AR01.40-P-8000A Remove/install timing case cover 27.7.
94
ENGINE 111 in MODEL 124, 163, 170, 202, 208, 210
P01.40-0249-09
Shown on engine 111.96
P01.40-0250-06
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A Bolts of the cylinder head to timing case
cover
i Tighten bolts to specified torque and
tightening angle
P01.40-0334-06
3 Dowel sleeves
P01.40-0251-06
Modification notes
6.8.97 Technical modification: bolts+washers of cylinder head to Step 28
timing case cover are replaced by Torx bolts without washer
ed Remove/Install
1 Disconnect/connect battery's ground cable AR54.10-P-0003A
2.1 Remove left charge-air line assembly with hot- Engines with compressor and aluminum intake
film air-mass sensor pipe
3 Remove oil-filter insert i so that engine oil in the oil filter flows off into AP18.00-P-0101-06ED
the oil pan
4.1 Remove viscous fan clutch Engines with viscous fan clutch AR20.40-P-5660A
5.1 Remove fan shroud Vehicles with fan cowl AR20.40-P-6800HA
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6 Remove oil pan Engines 111.940/960 in model 124 AR01.45-P-7500A
Engines 111.920/921/941/945 /961/974 in
model 202
Engine 111.946 in model 170
Engine 111.945 in model 208
Engine 111.977 in model 163 AR01.45-P-7500AG
Engine 111 in model 210 AR01.45-P-7500B
Engines 111.944/975 in models 202, 208 AR01.45-P-7500E
Engine 111.943/973 in model 170
7.1 Remove poly V-belt of supercharger Engines with compressor AR13.21-P-1202A
8 Remove poly V-belt AR13.22-P-1202A
9 Drain coolant AR20.00-P-1142HG
10.1 Remove compressor Models 170, 202, 208, 210 with compressor AR09.50-P-4705A
11 Remove generator bracket or generator/
compressor bracket
12 Remove poly V-belt tensioning device AR13.25-P-3200A
13 Remove front cover at cylinder head AR01.30-P-5700A
14 Remove coolant pump AR20.10-P-1271A
15 Remove belt pulley of power steering pump (44) l *603589004000
i In order to remove the screws, place poly-V-
belt on pulley (44) and apply counterholder.
AR46.30-P-0500A
16.1 Unscrew bracket (47) Engines fitted with aluminum intake manifold
17.1 Remove bracket (46b) If AC not fitted
18.1 Remove brackets (46 and 46a) with AC fitted
19 Remove power steering pump (45) with lines AR46.30-P-0500A
connected and place to one side
20 Turn crankshaft to 20° - 30° after ignition TDC
of cylinder 1 (arrow)
21 Lock camshafts in place with locating pins (01) l *111589031500
22 Mark camshaft gears (75) and (76) to timing p Installation: The color markings on the
chain with a colored marking (arrows) timing chain and on the camshaft sprockets
must be above each other (arrows).
23 Remove chain tensioner (14) p If the complete chain tensioner is slackened, AR05.10-P-7800A
it must be removed, disassembled and
reassembled as described.
24 Remove exhaust camshaft sprocket (76) l *000589011000
n *BA05.20-P-1001-02A
p Replace bolts of camshaft sprocket; use
only once
25 Remove inlet camshaft sprocket (74) l on engines without camshaft adjuster. *000589011000
n *BA05.20-P-1001-02A
p Replace bolts of camshaft sprocket; use
only once
26 Remove inlet camshaft with camshaft adjuster Engines with camshaft adjuster, refer to
Remove camshafts AR05.20-P-6992A
27 Pull out slide rail pins (11) l AR01.30-P-5800-04A
p Installation: Coat slide rail pins with sealing *BR00.45-Z-1014-01A
compound
k Modified bolts (Torx bolts) for cylinder head to BT01.30-P-0002-01A
timing case cover
28 Remove bolts (A) to timing case cover n *BA01.40-P-1002-01G
p Installation: Replace bolts (A),
bolts+washers of engines from 1994 (enlarged
bolt head contact surface,
with torx bolts without washer.
Oil bolt head contact surface, tighten bolts
to specified torque and tightening angle.
l *000589011000
29 Remove belt pulley/vibration absorber (95) AR03.30-P-1600A
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30 Mark remaining bolts for timing-case cover to
crankcase with colored marking
31 Remove bolts (1) and (2) for timing case cover n *BA01.40-P-1001-01G
32 Take off timing case cover (65) p Do not damage cylinder-head gasket (arrows)
p Installation: Pull the timing chain firmly
upwards when installing the timing-case cover
(65) to ensure that no chain loops are formed
between the crankshaft gear and the chain
locking journals to the timing-case cover (65).
33 Replace front crankshaft radial seal . AR03.20-P-3000A
34 Clean sealing surfaces at timing case cover (65) p Installation: Coat sealing surfaces with *BR00.45-Z-1014-01A
and at crankcase sealing compound.
Make sure that no sealant succeeds in entering
the oil reservoir (65a) for the chain tensioner.
Replace O-rings (66).
35 Install in the reverse order
a Danger! Risk of accident caused by vehicle starting off Secure vehicle to prevent it from moving. AS00.00-Z-0005-01A
by itself when engine is running. Risk of injury Wear closed and snug-fitting work clothes.
caused by contusions and burns when working Do not grasp hot or rotating parts.
in engine during starting procedure
36 Run engine and inspect for leaks
n Crankcase, timing case cover, end cover
Number Designation Engine 111
BA01.40-P-1001-01G Bolt of timing case cover to crankcase M8 Nm 25
BA01.40-P-1002-01G Bolt of cylinder head to timing case cover 1st stage Nm 18
Step 2 ° 90
n Camshaft, camshaft adjustment
Number Designation Engine 111
BA05.20-P-1001-02A Bolt of camshaft gear / flange shaft 1st stage Nm 20
Step 2 ° 60
Auxiliary repair materials
Number Designation Order number
BR00.45-Z-1014-01A Omnifit FD 3041 sealant (50 ml) 002 989 47 20 10
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603 589 00 40 00 111 589 03 15 00 116 589 20 33 00 116 589 01 34 00
Counterholder Retaining pins Impact extractor Threaded pin
000 589 01 10 00 605 589 00 33 00
Torx bit set Extractor
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