Remove/install left cylinder head cover

AR01.20-P-5013MNB

Remove/install left cylinder head cover

18.02.2020

Engine

178 in model 190

Modification notes

05.08.2019

Note document AH00.00-P-0500-01MNE added.

Operation step 16.

05.08.2019

Note document AH05.20-P-1000-09SZ added.

Operation step 21.

1

Cylinder head cover

2

Bolts

3

Vent line

4

Bolts

 

Remove/install

1

Remove engine with front axle carrier.

AR01.10-P-2500MNB

2

Disconnect the engine wiring harness for removing the cylinder head cover (1).

AR01.00-P-2410-04MNB

3

Remove front cap on left cylinder head.

AR01.30-P-5711MNA

4

Remove screws (4) and remove bleed line (3).

 Installation: Replace seal.

 Bolt, vent line to cylinder head cover/turbocharger

*BA01.20-P-1001-01J

5

Remove left fuel injectors.

AR07.03-P-0004MNA

6

Remove left high-pressure pump.

AR07.02-P-1023MNB

7

Remove left ignition coils.

AR15.12-P-2008MNB

8

Remove exhaust gas turbocharger heat shield from side of cylinder head cover (1).

 Bolt, side heat shield to cylinder head cover

*BA09.40-P-1007-01ZA

9

Remove right oil separator.

AR01.20-P-9750MNB

10

Remove low-pressure line from service connection, left cylinder head cover (1), fuel hose, crankcase, right cylinder head cover and right high-pressure pump.

AR07.03-P-1010-02MNB

11

Remove top cover from exhaust gas turbocharger.

 Installation: Check for correct seating of the cover.

12

Remove upper heat shield from exhaust gas turbocharger.

 Bolt, upper heat shield to bracket/side heat shield

*BA09.40-P-1006-01ZA

13

Unclip bleed line on left charge-air distributor and remove.

14

Remove screws and remove oil vent line on front cylinder head cover (1).

 Installation: Replace seal.

 Bolt, vent line to cylinder head cover/turbocharger

*BA01.20-P-1001-01J

15

Loosen screws (2) of cylinder head cover (1) in reverse order of tightening procedure and remove.

Bolt tightening procedure for cylinder head cover

AR01.20-P-5014-03MNA

 Observe tightening procedure.

 Installation: Replace screw/bolts (2).

 Bolt, cylinder head cover to cylinder head/ camshaft housing

*BA01.20-P-1004-01J

16

Carefully pry off cylinder head cover (1) from cylinder head and remove.

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

Notes on sealant path for cylinder head cover

AH01.30-P-1000-08MM


Do not pound in tool for prying off between cylinder head cover (1) and cylinder head.
The sealing surfaces can be damaged otherwise.

 Installation: Replace rear connection pieces.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

17

Modify position sensors of camshafts.

When replacing cylinder head cover (1) and cylinder head (parts are available only in combination).

AR15.12-P-2144MNB

18

Modify low-pressure line with service connection on cylinder head cover (1).

For replacing cylinder head cover (1) and cylinder head (components are only obtainable in combination)

 Bolt, fuel line service connection to left cylinder head cover

*BA07.03-P-1002-01H

19

Modify bracket on cylinder head cover (1).

When replacing cylinder head cover (1) and cylinder head (parts are available only in combination).

20

Modify slide rail on cylinder head cover (1).

When replacing cylinder head cover (1) and cylinder head (parts are available only in combination).



Check

21

Check camshaft mounts in cylinder head cover (1) and camshafts for galling and score marks.

General information on checking camshafts and bearing points of camshafts

AH05.20-P-1000-09SZ

If damage is present,



Replace camshafts

AR05.20-P-6992MNA

Replace cylinder head cover (1) and cylinder head (components are only obtainable in combination)

AR01.30-P-5770MNB



Clean

22

Clean sealing surfaces on cylinder head and the cylinder head cover (1).

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
The sealing surfaces can be damaged otherwise.

Loctite 7200

*BR00.45-Z-1038-04A

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

23

Install in the reverse order.

24

Check engine oil level and correct if necessary.



AP18.00-P-1848U

 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

25

Perform engine test run and check engine in terms of leak tightness while engine is running.

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 178

BA01.20-P-1001-01J

Bolt, vent line to cylinder head cover/turbocharger

Nm

9

 Crankcase ventilation system, cylinder head cover

Number

Designation

Engine 178

BA01.20-P-1004-01J

Bolt, cylinder head cover to cylinder head/ camshaft housing

Stage 1

Nm

10

Stage 2

°

90

 Injection nozzles, injection valves, lines

Number

Designation

Engine 178

BA07.03-P-1002-01H

Bolt, fuel line service connection to left cylinder head cover

Nm

9

 Turbocharger

Number

Designation

Engine 178

BA09.40-P-1006-01ZA

Bolt, upper heat shield to bracket/side heat shield

Nm

9

 Turbocharger

Number

Designation

Engine 178

BA09.40-P-1007-01ZA

Bolt, side heat shield to cylinder head cover

Nm

9

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

Henkel AG & Co. KGaA
http://www.loctite.de

BR00.45-Z-1046-04A

Loctite 7063 (400 ml) cleaning spray

A 001 986 71 71 09