Remove/install cylinder head cover

AR01.20-P-5014TD

Remove/install cylinder head cover

29.1.09



Remove

1

Remove trim panel of cylinder head cover

AR01.20-P-5015TD

Danger!

Risk of explosion if ignition takes place, 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, naked flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

2

Remove injectors

AR07.16-P-1000TD

3

Unscrew bolt (1) of charge air intake pipe to cylinder head cover (2) and press charge air intake pipe to the side

Left cylinder head cover

4

Remove charge air intake pipe on right

Right cylinder head cover

AR09.41-P-1318TD

5

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

Right cylinder head cover

6

Disconnect drain hose (3)

7

Remove bracket (4)

Left cylinder head cover

8

Remove cylinder head cover (2)



Install

9

Fit on cylinder head cover (2)

Do not tighten bolts (5) fully as injectors are aligned via the cylinder head cover. Otherwise, this can result in gas leaks and the injectors baking tight in the cylinder head, as well as in impermissible stresses in the injection lines. Replace gasket (6) of cylinder head cover (2)

10

Install injectors

Replace injector gasket and bolts of tensioning claws. Clean the injectors and the injector recesses on the cylinder head. Pay attention to maximum cleanliness while cleaning!

AR07.16-P-1000TD



Notes on injectors

AH07.16-P-1000-01A

11

Tighten bolts (5) of cylinder head cover (2)



*BA01.20-P-1001-01G

12

Connect drain hose (3)

13

Install bracket (4)

Left cylinder head cover

*BA18.20-P-1002-01M

14

Install charge air intake pipe

Right cylinder head cover

AR09.41-P-1318TD

15

Mount charge air intake pipe onto cylinder head cover

Left cylinder head cover



*BA09.41-P-1013-01H

16

Plug electrical connector on camshaft Hall sensor (B6/1)

Right cylinder head cover

17

Install trim panel of cylinder head cover

AR01.20-P-5015TD

 Danger!

Risk of accident as vehicle may start off by itself with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns

Secure vehicle to prevent it from moving.
Wear closed and snug-fitting work clothes.
Do not grasp hot or rotating parts.

AS00.00-Z-0005-01A

18

Run engine and inspect for oil leaks

 Danger!

Risk of explosion from fuel igniting. Risk of injury. Fuel may stream out and cause injury to eyes or skin.

Keep all ignition sources out of hazardous area.

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

AS07.16-Z-0001-01A

19

Run engine and inspect fuel system for leaks

20

Read out DTC memory



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 of cylinder head cover to cylinder head

NM

9

Number

Designation

Engine
628.961

BA18.20-P-1002-01M

Bracket at oil filter housing and cylinder head cover

NM

9

Number

Designation

Engine
628.961

BA09.41-P-1013-01H

Bolt of charge air intake manifold to cylinder head cover

NM

9