Contents: Removal ↡ Installation ↡
Caution! When removing the drive chain cover, a lifting mechanism must be used. When installing the cover, a sealant must be used.
Removal
Location of the two bolts on the front of the fuel filter and thermostat
Location of the lower powertrain support mounting bolt
Location of high pressure fuel pump mounting bolts to timing chain cover
Location of the bolts securing the drive chain cover to the cylinder head
Location of bolts securing the drive chain cover to the engine cylinder block
1. Remove the ground cable from the battery.
2. Open the hood and place it in a vertical position.
3. Remove the lower engine splash shield.
4. Remove the radiator and radiator fan assembly.
5. Remove the crankshaft pulley/vibration damper and hub.
6. Remove the auxiliary drive belt tensioner as follows:
- a - remove the plastic plug, unscrew the bolt and remove the auxiliary drive belt idler pulley;
- b - unscrew the bolts and remove the radiator fan pulley;
- c - unscrew the bolts and remove the tensioner shock absorber strut;
- d - remove the tension mechanism spring;
- e - remove the auxiliary drive belt tensioner mechanism.
7. Remove the brake vacuum pump.
8. Remove the power steering pump.
9. Remove the rear self-leveling suspension pump from the cylinder head.
10. Remove the generator.
11. Drain the engine oil from the engine.
12. Remove the cylinder head cover.
13. On models with air conditioning, cover the condenser with thick cardboard to prevent further damage.
14. Remove the two bolts at the front of the fuel filter and thermostat assembly (see Fig. Location of the two bolts on the front of the fuel filter and thermostat).
15. Unscrew the oil dipstick tube from the cylinder head.
16. Unscrew the bolts and remove the generator mounting bracket.
17. Mark the location and unscrew the crankshaft angle sensor bracket and move the sensor to the side.
18. Attach a lifting device to the front engine lifting eye.
19. Working under the vehicle on both sides of the engine, unscrew the lower powertrain mount mounting bolts (see Fig. Location of the lower powertrain support mounting bolt).
20. Raise the engine and remove the oil pan to timing chain cover mounting bolts and loosen the remaining oil pan mounting bolts.
21. Lower the engine.
22. Remove the three bolts securing the high pressure fuel pump to the timing chain cover (see Fig. Location of high pressure fuel pump mounting bolts to drive chain cover).
Information copied from the website: MERCEDESMAN
23. Through the hole in the top of the cylinder head, unscrew the two bolts securing the cylinder head to the timing chain cover (see Fig. Location of bolts securing the drive chain cover to the cylinder head).
24. Unscrew the remaining drive chain mounting bolts and remove the cover (see Fig. Location of bolts securing the drive chain cover to the engine cylinder block).
Caution! When removing the drive chain cover, a lifting mechanism must be used. When installing the cover, a sealant must be used.
25. When removing the timing chain cover, be careful not to damage the cylinder head and oil pan gaskets.
Installation
1. Clean the mating surfaces of the timing chain cover, cylinder head and cylinder block.
2. Check the condition of the cylinder head gasket. If the gasket is damaged, remove the cylinder head and replace the gasket.
3. Check the condition of the oil pan gasket. If the gasket is damaged, remove the oil pan and replace the gasket. If necessary, replace the front crankshaft sealing ring.
4. To prevent damage to the working edges of the crankshaft seal ring, wrap the front end of the crankshaft with adhesive tape.
5. Apply a thin layer of sealant to the surface of the cylinder block that mating with the timing chain cover.
6. Lubricate the front crankshaft oil seal lips with clean engine oil and carefully install the timing chain cover onto the engine.
7. Screw in the drive chain cover mounting bolts and tighten them to the specified torque.
8. Install the cylinder head to timing chain cover bolts through the holes in the top of the cylinder head and tighten them to the specified torque.
9. Remove the adhesive tape from the front end of the crankshaft.
10. Screw in and tighten the high pressure fuel pump mounting bolts and nuts to the specified torque.
11. Raise the engine, install the oil pan to timing chain cover bolts and tighten them to the specified torque.
12. Lower the engine and install the lower powertrain mount bolts.
13. In accordance with the previously made marks, install the crankshaft angle sensor bracket.
14. Install the generator mounting bracket.
15. Attach the oil dipstick tube to the cylinder head.
16. Install the fuel filter.
17. Install the cylinder head cover.
18. Install the generator.
19. Install the rear self-leveling suspension pump onto the cylinder head.
20. Install the power steering pump.
21. Install the brake system vacuum pump.
22. Install the auxiliary drive belt tensioner in the reverse order of removal.
23. Install the hub and crankshaft pulley/vibration damper.
24. Install the radiator fan assembly and radiator.
25. Install the lower engine splash shield.
26. Pour motor oil into the engine.
27. Connect the ground wire to the battery.