Remove/install cylinder head cover

AR01.20-P-5014OLC

Remove/install cylinder head cover

22.06.2020

Engine

654 in model 213, 238, 257

Modification notes

09.06.2020

New operation steps added.

Operation steps 12 to 15.

Shown on engine 654.9

1

Cylinder head cover

6

Screws

8

Screw

5

Support brace

7

Holder

Shown on engine 654.9

1

Cylinder head cover

2

Screws

3

Sealing rings

4

Holder

Shown on engine 654.9

9

Sealer bead

Shown on engine 654.9

A

Contact area

Shown on engine 654.8

1

Cylinder head cover

10

Screws

11

Holder

 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

 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

 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

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

 

Remove/install

1

Remove fuel injectors (Y76).

AR07.16-P-1000OLC

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

2

Remove rail.

AR07.03-P-1010OLC

3

Remove air intake line upstream of exhaust gas turbocharger.

AR09.40-P-0500OLC

4

Remove low pressure exhaust gas recirculation actuator (Y27/7) from the exhaust gas recirculation cooler and place to one side with connected lines.

AR14.20-P-7683OLC

5

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

AR15.18-P-1000-04OLC

6

Remove camshaft Hall sensor (B6/1).

AR15.10-P-1999OLC

7

Press sound insulation to the side and remove support (5).

Topical note

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

AH00.00-P-0020-01A

 Screw, bracket for low-pressure exhaust gas recirculation cooler to cylinder head cover/low-pressure exhaust gas recirculation cooler/lifting lug

*BA14.20-P-1015-01Q

8

Remove impact plate in front of poly-V-belt.

AR13.22-P-1202OLC

9

Remove NOx sensor controller unit at catalytic converter and place to one side with lines connected.

AR14.40-P-2063OLC

10

Remove screws (6), remove holder (7) and place to one side with lines connected.

 Screw, holder to high-pressure exhaust gas recirculation valve/high-pressure exhaust gas recirculation cooler

*BA14.20-P-1018-01Q

11

Loosen the screw (8).

Engine 654.9 in model 213, 238, 257

 Bolt, high pressure exhaust gas recirculation valve to bracket for high pressure exhaust gas recirculation cooler

*BA14.20-P-1010-01Q

12

Remove DPF differential pressure sensor (B28/8) and heat shield from the cylinder head cover (1).

Engine 654.8 in model 213, 238, 257

AR07.04-P-0025OLN

13

Remove low-pressure exhaust gas turbocharger boost pressure sensor (B5/4).

Engine 654.8 in model 213, 238, 257

AR09.41-P-6295OLN

14

Remove holder (11) of low-pressure exhaust gas turbocharger boost pressure sensor (B5/4) from cylinder head cover (1).

Engine 654.8 in model 213, 238, 257
Engine 654.9 in model 213, 238, 257
with code M014 (Engine uprated)

15

Remove screws (10).

Engine 654.8 in model 213, 238, 257

 Screw, heat shield for cylinder head cover to heat shield for exhaust manifold

*BA01.20-P-1002-03A

16

Remove screws (2) in reverse order to tightening procedure.

Tightening procedure

AR01.20-P-5014-03OLC

 Screw/bolt, cylinder head cover to cylinder head

*BA01.20-P-1001-03A

17

Remove the cylinder head cover (1).

Topical note

Notes on threaded connections with aluminum screws/bolts

AH00.00-P-0006-01RM

General information on checking camshafts and bearing points of camshafts

AH05.20-P-1000-09SZ

 Installation: Replace screws (2) and bushings made from aluminum with screws (2) and bushings made from steel.
Install new seals(3).
Remove sealing beads (9) at new seal.

18

Modify holder (4).

When replacing the cylinder head cover (1).

 Bolt, bracket for engine cover to cylinder head cover

*BA01.10-P-1003-01D

19

Degrease the sealing surfaces on the cylinder head, rear cap, and cylinder head cover(1) using a lint-free rag.

Notes on application of flange sealants to seal major assemblies

AH00.00-P-0500-01MNE

 Installation: Apply sealant to the contact area (A) between the cylinder head and the rear cap on the cylinder head.

Assembly cleaner

*BR00.45-Z-1028-04A

Sealant, Loctite 5970, 50 ml

*BR00.45-Z-1013-01A

20

Install in the reverse order.



Check

21

Check engine oil level and correct if necessary.



Engine 654 in model 213, 238, 257
with code M014 (Engine uprated)

AP18.00-P-0101FA



Engine 654 in model 213, 238, 257
except code M014 (Engine uprated)

AP18.00-P-0101FC

 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

22

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

23

Install upper engine cover.

AR01.10-P-2405OLC

 Engine cover

Number

Designation

Engine 654

BA01.10-P-1003-01D

Bolt, bracket for engine cover to cylinder head cover

Nm

8

 Cylinder head cover

Number

Designation

Engine 654

BA01.20-P-1001-03A

Screw/bolt, cylinder head cover to cylinder head

Steel screws/bolts

Nm

8

 Cylinder head cover

Number

Designation

Engine 654

BA01.20-P-1002-03A

Screw, heat shield for cylinder head cover to heat shield for exhaust manifold

Nm

8

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1010-01Q

Bolt, high pressure exhaust gas recirculation valve to bracket for high pressure exhaust gas recirculation cooler

Nm

10

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1015-01Q

Screw, bracket for low-pressure exhaust gas recirculation cooler to cylinder head cover/low-pressure exhaust gas recirculation cooler/lifting lug

Stage 1

Nm

8

Stage 2

°

30

 Exhaust gas recirculation

Number

Designation

Engine 654

BA14.20-P-1018-01Q

Screw, holder to high-pressure exhaust gas recirculation valve/high-pressure exhaust gas recirculation cooler

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-1028-04A

Assembly cleaner

A 000 986 56 01