Remove/install left cylinder head cover

AR01.20-D-5013SF

Remove/install left cylinder head cover

23.11.2017

Engine

642.896/898/992/993 in model 906

Modification notes

29.10.2014

Bolt, power steering oil reservoir to cylinder head cover and oil filter

MODEL 906 with ENGINE 642

BA46.30-N-1018-01A

Shown on engine 642.992

1

Cylinder head cover

2

Engine charge air duct

3

Screw

4

Bracket

5

Screw

6

Steering hydraulic fluid container

7

Screw

8

Coolant pipe (engine 642.992/993)

9

Screw/bolt (engine 642.992/993)

10

Rail

Shown on engine 642.992

1

Cylinder head cover

11

Screw

12

Fuel line

13

Injection line

14

Fuel hose

15

Fuel hose

16

Fuel filter

17

Screw

18

Engine wiring harness

19

High pressure pump

32

Leak oil line

Shown on engine 642.896

7

Screw

12

Fuel line

22

Bracket

25

Bracket (engine 642.896/898)

26

Coolant hose (engine 642.896/898)

27

Coolant hose (engine 642.896/898)

28

Bracket (engine 642.896/898)

29

Bracket (engine 642.896/898)

30

Vacuum line

31

Brake booster

32

Leak oil line

33

Retainer (engine 642.896/898/993)

34

Glow output stage

1

Cylinder head cover

20

Screw

21

Cover

22

Bracket

23

Bolts

24

Cover

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 

Remove/install

1

Drain off coolant

Engine 642.992/993 in model 906

AR20.00-D-1140SD

2

Detach vacuum line (30) on brake booster (31) and place to one side

 Installation: Check seal on brake booster (31) for damage, replace if necessary.

3

Remove cover of left cylinder head cover (1)

AR01.20-D-5015SG

4.1

Remove screw/bolt (7) and push bracket (25) with coolant hose (26) towards the front

Engine 642.896/898 in model 906

4.2

Remove screw/bolts (7, 9) and push coolant pipe (8) to one side

Engine 642.992/993 in model 906

 Bolt, coolant pipe to housing for coolant thermostat

*BA20.10-N-1011-01Q

5

Unscrew screws/bolts (3, 5) and remove bracket (4)

6

Remove rail (10) on left cylinder head

AR07.03-D-1010SF

7

Remove engine charge air duct (2) and hang up to the side

 Bolt, charge air line upstream of charge air cooler to bracket

*BA09.41-N-1005-01O

8

Remove steering hydraulic fluid container (6) and hang up to the side

 Bolt, power steering oil reservoir to cylinder head cover and oil filter

*BA46.30-N-1018-01A

9

Remove injector on left cylinder head

AR07.16-D-1000SF

10

Remove bracket (29) with glow output stage (34) and lay down to the side

Engine 642.896/898 in model 906

 Unclip coolant hose (27) from bracket (28). Do not disconnect electrical connections from glow output stage (34).

 Bolt, bracket to charge-air distributor

*BA09.41-N-1002-01O

11

Remove injection line (13) from cylinder head cover (1) and high-pressure pump (19)

 Installation: Check sealing cone of injection line (13) for damage; replace if necessary.

 Pressure line to high-pressure pump

*BA07.16-N-1008-01B

 Bolt, retaining clamp of high-pressure line to cylinder head cover

*BA07.16-N-1015-01B

12.1

Pull retainer (33) and disconnect leak oil line (32) from fuel line (12)

Engine 642.896/898/993 in model 906

 Seal leak oil line (32) and fuel line (12) using suitable  stop plugs.

 Installation: Check sealing rings for damage, and replace leak oil line (32) if necessary.

 Record plug

*129589009100

12.2

Open clamp and remove leak oil line (32) from fuel line (12)

Engine 642.992 in model 906

 Seal leak oil line (32) and fuel line (12) using suitable  stop plugs.

 Installation: Check clamp for damage, replace if necessary.

 Record plug

*129589009100

13

Remove fuel hose (14) at high-pressure pump (19).

 Seal openings with suitable  stop plug.

 Installation: Check clamp for damage, replace if necessary.

 Record plug

*129589009100

14

Remove fuel hoses (15) from fuel filter (16)

 Seal off fuel hose (15) with suitable  stop plugs.

 Installation: Check clamp for damage, replace if necessary.

 Record plug

*129589009100

15

Remove engine wiring harness (18) at cylinder head cover (1) and expose

 Installation: Check retaining clips for engine wiring harness (18) for damage; replace if necessary.

16

Remove screw/bolts (11, 17) and swivel fuel line (12) to one side

17

Unscrew screws/bolts (23) and remove bracket (22)

 Bolt, holder to oil filter housing and cylinder head cover

*BA18.20-N-1003-01O

18

Loosen and remove screw/bolts (20) in stages and in reverse order of the tightening procedure, for a cooled engine

Bolt tightening procedure for cylinder head cover

AR01.20-D-5014-03SF

 Installation:
Observe tightening pattern and tightening specifications for screw/bolts (20).
Distortion of the left cylinder head cover (1) can occur otherwise and lead to damage to the camshafts.

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-N-1001-01O

19

Press off cylinder head cover (1) to the corners (arrows) carefully from the cylinder head using a suitable tool

Notes on sealant path for cylinder head cover

AH01.30-N-1000-08SE


Press off cylinder head cover (1) from cylinder head with the greatest of care.
The cylinder head cover (1) may be damaged otherwise.

 The cylinder head cover (1) can only be replaced in combination with the cylinder head.

 Installation: Replace cover (21, 24).
Remove sealant residue from sealing surfaces on cylinder head cover (1) and cylinder head.
Lubricate bearing points for camshaft bearing.

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

If cylinder head cover (1) is damaged



Replace cylinder head cover (1) and cylinder head.

AR01.30-D-5770SF

20

Install in the reverse order

 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

21

Conduct engine test run and check engine for leaktightness in the area of the cylinder head cover (1)

 Crankcase ventilation, cylinder head cover

Number

Designation

Engine 642 in model 639
Engine 642 in model 906

BA01.20-N-1001-01O

Screw/bolt, cylinder head cover to cylinder head

Stage 1, apply

Nm

4

Stage 2, initial torque

Nm

6

Stage 3, final torque

Nm

8

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1008-01B

Pressure line to high-pressure pump

M141.5

Stage 1

Nm

20

Stage 2

°

60

 Common rail diesel injection (CDI)

Number

Designation

Engine 642.896/898/992/993 in model 906

BA07.16-N-1015-01B

Bolt, retaining clamp of high-pressure line to cylinder head cover

Nm

14

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1002-01O

Bolt, bracket to charge-air distributor

Nm

9

 Charge air pipe, charge air cooling, mixer housing

Number

Designation

Engine 642

BA09.41-N-1005-01O

Bolt, charge air line upstream of charge air cooler to bracket

Nm

9

 Engine lubrication, oil filter housing

Number

Designation

Engine 642

BA18.20-N-1003-01O

Bolt, holder to oil filter housing and cylinder head cover

Nm

14

 Coolant pump, coolant thermostat

Number

Designation

Engine 642 in model 639
Engine 642 in model 906

BA20.10-N-1011-01Q

Bolt, coolant pipe to housing for coolant thermostat

Nm

9

 Power steering pump

Number

Designation

Model 906 with engine 642

BA46.30-N-1018-01A

Bolt, power steering oil reservoir to cylinder head cover and oil filter

Nm

14

Repair materials

Number

Designation

Order number

BR00.45-Z-1013-01A

Sealant, Loctite 5970, 50 ml

A 003 989 98 20 10