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

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ENGINE 156 

Shown on engine 156.980 

Fig 1: Timing Case Cover Remove/Install Components
G09973905Courtesy of MERCEDES-BENZ USA
MODIFICATION NOTES

7.8.09 Value modified: Guide pulley on coolant pump housing (between power steering pump and guide pulley with grooved channel profile)   *BA13.25-P-1003-01U 
REMOVINGINSTALLING Remove/install     
1.1 Remove engine with front axle carrier Model 164, 251 AR01.10-P-2500GZS
1.2 Remove engine Model 204 AR01.10-P-2400CMG
Model 209 AR01.10-P-2400QMG
Model 211, 219 AR01.10-P-2400TMG
Model 212 AR01.10-P-2400EMG
Model 216, 221 AR01.10-P-2400SMG
Model 230 AR01.10-P-2400RMG
2 Detach engine from front axle carrier Model 164, 251 AR01.10-P-2510GZS
3 Detach transmission from engine    
4 Remove oil lines from automatic transmission at 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° marking on the belt pulley/vibration damper (9) must align with the positioning edge (arrow) on the timing case cover (7).  
7 Remove poly-V belt tensioning device (1) Model 164, 251 AR13.25-P-3200GZS
Model 204, 212 AR13.20-P-0001CMG
Model 209, 211, 219 AR13.25-P-3200TMG
Model 216, 221 AR13.25-P-3200SMG
Model 230 AR13.20-P-0001RMG
8 Remove expansion reservoir (2) for power steering Model 164, 209, 211, 219, 251 AR46.25-P-1000GZS
Model 204, 212 AR46.25-P-1000CMG
9 Remove air shutoff valves (3) IMPORTANT The air lines are unscrewed at the cylinder head.  
Model 164, 251 AR14.30-P-7200GZS
Model 204, 212 AR14.30-P-7200CMG
Model 209, 211, 219 AR14.30-P-7200TMG
Model 216, 221 AR14.30-P-7200SMG
Model 230 AR14.30-P-7200RMG
INSTALLATION IMPORTANT Replace seals.  
10 Remove oil filter housing (4) Model 164, 251 AR18.20-P-3471GZS
Model 204, 212 AR18.20-P-3471CMG
Model 209, 211, 219 AR18.20-P-3471TMG
Model 216, 221 AR18.20-P-3471SMG
Model 230 AR18.20-P-3471RMG
11 Remove cylinder head covers (5) Model 164, 251 AR01.20-P-5014GZS
Model 204, 212 AR01.20-P-5014CMG
Model 209, 211, 219 AR01.20-P-5014TMG
Model 216, 221 AR01.20-P-5014SMG
Model 230 AR01.20-P-5014RMG
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) Model 164, 209, 211, 219, 251 AR46.30-P-0500GZS
Model 204, 212 AR46.30-P-0500CMG
Model 230 AR46.30-P-0500RMG
14 Detach refrigerant compressor or compressor (A9) Model 164 AR83.55-P-5300GZ
Model 204 AR83.55-P-5300CMG
Model 209, 211, 219 AR83.55-P-5300TMG
Model 216, 221 AR83.55-P-5300SMG
Model 230 AR83.55-P-5300RMG
15 Remove alternator (G2) Model 164, 251 AR15.40-P-5032GZS
Model 204, 212 AR15.40-P-5032CMG
Model 209, 211, 219 AR15.40-P-5032TMG
Model 216, 221 AR15.40-P-5032SMG
Model 230 AR15.40-P-5032RMG
16 Remove chain tensioner Model 164, 251 AR05.10-P-7800GZS
Model 204, 212 AR05.10-P-7800CMG
Model 209, 211, 219 AR05.10-P-7800TMG
Model 216, 221 AR05.10-P-7800SMG
Model 230 AR05.10-P-7800RMG
17 Remove belt pulley/vibration damper (9) Model 164, 251 AR03.30-P-1600GZS
Model 204, 212 AR03.30-P-1600CMG
Model 209, 211, 219 AR03.30-P-1600TMG
Model 216, 221 AR03.30-P-1600SMG
Model 230 AR03.30-P-1600RMG
18 Disconnect electrical connector from thermostat housing    
19 Detach guide pulleys (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 204, 212 AR01.45-P-7555CMG
Model 209, 211, 219 AR01.45-P-7555TMG
Model 216, 221 AR01.45-P-7555SMG
Model 230 AR01.45-P-7555RMG
21 Remove oil pan Model 164, 251 AR01.45-P-7500GZS
Model 204, 212 AR01.45-P-7500CMG
Model 209 AR01.45-P-7500QMG
Model 211, 219 AR01.45-P-7500TMG
Model 216, 221 AR01.45-P-7500SMG
Model 230 AR01.45-P-7500RMG
22 Remove bolts (13) at timing case cover (7), remove timing case cover (7) INSTALLATION IMPORTANT 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 
    TORQUE SPECIFICATION *BA01.40-P-1003-01W 
    INSTALLATION IMPORTANT Replace crankshaft radial sealing ring (14), coolant passage seal and radial shaft sealing ring for oil centrifuge. Apply sealant to sealing surface of timing case cover (7).  
IMPORTANT Notes on sealant path for timing case cover   AH01.40-P-1000-01AMG
    SPECIAL TOOL Figure
    SPECIAL TOOL Fig 3
    Loctite sealant 5970 *BR00.45-Z-1013-01A 
CLEAN Clean     
23 Clean sealing surfaces NOTES 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 
24 Install in the reverse order    
25 Read out fault memory and erase if necessary IMPORTANT Faults which may have been caused by disconnecting wires or by a simulation must be erased in the fault memory after completing the work.  
REFER TO TEST & ADJUSTMENT VALUES Connect STAR DIAGNOSIS and read out fault memory   AD00.00-P-2000-04A
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, 159
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
M6X80 Nm 9
M8X80 Nm 20
M8X100 Nm 20
CRANKCASE, TIMING CASE COVER, END COVER

Number Designation Engine 156
BA01.40-P-1001-01W Bolt, timing case cover to cylinder 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)
G09973906Courtesy of MERCEDES-BENZ USA
Fig 3: Identifying Drift (156 589 00 15 00)
G09973907Courtesy of MERCEDES-BENZ USA
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
BR00.45-Z-1046-04A Cleaning spray, Loctite 7063 (150ml) A 001 986 71 71 10
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