device Fig 4
57 Connect ground line to battery   AR54.10-P-0003LW
58
REFER TO MAINTENANCE		 Check oil level of Engine and correct   AP18.00-P-1811MP
WARNING Risk of accident  from vehicle starting off by itself when Engine running. Risk of injury  (bruises and burns) resulting from working on the Engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
59 Perform an Engine test run and check Engine for proper operation and leaktightness    
60 Install lower Engine compartment paneling   AR61.20-P-1105LW
61 Install upper Engine cover    
METRIC SCREWS/BOLTS AND NUTS AS PER MBN 10 105, 10 143

Number Designation 8.8 10.9
BA00.10-P-1002-04A M6X1 Nm 9 13
CYLINDER HEAD

Number Designation Engine 274
BA01.30-P-1002-01Y Bolt, cylinder head to timing case cover M8 Nm 20
CRANKCASE, TIMING CASE COVER, END COVER

Number Designation Engine 274
BA01.40-P-1001-01K Bolt, timing case cover to crankcase M6   Nm 9
M8 Stage 1 Nm -
Stage 2 Nm -
M10   Nm 58
BELT TENSIONING DEVICE

Number Designation Engine 274
BA13.25-P-1004-01Z Bolt, guide pulley to alternator Nm 20
OIL COOLING

Number Designation Engine 274.9
BA18.30-P-1003-01L Screw/bolt, oil cooler connecting flange to timing case/crankcase Nm 20
Fig 2: Identifying Hose Clamp Pliers (003 589 03 37 00)
G12078806Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Application Gun (112 589 00 25 00)
G12081465Courtesy of MERCEDES-BENZ USA
Fig 4: Identifying Retainer Device (129 589 01 21 00)
G13744897Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1013-01A Sealant, Loctite 5970, 50 ml A 003 989 98 20 10
BR00.45-Z-1038-04A Loctite 7200 A 010 989 90 71
BR00.45-Z-1046-04A Loctite 7063 (400 ml) cleaning spray A 001 986 71 71 09
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