Remove/install cylinder head cover

AR01.20-P-5014MRD

Remove/install cylinder head cover

18.02.2020

Engine

274.9 in model 213

Engine

274.9 in model 238

Modification notes

05.08.2019

Information document AH00.00-P-0500-01MNE, added.

Operation step 21.

05.08.2019

Information document AH05.20-P-1000-09SZ, added.

Operation step 27.

30.01.2020

Water-cooled charge air cooler bracket screw at cylinder head cover/cylinder head/chain case cover

BA09.41-P-1003-01U

Shown on ENGINE 274.910 in MODEL 213

1

Air cleaner housing

2

Cap

3

Fuel high-pressure pump

4

Oil separator

5

Coolant vent line

6

Cylinder head cover

7

Bracket

8

Top slide rail

9

Front cover

10

Rail

11

Coolant vent line

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

Wear protective gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

 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

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

Topical note

Notes on threaded connections fastened using a tightening angle-based tightening process

AH00.00-P-0020-01A

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

General information on work on gasoline direct injection system

AH07.00-P-2000-01A

 

Remove/install

1

Drain off coolant.

AR20.00-P-1142OLC

 Installation: Only install lower engine compartment paneling after leak test.

2

Remove soundproofing.

Engine 274.9 in model 213
except code 920 (Direct petrol injection with stratified charging)
Engine 274.9 in model 238
except code 920 (Direct petrol injection with stratified charging)

AR94.30-P-5410MRD

 Installation: Install soundproofing only after the leak test.

3

Place coolant bleed line (5) to one side.

4

Remove charge air cooler.

AR09.41-P-0105MRD

 Installation: Only install upper engine cover after the leak test.

5

Remove ME-SFI [ME] control unit (N3/10).

AR07.08-P-7013MRD

6

Remove bracket of the charge air cooler.

 Screw, water-cooled charge air cooler holder to cylinder head cover/cylinder head/chain case cover

*BA09.41-P-1003-01U

7

Remove front cover (9).

AR01.30-P-5700MRD

8

Remove high-pressure fuel pump (3).

AR07.02-P-1028MRD

9

Remove rail (10) with fuel injectors.

AR07.03-P-1052MRD

10

Remove air filter housing(1).

AR09.10-P-1150MRD

11

Remove front bracket of the air filter housing (1).

 M81.25

*BA00.10-P-1005-04A

12

Remove rear right engine lifting lug and place to one side.

 Bolt, lifting eye to cylinder head/cylinder head cover

*BA01.30-P-1008-01Y

13

Remove ignition coils.

AR15.12-P-2003MRD

14

Remove valve lift changeover actuator.

Engine 274.910 in model 213

AR05.20-P-6500MRA

15

Remove oil separator (4) from the cylinder head cover (6) and place to one side.

Engine 274.9 in model 213
except code 494 (US version)
except code 945 (China Stage 6 exhaust treatment)
Engine 274.9 in model 238
except code 945 (China Stage 6 exhaust treatment)

AR01.20-P-9691MRD

Engine 274.9 in model 213
with code 494 (US version)

AR01.20-P-9691MRU

16

Remove coolant bleed line (11) from the cylinder head cover (6), unclip from the brackets, and place to one side.

 Hose clamp pliers

*003589033700

17

Disconnect engine wiring harness.

AR15.18-P-1000-04MRD

 M61

*BA00.10-P-1002-04A

18

Remove the vacuum pump.

AR43.05-P-1320MRD

19

Remove cap (2).

 Installation: Replace cap (2).

20

Loosen screws of cylinder head cover (6) in reverse order to tightening procedure and remove.

AR01.20-P-5014-03MR

 Installation: Replace screw/bolts.
Observe tightening procedure for cylinder head cover (6).

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-P-1001-01R

21

Remove cylinder head cover (6) from the cylinder head.

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 hammer in a tool to pry off between cylinder head cover (6) and cylinder head.
Otherwise, damage to the sealing surfaces can occur.

 Cylinder head cover (6) and cylinder head must be replaced together.

 Use puller screw if necessary.

 Installation: Install new sealing rings.

 Installation: Apply sealant to cylinder head cover (6).

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

 Application gun

*112589002500

22

Remove brackets (7) of the engine cover.

When installing new cylinder head cover (6).

23

Remove Hall sensors of the camshafts.

When installing new cylinder head cover (6).

AR15.10-P-1999MRD

24

Remove top slide rail (8).

When installing new cylinder head cover (6).

AR05.10-P-8480MRD

25

Remove oil filler cap with molded seal.

When installing new cylinder head cover (6).



Check

26

Check top slide rail (8) of the timing chain for galling and score marks.

AR05.10-P-8480MRD

If galling and score marks are present,



Replace upper slide rail (8).

27

Check camshaft bearing points in the cylinder head cover (6), cylinder head, and on the camshafts for galling and score marks.

General information on checking camshafts and bearing points of camshafts

AH05.20-P-1000-09SZ

If galling and score marks are present,



replace cylinder head cover (6), cylinder head, and camshafts.

Replace cylinder head

AR01.30-P-5800MRD

Replace camshafts

AR05.20-P-6992MRD



Clean

28

Clean sealing surfaces on cylinder head and cylinder head cover (6).

AR01.00-P-0050-01A


Do not use any sharp-edged tools or abrasive paper.
Otherwise, damage to the sealing surfaces can occur.

Loctite 7063 (400 ml) cleaning spray

*BR00.45-Z-1046-04A

Loctite 7200

*BR00.45-Z-1038-04A

29

Install in the reverse order.

 Warning

Risk of burn injuries, suffocation and poisoning when working on the exhaust system and the components connected to it. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust.

Wear protective clothing and safety glasses. Use the extraction system. Move people out of the hazard area.

AS49.00-Z-0001-01A

 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

30

Carry out engine test run and check engine for proper leak tightness and leak tightness.

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1002-04A

M61

Nm

9

13

 Metric screws/bolts and nuts as per MBN 10 105, 10 143

Number

Designation

8.8

10.9

BA00.10-P-1005-04A

M81.25

Nm

22

32

 Crankcase ventilation system, cylinder head cover, camshaft housing

Number

Designation

Engine 274

BA01.20-P-1001-01R

Screw/bolt, cylinder head cover to cylinder head

Stage 1

Nm

10

Stage 2

°

90

 Cylinder head

Number

Designation

Engine 274

BA01.30-P-1008-01Y

Bolt, lifting eye to cylinder head/cylinder head cover

M8

Nm

20

 Charge air pipe/charge air cooling

Number

Designation

Engine 274

BA09.41-P-1003-01U

Screw, water-cooled charge air cooler holder to cylinder head cover/cylinder head/chain case cover

Nm

8

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