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

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ENGINES 272, 273 in MODEL 212

Shown on engine 272.980

Fig 1: Timing Case Cover Remove/Install Components - Shown On Engine 272.980 (1 Of 2)

Courtesy of MERCEDES-BENZ USA

Fig 2: Timing Case Cover Remove/Install Components - Shown On Engine 272.980 (2 Of 2)

Courtesy of MERCEDES-BENZ USA

MODIFICATION NOTES

9.11.11

Operation sequence adapted to the change in repair method

	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
	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 code (889) Keyless-Go: Press Keyless-Go start/stop button repeatedly until ignition is switched off.
2	Remove air filter housing with engine air intake ducts		AR09.10-P-1150EWS
3	Remove lower engine compartment paneling		AR61.20-P-1105EW
4	Drain engine oil		AP18.00-P-0101EW
	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-1142EWS
	Notes on coolant		AH20.00-N-2080-01A
6	Disconnect coolant hose on coolant temperature regulator housing
7	Detach coolant hose (3) at coolant pump
8	Remove fan unit		AR20.40-P-5050EW
9	Attach guard plate for radiator/condenser
	Guard plate for radiator/condenser		WF58.50-P-0110-01A
10	Remove poly-V belt, tensioning device and guide pulley (2)		AR13.20-P-0001EWS
11.1	Remove air pump	Except model 212.057	AR14.30-P-7251EW
11.2	Open hose clamps using hose clamp pliers and detach coolant lines (16)	Model 212.057
			Fig 3
12	Remove coolant temperature control housing	Install new O-ring and seal.	AR20.10-P-2460EW
13	Remove oil filter housing with oil-water heat exchanger		AR18.20-P-3471EW
14.1	Remove left and right air shutoff valve	Except model 212.057	AR14.30-P-7200EW
14.2	Disconnect electrical connector (16a), remove screw/bolts (16b) and low-temperature circuit shutoff valve (Y125)	Model 212.057
			*BA01.30-P-1019-01O
15.1	Remove intermediate flange (1) of air shutoff valve	Except model 212.057
			*BA14.30-P-1004-02A
15.2	Remove Screw/bolts (17a) and bracket (17)	Model 212.057
			*BA01.30-P-1018-01O
16	Rotate engine at crankshaft center bolt in direction of rotation of engine to a 40° crankshaft angle after ignition TDC		Figure
17	Install retaining lock for crankshaft/starter ring gear		AR03.30-P-5000EWS
18	Remove belt pulley/vibration damper		AR03.30-P-1600EWS
19	Remove front cover at left cylinder head	After installing the front cover, check that the camshafts are positioned at 55° crank angle BTDC: ↓	AR01.30-P-5700EWL
		Check basic position of camshafts.	AR05.20-P-6010EW
20	Remove front cover at the right cylinder head	After installing the front cover, check that the camshafts are positioned at 55° crank angle BTDC: ↓	AR01.30-P-5700EWR
		Check basic position of camshafts.	AR05.20-P-6010EW
21	Remove chain tensioner	The previously installed chain tensioner must not be reinstalled because, during removal, its pressure pin is pressed into the end position. The thrust pin latch prevents this return stroke. This would overstretch the timing chain on reinstalling.	AR05.10-P-7800EW
22	Remove camshaft adjuster for exhaust camshafts.		AR05.20-P-7201EWA
23	Remove camshaft adjuster for intake camshafts.		AR05.20-P-7201EWE
24	Remove alternator		AR15.40-P-5032EW
25	Remove the oil dipstick guide tube	Vehicles with a middle sump	AR18.40-P-3510EWX
25	Remove the oil dipstick guide tube	Vehicles without a middle sump	AR18.40-P-3510EW
26	Remove power steering pump (8)	Detach power steering pump (8) with expansion reservoir from front cover or from timing case cover (7) and place to one side with their connected lines.	AR46.30-P-0500EWL
27	Remove refrigerant compressor (A9) and lay down to side with connected lines		*BA83.55-P-1001-01M
28	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.
		Engine 273	AR01.45-P-7500EW
		Engine 272	AR01.45-P-7500EWD
		Engine 272, 273 with 4MATIC	AR01.45-P-7500EWX
29	Remove screw/bolts (12, 13)		*BA01.30-P-1003-01O
30	Detach timing case cover (7)	Observe different bolt lengths and diameters: ↓
		Bolt plan for timing case cover:	AR01.40-P-8000-01VA
		Engine 272	*BA01.40-P-1001-01G
		Engine 273	*BA01.40-P-1001-01T
		Replace crankshaft radial sealing ring (9). Replace both sealing rings in timing case cover (7) and apply sealant to sealing surface of the timing case cover (7): ↓
		Notes on sealant path for timing case cover	AH01.40-P-1000-01VA
			Figure
		Loctite 5970 sealant	*BR00.45-Z-1013-01A
	Clean
31	Clean sealing surfaces on oil pan, oil pan bottom section and timing case cover (7)	Do not use any sharp-edged tools or abrasive paper. The sealing surfaces will be damaged otherwise.	AR01.00-P-0050-01A
		Loctite 7200	*BR00.45-Z-1038-04A
		Loctite 7063 cleaning spray (150 ml)	*BR00.45-Z-1046-04A
32	Install in the reverse order
33	Check engine oil level; correct if necessary		AP18.00-P-0101EW
	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
34	Carry out an engine test run and check engine for leaks
35	Inspect cooling system for leaks		AR20.00-P-1010EW

AIR SHUTOFF VALVE

Number	Designation		Engine 272	Engine 273
BA14.30-P-1004-02A	Screw/bolt, left air shutoff valve intermediate flange to cylinder head	Nm	14	14

CYLINDER HEAD

Number	Designation			Engine 272	Engine 273
BA01.30-P-1003-01O	Cylinder head bolt on timing case	M8	Nm	20	20

CRANKCASE, TIMING CASE COVER, END COVER

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

CRANKCASE, TIMING CASE COVER, END COVER

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

REFRIGERANT COMPRESSOR

Number	Designation		Engine 272	Engine 273
BA83.55-P-1001-01M	Screw/bolt, refrigerant compressor to timing case/crankcase/engine support	Nm	20	20

CYLINDER HEAD

Number	Designation		Engine 272
BA01.30-P-1018-01O	Screw/bolt, NT circuit coolant line bracket to cylinder head or cylinder head front cover	Nm	9
BA01.30-P-1019-01O	Screw/bolt, shutoff valve bracket to cylinder head	Nm	9

Fig 3: Identifying Hose Clamp Pliers (003 589 03 37 00)

Courtesy of MERCEDES-BENZ USA

Fig 4: Identifying Squeeze Gun (112 589 00 25 00)

Courtesy of MERCEDES-BENZ USA

Fig 5: Identifying Wrench Socket (001 589 65 09 00)

Courtesy of MERCEDES-BENZ USA

REPAIR MATERIALS

Number	Designation	Order number
BR00.45-Z-1013-01A	Loctite 5970 sealant	A 003 989 98 20
BR00.45-Z-1038-04A	Loctite 7200	Henkel Loctite Deutschland GmbH
BR00.45-Z-1046-04A	Loctite 7063 cleaning spray (150 ml)	A 001 986 71 71 10