Remove/install cylinder head cover

AR01.20-P-5014M

Remove/install cylinder head cover

29.1.09

15.4.03

Safety note for lifting platform, added

15.4.03

Remove cover, added

Step 6.1



Removing

Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

1

Turn key in electronic ignition switch control unit to position "0"

 Vehicles with Keyless-Go Code 889: Press Start/Stop button repeatedly until ignition is switched off.

2.1

Remove air filter housing

Model 220

AR09.10-P-1050M

3.1

Remove left and right hot film mass air flow sensor (B2/6, B2/7) with air intake manifold

Model 220

AR07.07-P-1454M

3.2

Detach intake air distribution pipe

Model 163

AR09.10-P-1250CD

4.1

Remove charge air intake pipe (2) from cylinder head cover (3) and press to side

Model 220

Model 163, left charge air intake pipe (2)

5.1

Remove charge air intake pipe (2) from cylinder head cover (3) and exhaust gas turbocharger and press to side

Model 163, left charge air intake pipe (2)

6.1

Remove cover (6) from cylinder head cover (3)

Model 220

AR01.20-P-5015M

7.1

Disconnect electrical connector at camshaft Hall sensor (B6/1)

When removing right cylinder head cover (3).

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

8

Remove injectors

AR07.16-P-1000M



Notes on injectors

AH07.16-P-1000-01A

9

Disconnect drain hose (7) from left and right cylinder head cover (3)

10

Remove bolts (8)

 Press fuel lines on left cylinder head cover (3) to side.

11.1

Remove bracket (12) with intake port shutoff switchover valve (Y83)

When removing left cylinder head cover (3).

12.1

Remove bolts on front engine mount at front axle carrier

Model 220

AR22.10-P-1260MB

13.1

Mount engine hoisting gear and raise engine

Model 220

AR33.10-P-0105M

14

Remove cylinder head cover (3)



Install

15

Fit on cylinder head cover (3)

 Do not tighten bolts (4) because injectors are aligned via the cylinder head cover (3). otherwise gas leaks can occur and baking tight of injectors (11) in the cylinder head as well as impermissible stresses in the injection line.

 Replace gasket (3a) on cylinder head cover (3).

16.1

Lower engine and remove engine hoist

Model 220

AR33.10-P-0105M

17.1

Tighten bolts on front engine mount on front axle carrier

Model 220



*BA22.10-P-1001-01D

18

Install injectors

 Replace injector seal and screws for clamping claws. Clean injectors (11) and injector shafts on cylinder head. Ensure maximum cleanliness while cleaning!

AR07.16-P-1000M



Notes on injectors

AH07.16-P-1000-01A

19

Tighten bolts (4) on cylinder head cover (3)



*BA01.20-P-1001-01G

20.1

Tighten bolts (8)

When installing left cylinder head cover (3).

21

Connect drain hose (7) to left and right cylinder head cover (3)

22.1

Install bracket (12) with intake port shutoff switchover valve (Y83)

When installing left cylinder head cover (3).

23

Install charge air intake pipe (2) at cylinder head cover (3)

Model 220

Model 163, right charge air intake pipe (2)



*BA09.41-P-1013-01H

24.1

Install charge air intake pipe (2) on cylinder head cover (3) and exhaust gas turbocharger

Model 163, left charge air intake pipe (2)



*BA09.41-P-1013-01H

25.1

Install left and right hot film mass air flow sensor (B2/6, B2/7) with air intake pipes

Model 220

AR07.07-P-1454M

 Ensure that in the installation position the screws of the hose clamps are below the air intake pipes as much as possible. Otherwise they might strike against the suspension strut mounts during the load alteration reactions of the engine.

26.1

Attach the intake air distribution pipe

Model 163

AR09.10-P-1250CD

27.1

Install air filter housing

Model 220

AR09.10-P-1050M

 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

28

Check for oil leaks with engine running

 Danger!

Risk of explosion from fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure.

Keep all ignition sources out of hazard area.

Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

29

Check fuel system for leaks with engine running

30

Read out fault memory

STAR DIAGNOSIS diagnosis system



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

Number

Designation

Engine
628.960/961/
962/963

BA01.20-P-1001-01G

Bolt, cylinder head cover to cylinder head

Nm

9

Number

Designation

Engine 628.960
in model 220

BA22.10-P-1001-01D

Bolt, front engine mount to front axle carrier

Nm

35

Number

Designation

Engine 628.960/963

BA09.41-P-1013-01H

Bolt, charge air intake pipe to cylinder head cover

Nm

9